power plant cooling --what are the trade-offs?...38 summary— combined-cycle plants once-through...
TRANSCRIPT
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Power Plant Cooling--What are the trade-offs?
John S. MaulbetschMaulbetsch Consulting
December 7, 2005
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2
Overview
Power plants use waterLargest use is for condenser coolingSome cooling systems use less water than othersTradeoffs are
• Amount of water used• Cost• Plant efficiency and output
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3
The conclusions-in advance
Water conserving cooling systems are available at a price
Increased capital cost---500 MW plants0.4% to 12.5%
Increased cooling system power0.5 to 3.0 MW
Increased plant heat rates0.4 to 4.0 %
Increased power production costs1.9 to 4.9%
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4
Plants
Discussion limited to…….
Plants with condenser cooling• Combined-cycle plants• Steam plants• Not simple cycle turbines or
reciprocating enginesNew plants• Not retrofits
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5
Combined Cycle Plant
COMPRESSOR
GASTURBINE
FUEL
GENERATOR
GENERATOR
STEAMTURBINE
HRSG
EXHAUSTPUMP
CONDENSER
COMPRESSOR
GASTURBINE
FUEL
GENERATOR
GENERATOR
STEAMTURBINE
HRSG
EXHAUSTPUMP
CONDENSER
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6
Steam Plant
COMPRESSOR
GASTURBINE
FUEL
GENERATOR
GENERATOR
STEAMTURBINE
HRSG
EXHAUSTPUMP
CONDENSER
COMPRESSOR
GASTURBINE
FUEL
GENERATOR
GENERATOR
STEAMTURBINE
HRSG
EXHAUSTPUMP
CONDENSER
Fuel
Boiler
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7
Cooling systems
Commonly used• Once-through• Wet cooling• Dry cooling
Others• Hybrid (wet/dry) cooling• Spray enhanced dry cooling
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8
Once-through
to HRSG
Cold CW
Hot CW
CW Pump(s)
Exhaust Steam
to HRSG
Cold CW
Hot CW
CW Pump(s)
Exhaust Steam
Water source—ocean, river, lake, etc
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9
Wet Cooling Tower
Fans
Cooling Tower
BlowdownMakeup
Fans
Cooling Tower
BlowdownMakeup
Hot CW
Cold CW
Ambient air
from condenser
to condenser
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10
Wet cooling tower
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11
Air Cooled Condenser
Fans
to HRSG
Exhaust steam
Air Cooled Condenser
Fans
to HRSG
Exhaust steam
Air Cooled Condenser
Ambient air
from steam turbine
to boiler or HRSG
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13
Water source
NaturalOcean Fresh surface waterGroundwater• potable• brackish
ReclaimedMunicipal dischargeAgricultural run-off
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Cooling Water Taken In---500 MW Combined Cycle Plant
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
Once-through Wet Dry
Wat
er T
aken
In, g
pm
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Cooling Water Consumption---500 MW Combined Cycle Plants
0
500
1,000
1,500
2,000
2,500
Once-through Wet Dry
Wat
er C
onsu
med
, gpm
?
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Plant Capital Cost Capital Cost---500 MW Combined Cycle Plant
185,000,000
190,000,000
195,000,000
200,000,000
205,000,000
210,000,000
215,000,000
220,000,000
225,000,000
230,000,000
Once-through Wet Dry
Cooling System Type
Cap
tial C
ost,
$
Base+1.20 %
+12.5 %
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Normalized Plant Cost Normalized Capital Cost---500 MW Combined Cycle
380
390
400
410
420
430
440
450
460
470
Once-through Wet Dry
Cooling System Type
Nor
mal
ized
Cap
ital C
ost,
$/kW
Base +1.2 %
+12.5 %
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Design Heat Rate---500 MW Combined Cycle Plant
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Once-through Wet Dry
Cooling System Type
Hea
t Rat
e, B
tu/k
Wh
Base
+0.37 %
+0.71%
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Hot Day OutputHot Day Capacity Loss---500 MW Combined Cycle Plants(Includes Effect on Combustion Turbines)
0
10
20
30
40
50
60
Once-through Wet Dry
Cooling System Type
Hot
Day
Cap
acity
Los
s, M
W
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Cooling Water Taken In---500 MW Steam Plant
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
160,000
180,000
200,000
Once-through Wet Dry
Coo
ling
Wat
er T
aken
In, g
pm
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Cooling Water Consumed---500 MW Steam Plant
0
500
1,000
1,500
2,000
2,500
3,000
3,500
Once-through Wet Dry
Wat
er C
onsu
med
, gpm
?
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Capital Cost---500 MW Steam Plant
280,000,000
290,000,000
300,000,000
310,000,000
320,000,000
330,000,000
340,000,000
350,000,000
Once-through Wet Dry
Cooling System Type
Cap
tial C
ost,
$
Base +.43 %
+12.6 %
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Normalized Capital Cost---500 MW Steam Plant
560
580
600
620
640
660
680
700
720
Once-through Wet DryCooling System Type
Nor
mal
ized
Cap
ital C
ost,
$/kW
Base +.47 %
+12.8 %
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Design Heat Rate---500 MW Steam Plant
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Once-through Wet Dry
Cooling System Type
Hea
t Rat
e, B
tu/k
Wh
Base +3.7 %
+4.2%
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Hot Day Heat Rate Increase---500 MW Steam Plants
0%
1%
2%
3%
4%
5%
6%
7%
8%
9%
10%
Once-through Wet DryCooling System Type
Hea
t Rat
e In
crea
se, %
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Power costsPower for Cooling System Pumps and Fans
0
1,000
2,000
3,000
4,000
5,000
6,000
Once-through Wet Dry
Cooling System Type
Coo
ling
Sys
tem
Pow
er, k
W
Combined Cycle Steam
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Maintenance Costs
Labor, chemicals and equipment
Highly site-specific
Estimated at 1 to 3% of cooling system capital cost
10’s to 100’s of k$ per year---negligible in comparison to other cost items
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Levelized Cost Components for Sample Combined-Cycle Natural Gas Power Plant
Fuel Costs75%
Ins urance & Ad Valorem Costs
2%
Corporate Taxe s (w/Credits)
4%
Fixed O&M Costs1%
Capital & Financing -
Construction16%
Var iable O&M2%
Levelized Cost Components By Percent
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Production Cost Breakdown---Dry Cooling500 MW Combined-Cycle Plant
Capital10.86%
Fuel88.16%
Cooling power0.78%
Cooling Maintenance
0.19%
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Cost of Electricity---500 MW Combined-Cycle Plant
0
5
10
15
20
25
30
35
40
45
50
Once through Wet DryType of Cooling System
Cos
t of E
lect
rici
ty, $
/MW
h
Cost due to Capital Cost due to fuel
Base +1.86 % +3.30 %
Annualization factor--0.075; Cost of fuel--$6/MMBtu; Capacity factor--8,100 hours/year
43.05 $/MWh 43.85 $/MWh 44.47 $/MWh
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Cost of Electricity---500 MW Steam Plant
0
10
20
30
40
50
60
Once through Wet DryType of Cooling System
Cos
t of E
lect
rici
ty, $
/MW
h
Cost due to Capital Cost due to fuel
Base +3.08 % +4.86 %
Annualization factor--0.075; Cost of fuel--$6/MMBtu; Capacity factor--8,100 hours/year
52.60 $/MWh 54.22 $/MWh 55.16 $/MWh
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Additional considerations
Benefit of “a little bit” of water– Hybrid (wet/dry) systems – Spray enhancement
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Hybrid (wet/dry) system
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Tucuman 450 MW Combined Cycle (Argentina)PAC SYSTEM®
(Air Cooled Condenser & Wet Cooling System)
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Hybrid System Cost Estimate
Capital Cost of Cooling System
Water Conservationx
Plume Abatement
x
Hybrid System Range of Water Use
0% 100% (All Wet)15% 85%
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36
Spray enhancement
Spray water into inlet air stream of air-cooled condenserLow capital cost approachLow annual water useReduce inlet temperature by 5 to 10 FRestore “hot day” capacity loss
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38
Summary—Combined-Cycle Plants
Once-through Wet tower Dry cooling HybridPlant Cost
Capital, $ 198,800,000 201,200,000 223,700,000 VariableNormalized Capital Cost, $/kW 405.7 410.6 456.5 Variable
PerformanceCooling Sysem Power, kW 2,075 2,720 2,980 VariableDesign Heat Rate, Btu/kWh 6,549 6,573 2,980 Close to dry
Hot day Capacity Loss, MW Base 2.7 26.1 Close to wet
WaterWater taken in, gpm 132,410 2,290 0 (for cooling) 20 - 30% of wet
Water consumed, gpm De minimis ?? 2,048 0 (for cooling) "
Cooling SystemItems for comparison
500 MW Combined-Cycle Plant
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39
Summary—Steam Plants
Once-through Wet tower Dry cooling HybridPlant Cost
Capital, $ 302,900,000 304,200,000 341,300,000 VariableNormalized Capital Cost, $/kW 405.7 410.6 456.5 Variable
PerformanceCooling Sysem Power, kW 2,021 4,580 5,095 VariableDesign Heat Rate, Btu/kWh 7,800 8,088 8,129 Close to dry
Hot day Heat Rate, Btu/kWh Base 0.48% 8.62% Close to wet
WaterWater taken in, gpm 180,500 3,680 0 (for cooling) 20 - 30% of wet
Water consumed, gpm De minimis ?? 2,940 0 (for cooling) "
Items for comparison Cooling System500 MW Steam Plant