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Page 1: Air cooled condensers

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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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

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NEED OF HOUR “AIR COOLED CONDENSER TO

CURTAIL POWER PLANT THIRST’’

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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

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WHY AIR COOLED CONDENSER

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WHY AIR COOLED CONDENSER CONTD...

Source: 2nd water council, worldwatercouncil.org

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WHY AIR COOLED CONDENSER CONTD...

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WHY AIR COOLED CONDENSER CONTD...

Water energy nexus

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It’s been said,

we’re going to

run out of fresh water,

before we run out of OIL.

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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

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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

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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

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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

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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.

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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

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AIR COOLED CONDENSER

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Wuxiang, China 2x600 MW Coal Fired Power Plant

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

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Types of AIR COOLED CONDENSER

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Types of AIR COOLED CONDENSER

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Hybrid Cooling System

Types of AIR COOLED CONDENSER

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AIR COOLED CONDENSER

Finned tubes

• Steel tube

• Aluminium fins

• Aluminium coated on tube air side

Source: M/s SPX Air cooled Condenser Brochure

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Routine maintenance of

DCS using jet

AIR COOLED CONDENSER

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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.

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GLOBAL STATIONS RUNNING ON AIR COOLED CONDENSER

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RESEARCH

AND

FINDINGS

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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

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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

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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

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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

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@ 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)

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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

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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

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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

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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.

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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

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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.

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It’s a thirsty world...

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Industry is thirsty…

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Agriculture is thirsty…

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We are thirsty…

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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

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Thank you


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