developing water conserving cooling options for...

Kent ZammitSr. Program Manager

Sean Bushart/Jessica Shi/Jose MarasiganSr. Program/Project Managers

EUEC ConferenceFebruary 1, 2011

Developing Water Conserving Cooling Options for Existing and New Power

Generation Plants

2© 2012 Electric Power Research Institute, Inc. All rights reserved.

Technology Innovation Water Conservation Program Overview and Objective• Initiated in early 2011• Funded by EPRI Office of Technology Innovation• Collaborated by three EPRI Sectors (Nuclear,

Generation, and Environment)• Broadly distributed Request for Information (RFI) to

solicit top technologies for development in Feb 2011

Objective

Seek and develop “out of the box”, game changing, early stage, and high risk cooling ideas and technologies with high potential for water conservation, performance, and financial improvements to members.


Received More Than 70 RFI Responses

• Many respondents never worked with power industry

• Second RFI will start later this year


Project 1: Replacing Cooling Tower and Steam Condenser with Green Chillers

• Cooling – Consumption: Water ~200 to 700

gal/MWh• Steam condensation temperature

– 100 °F

Present

Typical 500 MW Power Plant Cooling System.

Innovative ApproachGreen Chiller

Replace the cooling tower and steam condenser with green chillers.

Pros: • Evaporative cooling

Significantly higher heat removal rate than convective water cooling

• Closed loop cooling systemNear Zero water use and consumption

• Reduced condensation temperature As low as 50 °FPotential for increased power production

http://www.greenchiller.biz/

Waste HeatCold Air

http://www.greenchiller.biz/


Project 2: Advanced Fill to Enable Dew Point Cooling

Present FillWet Cooling Towers

– Water Consumption: ~200 to 700 gal/MWh– Evaporative and drift Loss: ~2/3 of

consumption– Cooled through cooling tower from 110 °F to

85 °F

Innovation: Advanced Fill• Cooling Water

– Consumption: Potential for 20% less evaporative loss

– Hot water cooled through cooling tower from 110 °F to 55 °F

– Lower steam condensation temperature potential

– More power production potential


Project 3: Thermosyphon Cooler

Innovation: Thermosyphon Cooler• Cooling Water Consumption:

More than 50% less annual evaporative lossMore than 50% annual makeup water use reduction

• In cold weather:Hot water cooled through cooling tower to lower than 85 °F if desirable

• Lower steam condensation temperature potential• More power production potential

PresentWet Cooling Towers

– Water Consumption: ~200 to 700 gal/MWh– Evaporative and drift Loss: ~2/3 of

consumption– Cooled through cooling tower from 110 °F to

85 °F

The thermosyphon cooler cools the hot coolant before the evaporative cooling in the cooling tower


Cooling Tower Steam

Condenser

Cool Water

Warm Water

Blo

wdo

wn

Mak

e-up

Wat

er

Evaporation & Drift

Breakthrough Technology Project:Heat Absorption Nanoparticles in Coolant

Innovation Benefits• Cooling Water Consumption:

20% less evaporative loss potentialLess drift Loss20% makeup water reduction potential

• NanoparticlesEnhanced cooling fluid thermal propertiesEase of retrofitting/Broad application

Phase Change Material (PCM) Core/Metal Shell Nano-particles added

into the coolant.

Nanoparticles with Heat Absorption Cores -Argonne National Laboratory • Particles provide increased surface tension/ heat of vaporization as well as increased heat capacitance of fluid • EPRI project will evaluate the concept of adding the Nanoparticles to power plant coolant to reduce evaporative loss


Summary and Future Activities

2011- Water Innovation Program Launch• Scouting through outreach to researchers, technology reviews

and Request for Information (RFI)• Received > 70 responses; Initializing five selected projects

2012- Expand Technology Innovation Activities• RFI Round 2

• New scouting focus on water treatment • Visits with key researchers• EPRI workshop on Water Treatment and Cooling Innovation

Strategic Industry Opportunity: Efficient electric technologies for water treatment, transport, and industrial processes can reduce

water demand and conserve electricity

Advanced Cooling Technology Supplemental Project


Advanced Cooling Technologies Project

Recent Deliverables• Technical Report 1024710,

Hybrid Cooling System; Technology Overview, November 2011

• Technical Update 1024495,Cooling Requirements and Water Use Impacts of Advanced Coal-fired Power Plants with CO2 Capture, December 2011

• Technical Update 1024805, Economic Evaluation of Alternative Cooling Technologies, January 2012

• Hybrid Steam Condensing System Optimization Tool, Final Software Version due March 2012


Potential ACT Projects to Support

• Corrosion Mechanisms in Air Cooled Condensers• Nano and Micro Structured Features to Promote Drop-

wise Condensation• Dual Coil Closed Circuit Cooler Technology• Wind Effects on Air-Cooled Condensers• Field Pilots of Thermosyphon Coolers


Corrosion Mechanisms in Air Cooled Condensers

Objectives and Scope• Research the corrosion mechanisms in

the ACC– Develop control techniques to

manage – Mitigate corrosion

• Reduce impact of deposition• Quantify benefits of advanced

technologies

Value• Improve performance and reduce

damage and reduce O&M cost• Increase component life and reliability

Improved Understanding and Control of Corrosion in ACC’s


Nano and Micro Structured Features to Promote Drop-wise Condensation

Objectives and Scope• Improve the efficiency of the

steam condensation process• Determine potential for lowering

turbine back-pressure• Development of an economical

and durable mechanism to promote higher drop-wise condensation efficiency

Value• Less water used for cooling• Increase power generation

efficiency

Improve cooling water efficiency for steam condensation


Dual Coil Closed Circuit Cooler Technology

Objectives and Scope• Evaluation of new hybrid wet/dry

cooling technologies• Improve efficiency of both

sensible and latent heat transfer• Development of an economical

and durable cooling process without the air side pressure drop increase

Value• Less water used for cooling• Plume abatement• Smaller footprint than ACCs or

other hybrid cooling designs

Evaluation of new hybrid cooling technologies


Wind Effects on Air-Cooled Condensers

Objectives and Scope• Evaluation of new design to

mitigate wind effect on ACC performance

• Continue work in wind models and sheer effect testing to optimize modifications

Value• Improve plant performance and

availability• Reduce hub and blade damage

caused by increased sheer forces

• Improve reliability and safety

Improve ACC performance, reduce blade and hub failures


Next ACT Project Meeting

• Scottsdale Resort & Conference Center

• Tuesday, February 21, 2012• Meeting agenda items

include:– Demonstration of Hybrid

Steam Condensing System Optimization Tool

– Review of specific ACT projects funded in 2012

– Identify additional ACT projects to support


Together…Shaping the Future of Electricity

developing water conserving cooling options for...

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