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Air cooled condensers

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PC- TEAM AMIT NAYAK PRAVEEN PRAJAPATI RAVI PAL SINGH SHAHNAWAZ AKHTAR KHAN CO ORDINATOR SHRI D. N. TIWARI AGM MAINTENANCE NTPC TANDA
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  • PC-

    TEAM AMIT NAYAK

    PRAVEEN PRAJAPATI RAVI PAL SINGH

    SHAHNAWAZ AKHTAR KHAN

    CO ORDINATOR SHRI D. N. TIWARI AGM MAINTENANCE

    NTPC TANDA

  • Sl. No DATE THEME/TOPIC SPEAKER Name & NO. OF

    MEMBER PRESENT

    SYNOPSIS OF

    PRESENTATION

    1

    2-JULY-

    2012 Sacrificial anode AMIT NAYAK

    O&M

    executives; 12 nos

    Knowledge sharing:

    Condenser Tube

    leakages causes &

    remedies

    2

    8-AUG-

    2012 Condensate System RAVI PAL SINGH

    Operation Group-C

    executives; 20 nos

    Knowledge sharing:

    Condensate System

    Emergency handling

    3

    6-SEP-

    2012 APH Performance PRAVEEN PRAJAPATI

    O&M

    executives; 12 nos

    Knowledge sharing:

    APH Performance and

    Leakage Control

    4 3- OCT-

    2012

    Compressed Air

    System

    SHAHNAWAZ

    AKHTAR KHAN

    O&M

    executives; 15 nos

    Knowledge sharing:

    Compressed Air System

    performance

    5 4-JAN-

    2013 Rotary Parts PRAVEEN PRAJAPATI

    NRHQ, GM-OS and

    senior executives of

    NTPC stations of

    Northern Region; 35

    nos

    Outages and O&M

    Practices @ NTPC

    Tanda

    KNOWLEDGE SHARING BY ShARP

  • NEED OF HOUR AIR COOLED CONDENSER TO

    CURTAIL POWER PLANT THIRST

  • LAYOUT

    WHY AIR COOLED CONDENSER WATER USED IN THERMAL POWER PLANTS FUTURE WATER DEMAND WATER CONSERVATION IN POWER PLANTS AIR COOLED CONDENSER STATIONS RUNNING ON AIR COOLED CONDENSER RESEARCH AND FINDINGS VENDORS FUTURE SCOPE MAJOR IMPACT USING AIR COOLED CONDENSER CONCLUSION

  • WHY AIR COOLED CONDENSER

  • WHY AIR COOLED CONDENSER CONTD...

    Source: 2nd water council, worldwatercouncil.org

  • WHY AIR COOLED CONDENSER CONTD...

  • WHY AIR COOLED CONDENSER CONTD...

    Water energy nexus

  • Its been said,

    were going to

    run out of fresh water,

    before we run out of OIL.

  • Water Use in Thermal Power Plants

    POWER PLANT TYPE Range

    m3/MW

    Gas based power plants 1.7 - 2.0

    200 MW coal based thermal power plants 4.5 - 5.0

    500 MW coal based thermal power plants 3.5 - 4.5

    200 MW coal based power plants with ash water recycling 3.5 - 4.0

    660 MW coal based super thermal power plants with ash

    water recycling 3.0 - 4.0

    110 MW coal based old power plants 7.0 - 8.0

    Source: Report on minimization of water requirement in coal based thermal power stations by CEA : January 2012

  • Water Use in Thermal Power Plants

    Cooling Water (CW)

    Make-up Water

    Demineralised Water (DM water)

    Ash Handling Water

    Service Water

    Fire Water

    Potable Water

  • Water use for specific purposes (2x500 MW)

    Cooling tower make up

    DM water make up

    Potable & service water

    Clarifier sludge etc.

    Coal dust suppression

    AREA CONSUMPTION m3/h WATER USE (%)

    Cooling tower make up 3450 86.25

    DM water make up 120 3

    Potable & service water 250 6.25

    Clarifier sludge etc. 110 2.75

    Coal dust suppression 70 1.75

    TOTAL 4000 100

    Ash disposal* 1300 32.5

    *To be tapped from CW system as blow down water and as such not considered in consumptive water.

    Water Use in Thermal Power Plants

    Source: Report on minimization of water requirement in coal based thermal power stations by CEA : January 2012

  • Future water demand

    0

    20

    40

    60

    80

    100

    120

    140

    2010 2025 2050

    STANDING SUB COMMITTEE, MOWR

    NCIWRD

    Wat

    er D

    eman

    d (

    BC

    M)

    Source: Water Use and Efficiency in Thermal Power Plants : FICCI HSBC Knowledge Initiative

  • Water Stress in INDIA

    Lots of Power Projects are getting delayed due to land acquisition problems.

    Barren or arid Land for setting power plants can be a solution.

  • Water conservation in thermal power plants

    Increasing cycles of concentration

    Optimising ash-water ratio

    Recycling ash water from the ash dyke

    Using air cooled condensers

    Reducing leaks and over flows

    Wastewater recycling

  • AIR COOLED CONDENSER

  • Wuxiang, China 2x600 MW Coal Fired Power Plant

  • Rio Bravo, Mexico ACC for 3x515 MW Combined Cycle Power Plant

  • Types of AIR COOLED CONDENSER

  • Types of AIR COOLED CONDENSER

  • Hybrid Cooling System

    Types of AIR COOLED CONDENSER

  • AIR COOLED CONDENSER

    Finned tubes

    Steel tube

    Aluminium fins

    Aluminium coated on tube air side

    Source: M/s SPX Air cooled Condenser Brochure

  • Routine maintenance of

    DCS using jet

    AIR COOLED CONDENSER

  • STATIONS RUNNING ON AIR COOLED CONDENSER Power Plants

    2X350MW Ind Barath Power India Ltd. Orissa.

    135 MW KSK Energy, Rajasthan.

    81.5 MW Sarda Energy, Siltara plant.

    Captive Power Plants

    Birla White

    Jaypee Group

    J.K. Laxmi

    Shree Cements

    Ultratech Cements.

  • GLOBAL STATIONS RUNNING ON AIR COOLED CONDENSER

  • RESEARCH

    AND

    FINDINGS

  • ASSUMPTIONS

    Capital cost : 5 crore/MW

    Auxiliary power consumption : 6.5 % with IDCT

    : 6.0% with NDCT

    O&M cost : 13 lakh/MW/year

    Unit heat rate : 2425 kcal/kWh

    For 2X500 MW PLANT

  • Findings Sl no

    Description

    Wet Cooling System (NDCT)

    Direct Dry Cooling System (ACC)

    Indirect Dry Cooling System (ACC)

    1 Condenser Pressure 0.1019 Ksc .1835 Ksc .2243 Ksc 2 Gross unit output, MW 500 466.72 465.11 3 Capital cost Crore 2500 2601.5 2675.5 4 Crore/MW 5 5.57 5.75

    5 Auxiliary power

    consumption, % of gross

    output 6 6.64 6.12 6 Gross heat rate, kcal/kWh 2425 2597.9 2606.9 7 O&M cost lakh/MW 13 12.08 12.13

    8

    First year tariff

    Fixed charges Rs/kWh 1.59 1.75 1.79

    Variable charges

    Rs/kWh 0.71 0.77 0.77

    Total Rs/kWh 2.31 2.52 2.56 9 Difference in tariff Rs/kWh Base 0.21 0.25

    10

    Levelised tariff

    Fixed charges Rs/kWh 1.42 1.53 1.56

    Variable charges

    Rs/kWh 1.21 1.3 1.3

    Total Rs/kWh 2.63 2.83 2.86 11 Difference in tariff Rs/kWh Base 0.21 0.23

    Source: Report on minimization of water requirement in coal based thermal power stations by CEA : January 2012

  • Findings

    Description

    Difference in Levelised Tariff(Rs/Kwh)

    Wet Cooling

    System

    Direct Dry Cooling

    System

    Indirect dry cooling

    system

    Condenser Back

    Pressure .1835 Ksc .2243 Ksc

    Plant at load

    Centre

    Base(NDCT) 0.31 0.34

    Base (IDCT) 0.32 0.34

    Plant at pit-head Base(NDCT) 0.21 0.23

    Base (IDCT) 0.21 0.24

  • CW Water & Treatment Cost @ NTPC Tanda

    DESCRIPTION Consumption(Kg/Day) Matl Cost(Rs/KG) Total Annual Cost Manpower

    Cost(Per Month)

    Annual ManpowerCost

    POLY ALUMINIUM CHLORIDE 500.00 6.75 1231875.00 24000.00 2,88,000.00

    SCALE INHIBITOR 84.00 70.00 206955.00

    35000.00 4,20,000.00 CORROSION INHIBITOR 84.00 60.00 206955.00

    BIO DISPERSANT 24.00 40.00 59130.00

    CLO2 8.00 55.00 19710.00

    CHLORINE DOSING 400.00 11.00 985500.00 30000.00 3,60,000.00

    SUB TOATAL 2710125.00 10,68,000.00

    TOTAL TREATMENT COST 37,78,125.00

    WATER COST PAID TO IRRIGATION DEPT

    2,64,00,000.00

    TOTAL COST OF CW WATER 3,01,78,125.00

    ANNUAL LDO CONSUMTION .54 ml per unit 1,449.36

    TOTAL COST OF LDO Rs 40000 per kl 5,79,74,400.00

  • @ NTPC Tanda

    TOTAL COST OF CW WATER : 3,01,78,125.00 TOTAL COST OF LDO : 5,79,74,400.00 (in Rs. Per annum)

  • LAND SAVING WITHOUT RESERVOIR

    MW STEAM FLOW TPH ACRE m2 ACC m2

    LAND SAVING % LAND SAVING

    500 1568.00 14.00 56000.00 9910.00 46090.00 82.30

    660 2250.00 18.00 72000.00 14016.00 57984.00 80.53

    800 2400.00 22.50 90000.00 15336.00 74664.00 82.96

    WITH RESERVOIR

    MW STEAM FLOW TPH ACRE m2 ACC m2

    LAND SAVING % LAND SAVING

    500 1568.00 34.00 136000.00 9910.00 126090.00 92.71

    660 2250.00 44.00 176000.00 14016.00 161984.00 92.04

    800 2400.00 55.00 220000.00 15336.00 204664.00 93.03

    SOURCE: REVIEW OF LAND REQUIREMENTFOR THERMAL POWER STATIONS-CEA, SEPT 2010

  • VENDORS

    M/S SPX, NORTH CAROLINA,USA

    M/S THERMAX, PUNE.

    M/S GEA ENERGY TECHNOLOGY, BHOPAL DIVISION

    M/S ENERGO

    M/S CLASSIK COOLING TOWERS, COIMBATORE

    M/S PRECESION COOLING SYSTEM, CHENNAI

  • Design parameters

    DESIGN REQUIREMENTS VALUE UNIT

    EXHAUST STEAM FLOW 100 t/hr

    EXHAUST STEAM PRESSURE 0.1835 Ksc

    EXHAUST STEAM QUALITY 92 %

    AIR INLET TEMPERATURE 30 C

    BAROMETRIC PRESSURE 101.3 kPa

    TEHRMAL PERFORMANCE VALUE UNIT CONDENSING TEMPERATURE 58 C

    HEAT LOAD 60.4 MW

    ARRANGMENT VALUE UNIT NUMBER OF FAN MODULES

    REQUIRED 4 NUMBER OF A-FRAMES

    REQUIRED 1

    PLOT AREA 585 m2

    ACC WIDTH 12.3 m

    ACC LENGTH 47.6 m

    INLET HEIGHT 9.2 m

    FAN DETAILS VALUE UNIT

    FAN DIAMETER 32 ft

    FAN SHAFT POWER (TOTAL) 765 kW

    FAN SHAFT POWER (PER FAN) 191.2 kW Source : GEA energy technology

  • FURTHER SCOPE OF AIR COOLED CONDENSER Utilisation of hot air discharge in air-flue gas

    cycle of boiler.

    Natural draught cooling towers in place of forced draught fans to reduce APC in dry cooling system.

  • MAJOR IMPACT USING AIR COOLED CONDENSER

    Systems Wet Cooling System Dry Cooling System

    Major Equipments Cooling tower and surface condenser Air Cooled Condenser

    Availability of coolant Water at what cost / Is it available ? Air is free

    Plant location Should be near water source to reduce

    cost Water source is not criteria

    Maintenance cost High 25% of that for wet cooling

    system

    Effluent treatment Necessary Not required

    Fouling and scaling Major concern Not a concern

    Cleaning Frequent tube side cleaning is

    necessary

    Occasional fin cleaning is

    required

    Total plant set up Involves intake water, pumping system

    and storage facility No such infrastructure required

    Area for complete

    system More Less

    Annual Energy

    Consumption High Low

  • CONCLUSION Exponentially rising demand of power In future there may be a situation in which water sources may not

    cope up with this requirement. Norms of the regulatory authorities regarding usage of natural

    resources will be further tightened, which will curtail the freedom of usage of water in power plant.

    By employing air cooled system, which eliminate dependencies on water for CW, locating stations in water scarce regions will be more possible.

    Although dry cooling systems are costly technologies on techno-economic considerations, but foreseeing the future, it is the need of hour to employ dry cooling system, which offers possible solution for power plant installation eliminating the above mentioned challenges.

  • Its a thirsty world...

  • Industry is thirsty

  • Agriculture is thirsty

  • We are thirsty

  • REFRENCES Mr. Romit Sen, Senior Assistant Director, FICCI Water Mission: FICCI HSBC, Knowledge

    Initiative on Water Use and Efficiency in Thermal Power Plants. The Integrated Energy Policy, Govt. of India www.indiapower.org - accessed on June 30, 2011 The Bulletin on Energy Efficiency, 2006, Volume 7, Issue 3 Report of the Steering Committee on Water Resources for XI Five Year Plan Phansalkar Sanjiv and Verma Shilp; India's Water Future 2050: Potential Deviations from

    Business International Journal of Rural Management (2007) 3: 14 Technical EIA Guidance Manual for Thermal Power Plants, MoEF, 2009 Report on minimization of water requirement in coal based thermal power stations:

    central electricity authority, New Delhi, January 2012 C. P. Kumar Scientist F, National Institute of Hydrology, Roorkee: Water Status and

    Problems in India Audrey Maheu, McGill University: Energy choices and their impacts on demand for water

    resources: An assessment of current and projected water consumption In global energy production

    Anna Delgado Martin, Massachusetts of Technology: Water Footprint of Electric Power Generation: Modelling its uses and Analyzing options for a water-scarce future

  • Thank you


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