Bat Cooling Tower

BALCKE-DRR GmbH
BALCKE COOLING TECHNOLOGY

CWT/Te // BestAvailTec1.ppt # 1 Rel. 1.2 - 28.12.2002
BALCKE-DRR GmbH
BALCKE-DUERR GmbH

BALCKE-DRR GmbH
Topics
What is "Best Available Technique"? Wet Cooling Towers for Power Stations
Construction Principles Thermodynamic basics
Comparison Mechanical <-> Natural Draught

Design Data Type-specific advantages Economic comparison
Conclusion
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What is "Best Available Technique"?

Evaluation of distinctive marks relative to:
economic reason environmental restrictions requirements regarding cooling behaviour and temperature level principle of cooling air transportation construction demands availability of materials
Taking into account individual parameters:

geographic location (seismic risk, wind load, water quality, etc.) special site conditions (grounding, highway or airfield nearby, etc.) political situation (laws, government restrictions, etc.)

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The Power Generation Process
cooling ???
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Alternative Systems: recooling systems
wet
hybrid
dry
natural draught
mechanical draught with natural draught support
mechanical draught
forced draught preference on counter recooling flow systems

Rel. 1.2 - 28.12.2002
induced draught
forced draught
cross flow
counter flow
counter flow
cross flow
counter flow

CWT/Te // BestAvailTec1.ppt # 6
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Preference on Recooling Systems (2)
Which is the better one ?

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To answer the Question,

lets start with some basics!

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Basics of Heat and Mass Transfer (1)

1. Some basics of heat and mass transfer: basic equation by Merkel
K a V c dt Me Kv = w , L h2 h1 HWT
CWT
& L mw
Solving of this equation needs an iterative computer calculation! Start data are: dry bulb temperature wet bulb temperature hot water temperature cold water temperature Parameter is: air-water mass flow ratio DBT WBT HWT CWT
& mair G = (american literature) & water m L

Rel. 1.2 - 28.12.2002
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The cooling curve is a function of - DBT, WBT - HWT, CWT with as parameter
Merkel number
10
Choosing a cooling fill defines the necessary air-water mass flow ratio
The quality of a cooling fill influences the -value
0,1 0,1 1 10
air-water mass flow ratio

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Fill characteristics as an example !!
10
60
resistance coefficient z
0,1 1 10
Merkel number
40
20
0,1
0 0 1 2 3 4 5
air-water mass flow ratio
afflux velocity v [m/s]
Each fill has a thermal and an aerodynamic characteristic, and both influence the design! BALCKE COOLING TECHNOLOGY
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Conclusion
The thermal design data and the chosen fill define the air-water mass flow ratio is independent of the kind and the size of the cooling tower !
& With the circulating cooling water mass flow mw the absolute air & mass flow mair is defined by
The specific water loading per cross area = rain density now influences the design

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Design Data for a 500 MW Power Station

water flow rate hot water temperature cold water temperature cooling range dry bulb temperature wet bulb temperature relative humidity barometric pressure WFR HWT CWT z DBT WBT pb t/h C C K C C % hPa 60 000 42.7 32.0 10.7 36.0 27.0 50.0 1013

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Dimensions of the Possible Solutions

Cell type cooling tower in-line (double air inlet)
2 banks ! 30
10 3.5
14 .4
16.8 BALCKE COOLING TECHNOLOGY

12
ce lls
17 2.8
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Cell type cooling tower back-to-back (single air inlet)
2 banks ! 30
12
6.0
16 .8
14.4 BALCKE COOLING TECHNOLOGY

6t wi n 10 -ce 0. lls 8 =
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Natural draught cooling tower
70
165 154
108 11
~118 BALCKE COOLING TECHNOLOGY

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Induced Draught In-Line Cell CT

constant air volume flow rate in relation small rain area (heat exchange area) low pumping head low investment cost
high demand in ground area long pipelines, many valves high expense in mechanical equipment high expense in maintenance & repair needs a switch yard, cables, sensors & control system sensible against cross wind: recirculation and interference ! design correction according to Standards! ground pluming possible

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Induced Draught Back-to-back Cell CT

constant air volume flow rate in relation small rain area (heat exchange area) ground area lower than in-line design low investment cost
high pumping head bad air distribution, lower thermal efficiency long pipelines, many valves high expense in mechanical equipment high expense in maintenance & repair needs a switch yard, cables, sensors & control system sensible against cross wind: recirculation and interference ! design correction according to Standards! ground pluming possible

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Natural Draught Cooling Tower
simple and cheap pipeline design no mechanical equipment neglectable maintenance and repair no electrical equipment, no extra power consumption no start-up regulations no recirculation or ground pluming
air flow dependent on ambient air conditions low air velocity, great rain area (exchange area) high chimney, high investment cost

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Some Arguments in Detail ...

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Fan Power Consumption as a Function of the Rain Area

3,5
3,0
2,5
Pfan /Pfan0
2,0
1,5
1,0 0,6 0,5
0,7
0,8
0,9
1,0
1,1
Arain / Arain0
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Ground Area Requirement

Two banks of in-line-cells need around 178 x 120 m ground 21 360 m Two banks of back-to-back-cells need around 110 x 140 m ground 15 400 m
The natural draught CT needs a circle of ~120 m ground 11 300 m

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Recirculation and Interference
Feed-back of emitted plume is called RECIRCULATION ...
... and feeding the neighbouring bank with plume is called INTERFERENCE BALCKE COOLING TECHNOLOGY
Rel. 1.2 - 28.12.2002
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Recirculation and Interference (2)

Recirculation and interference are physical effects which can not be avoided recirculation depends on wind velocity and wind direction:
wind velocity between 3 and 10 m/s (maximum ~ 5 m/s) wind direction between 30 to 150 to longitudinal axis (maximum around 60 resp. 120)
interference is a function of the wind velocity and wind direction as well as the site arrangement:
velocity and direction as above mentioned small distance of banks increase the interference impact, distance = bank length: interference neglectable the worst multiple-bank-arrangement is perpendicular to the main wind direction

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Recirculation and Interference (3)

The recirculation rate amounts to 5 to 10 % feed-back of plume The interference may increase up to 50 % plume in the incoming air, 10 to 20 % is not unusal The consequence is an increase in air inlet temperature and humidity, i.e. increase in WBT According to British Standard 4485, part 3 it is recommended to oversize a cell type cooling tower The BS recommendation is a weak solution (wind tunnel test) The effect of recirculation is demonstrated
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Necessary Oversizing of Cell CTs due to Recirculation

20 18 16
recirculation rate [%]
4
no of additional cells
14 12 10 8 6 4 2 0 0,0 0,5 0,5 1,0 1,0 1,5 1,5 WBT [K][K] WBT 2,0 2,0 0 1 2 3
2,5 2,5

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Economic Comparison
between In-Line Cell Type Cooling Tower and Natural Draught Cooling Tower
Please, remember: all factors in the following are relative !!

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Cost Factors for NDCT

Investment cost
civil construction including engineering Thermo-hydraulic equipment Transport and erection (labour)
Operation cost (annual cost)

pumping power consumption maintenance and repair spare parts

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Cost Factors for IDCCT (1)

Investment cost
civil construction including engineering Thermo-hydraulic equipment Mechanical parts (fan, gearbox, shaft, motor etc.) Transport and erection (labour) electrical components for power supply transformer switch house circuit breakers cables and cable trays etc.

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Cost Factors for IDCCT (2)

Operation cost (annual cost)
pumping power consumption fan power consumption maintenance and repair permanent checks of
oil temperature oil filling level vibrations, noise current (amps) control circuit breakers contacts etc.
spare parts lifetime of a gearbox ~ 40 000 h lifetime of a motor ~ 80 000 h lifetime of a fan ~ 60 000 h
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Cost Comparison
Investment cost
Erection - installation Cooling Tower Erection-installation power supply Total investment Difference in investment $ $ $ $
Induced Draught Cell CT
15.100.000 0 15.100.000 5.915.000
8.700.000
Evaluation parameters:
485.000 specific energy price: 9.185.000 0.05 $/kWh
annual operating hours: 7 500 h/a
Operating cost
Pumping power consumption (only CT) Fan power consumption Total power consumption kW kW kW 2.500 0 2.500 1.750 2.088 3.838
Evaluated power consumption Maintenance, repair, spare parts Annual cost Difference in annual cost
$/a $/a $/a $/a
937.500 ???
1.439.250 ???
15.000
952.500 ???
480.000
1.919.250 ???
966.750 ???

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Operating Cost: Graphic Calculation

180 160 140 120 100
annual cost [1000 $/a]
example: power consumption: 175 kW energy cost : 0,05 $/kWh operation time : 7'500 h/a result: annual cost :66'500 $/a
annual operation time
80 60 40 20 0 -20 -40 -60 -80 0 20 40 60 80 100 120 140 160 180 200
52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0
8760 h/a 8000 h/a 7000 h/a 6000 h/a 5000 h/a 4000 h/a
0,08 $/kWh 0,06 $/kWh 0,04 $/kWh 0,02 $/kWh
220
power consumption [kW]

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Cost Comparison, modified example

Natural Draught Cooling Tower Induced Draught Cell Evaluation parameters: CT
Investment cost
Erection - installation Cooling Tower Erection-installation power supply Total investment Difference in investment $ $ $ $ 15.100.000 0 15.100.000 5.915.000
specific energy price:

8.700.000 485.000
0.07 $/kWh annual operating hours: 8 000 h/a
9.185.000
Operating cost
Pumping power consumption (only CT) Fan power consumption Total power consumption kW kW kW 2.500 0 2.500 1.750 2.088 3.838
Evaluated power consumption Maintenance, repair, spare parts Annual cost Difference in annual cost
$/a $/a $/a $/a
1.400.000
2.149.280
15.000
1.415.000
480.000
2.629.280
1.214.280

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Break-even of Compared CTs

0,05 $/kWh 7 500 h/a 0,07 $/kWh 8 000 h/a 5.915.000 1.214.280 4,9 20,5
Difference in investment Difference in annual cost

Simplified pay-back time Necessary annuity
$ $/a a %/a %/a a
5.915.000 966.750 6,1 16,4
/ * 100
Interest rate
14
14,8
12
7,8
Commercial calculated pay-back time
annuity
IndiaComparison.xls

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Summary
1. Background of the economic comparison
There are 4 independent variables for evaluation: specific price for energy $/kWh number of operating hours per year h/a interest rate for credits %/a The pay-back time can be calculated simplified (valid only for low interest rates) using the commercial annuity as a function of interest rate and pay-back time %/a The correct figures depend on country political and economic situation and what you want to get!!
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2. Technical/economic comparison of the Cooling Systems

The specifics of the IDCCT:
always the lowest investment a small advantage in pumping head great expense in mechanical devices, maintenance & repair, spare parts high demand in personnel stuff
The specifics of the NDCT:

always the highest investment higher pumping head compared to In-line IDCCT (not against Back-to-back IDCCT!) no trouble, no cost after start-up
Not taken into account for evaluation

Recirculation/Interference influence on design data for IDCCT Ground area demand of IDCCT
Not regarded, but not decisive:

erection time (more or less the same) noise reduction BALCKE COOLING TECHNOLOGY
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Conclusion
For basic load and long time investment ( 15 years) the

is always the most rigid and most economic solution !
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The End
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Splash fill for muddy water Types of Cooling Fill

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Foil fill for clean water

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Annuity for Transfer from Investment to Annual Payment

28 26
Annuitt annuity [%/a]
24 22 20 18 16 14 12 10 8 6 5 Jahre - years 8 Jahre - years 10 Jahre - years 12 Jahre - years 15 Jahre - years 20 Jahre - years
10 11 12 13
14
15 16
Zinssatz interest rate [%/a]


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BALCKE-DRR GmbH

BALCKE COOLING TECHNOLOGY

BALCKE COOLING TECHNOLOGY

Comparison Mechanical <-> Natural Draught

What is "Best Available Technique"?

Taking into account individual parameters:

BALCKE COOLING TECHNOLOGY

The Power Generation Process

Alternative Systems: recooling systems

mechanical draught with natural draught support

forced draught preference on counter recooling flow systems

BALCKE COOLING TECHNOLOGY

Preference on Recooling Systems (2)

Which is the better one ?

To answer the Question,

BALCKE COOLING TECHNOLOGY

Basics of Heat and Mass Transfer (1)

& mair G = (american literature) & water m L

Rel. 1.2 - 28.12.2002

Basics of Heat and Mass Transfer (2)

The quality of a cooling fill influences the -value

air-water mass flow ratio

BALCKE COOLING TECHNOLOGY

Basics of Heat and Mass Transfer (3)

air-water mass flow ratio

afflux velocity v [m/s]

BALCKE COOLING TECHNOLOGY

Design Data for a 500 MW Power Station

BALCKE COOLING TECHNOLOGY

Dimensions of the Possible Solutions

16.8 BALCKE COOLING TECHNOLOGY

Dimensions of the Possible Solutions

14.4 BALCKE COOLING TECHNOLOGY

Dimensions of the Possible Solutions

~118 BALCKE COOLING TECHNOLOGY

Induced Draught In-Line Cell CT

BALCKE COOLING TECHNOLOGY

Induced Draught Back-to-back Cell CT

BALCKE COOLING TECHNOLOGY

Natural Draught Cooling Tower

BALCKE COOLING TECHNOLOGY

Some Arguments in Detail ...

BALCKE COOLING TECHNOLOGY

Fan Power Consumption as a Function of the Rain Area

1,0 0,6 0,5

Ground Area Requirement

The natural draught CT needs a circle of ~120 m ground 11 300 m

BALCKE COOLING TECHNOLOGY

Recirculation and Interference

Feed-back of emitted plume is called RECIRCULATION ...

Rel. 1.2 - 28.12.2002

Recirculation and Interference (2)

BALCKE COOLING TECHNOLOGY

Recirculation and Interference (3)

Necessary Oversizing of Cell CTs due to Recirculation

BALCKE COOLING TECHNOLOGY

Please, remember: all factors in the following are relative !!

Cost Factors for NDCT

Operation cost (annual cost)

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Cost Factors for IDCCT (1)

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Cost Factors for IDCCT (2)