Developing Water Conserving Cooling Options for Existing and New Power Generation Plants

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1 Developing Water Conserving Cooling Options for Existing and New Power Generation Plants Kent Zammit Sr. Program Manager Sean Bushart/Jessica Shi/Jose Marasigan Sr. Program/Project Managers EUEC Conference February 1, 2011

2 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. 2

3 Received More Than 70 RFI Responses Many respondents never worked with power industry Second RFI will start later this year 3

4 Project 1: Replacing Cooling Tower and Steam Condenser with Green Chillers Present Typical 500 MW Power Plant Cooling System. Replace the cooling tower and steam condenser with green chillers. Innovative Approach Green Chiller Cold Air Waste Heat Cooling Consumption: Water ~200 to 700 gal/mwh Steam condensation temperature 100 F Pros: Evaporative cooling Significantly higher heat removal rate than convective water cooling Closed loop cooling system Near Zero water use and consumption Reduced condensation temperature As low as 50 F Potential for increased power production 4

5 Project 2: Advanced Fill to Enable Dew Point Cooling Present Fill Wet 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 5

6 Project 3: Thermosyphon Cooler The thermosyphon cooler cools the hot coolant before the evaporative cooling in the cooling tower Present Wet 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: Thermosyphon Cooler Cooling Water Consumption: More than 50% less annual evaporative loss More 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 6

7 Breakthrough Technology Project: Heat Absorption Nanoparticles in Coolant Evaporation & Drift Make-up Water Cooling Tower Blowdown Warm Water Cool Water Steam Condenser 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 Innovation Benefits Cooling Water Consumption: 20% less evaporative loss potential Less drift Loss 20% makeup water reduction potential Nanoparticles Enhanced cooling fluid thermal properties Ease of retrofitting/broad application 7

8 Summary and Future Activities Water Innovation Program Launch Scouting through outreach to researchers, technology reviews and Request for Information (RFI) Received > 70 responses; Initializing five selected projects 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 8

9 Advanced Cooling Technology Supplemental Project

10 Advanced Cooling Technologies Project Recent Deliverables Technical Report , Hybrid Cooling System; Technology Overview, November 2011 Technical Update , Cooling Requirements and Water Use Impacts of Advanced Coal-fired Power Plants with CO 2 Capture, December 2011 Technical Update , Economic Evaluation of Alternative Cooling Technologies, January 2012 Hybrid Steam Condensing System Optimization Tool, Final Software Version due March

11 Potential ACT Projects to Support Corrosion Mechanisms in Air Cooled Condensers Nano and Micro Structured Features to Promote Dropwise Condensation Dual Coil Closed Circuit Cooler Technology Wind Effects on Air-Cooled Condensers Field Pilots of Thermosyphon Coolers 11

12 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 12

13 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 13

14 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 14

15 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 15

16 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 16

17 Together Shaping the Future of Electricity 17