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

Rel. 1.2 - 28.12.2002
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
Rel. 1.2 - 28.12.2002
BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
The Power Generation Process
cooling
???
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BALCKE-DRR GmbH
Alternative Systems: recooling systems
wet
natural
draught
hybrid
mechanical draught
with natural draught
support
forced
draught
cross
flow
counter
flow
preference
on
counter
recooling
flow
systems
dry
mechanical
draught
induced
draught
counter
flow
forced
draught
cross
flow
counter
flow

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BALCKE-DRR GmbH
Preference on Recooling Systems (2)
Which is the
better one ?
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BALCKE-DRR GmbH
To answer the Question,

lets start with some basics!

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BALCKE-DRR GmbH
Basics of Heat and Mass Transfer (1)

1. Some basics of heat and mass transfer:
K a V
c dt
Me Kv
= w
,
L
h2 h1
HWT
CWT
basic equation by Merkel
&w
Lm
Solving of this equation needs an iterative computer calculation!

Start data are:
dry bulb temperature
DBT
wet bulb temperature
WBT
hot water temperature
HWT
cold water temperature
CWT
Parameter is:
air-water mass flow ratio
& air
m
G
=
(american literature)
&
m water
L
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BALCKE-DRR GmbH

The cooling curve is a function of
10
- DBT, WBT
- HWT, CWT
Choosing a cooling fill

defines the necessary
The quality of a cooling fill

influences the -value
Merkel number
with as parameter
0,1
0,1
10

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BALCKE-DRR GmbH

Fill characteristics as an example !!
60
resistance coefficient z
Merkel number
10
0,1
40
20
0,1
10
afflux velocity v [m/s]
Each fill has a thermal and an aerodynamic characteristic,

and both influence the design!
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BALCKE-DRR GmbH
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 !
& w the absolute air

With the circulating cooling water mass flow m
& air is defined by
mass flow m
The specific water loading per cross area = rain density
now influences the design

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BALCKE-DRR GmbH
Design Data for a 500 MW Power Station
water flow rate

hot water temperature
cold water temperature
cooling range
WFR
HWT
CWT
z
t/h
C
C
K
dry bulb temperature

wet bulb temperature
relative humidity
barometric pressure
DBT
WBT
pb
C
C
%
hPa
60 000
42.7
32.0
10.7
36.0
27.0
50.0
1013

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BALCKE-DRR GmbH
Dimensions of the Possible Solutions

Cell type cooling tower in-line (double air inlet)
2 banks !
12
ce
lls
17
2.8
30
10
14
.4
3.5
16.8
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BALCKE-DRR GmbH

Cell type cooling tower back-to-back (single air inlet)
2 banks !
12
6t
wi
n
10 -ce
0. lls
8
=
30
16
.8
6.0
14.4
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BALCKE-DRR GmbH

Natural draught cooling tower
70
165 154
108
11
~118
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BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
Some Arguments in Detail ...

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BALCKE-DRR GmbH
Fan Power Consumption as a Function of the Rain Area

3,5
3,0
Pfan /Pfan0
2,5
2,0
1,5
1,0
0,6
0,7
0,8
0,9
1,0
1,1
0,5
Arain / Arain0
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BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
Recirculation and Interference
Feed-back of emitted plume is called

RECIRCULATION ...
... and feeding the neighbouring bank

with plume is called INTERFERENCE
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BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
Necessary Oversizing of Cell CTs due to Recirculation

20
18
4
14
12
10
8
6
4
no of additional cells
recirculation rate [%]
16
2
0
0
0,0
0,5
0,5
1,01,0
1,5 1,5
2,0 2,0
2,5 2,5
WBT
WBT
[K][K]

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

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BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
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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BALCKE-DRR GmbH
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
Rel. 1.2 - 28.12.2002
BALCKE-DRR GmbH
Cost Comparison
Natural Draught
Induced Draught
Cooling Tower
Cell CT
8.700.000
Investment cost
Erection - installation Cooling Tower
15.100.000
Erection-installation power supply
Total investment
15.100.000
5.915.000
Difference in investment
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)
kW
2.500
1.750
Fan power consumption
kW
2.088
kW
2.500
3.838
Evaluated power consumption
$/a
937.500
???
1.439.250
???
Maintenance, repair, spare parts
$/a
15.000
480.000
Annual cost
$/a
952.500
???
1.919.250
???
Total power consumption
Difference in annual cost
$/a
966.750
???

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BALCKE-DRR GmbH
Operating Cost: Graphic Calculation

180
160
140
120
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
annual operation time
example:
power consumption: 175 kW
energy cost
: 0,05 $/kWh
operation time
: 7'500 h/a
result:
annual cost
:66'500 $/a
annual cost [1000 $/a]
100
80
60
40
20
0
-20
-40
-60
-80
0
20
40
60
80
100
120
140
160
180
200
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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BALCKE-DRR GmbH
Cost Comparison, modified example

Natural Draught
Cooling Tower
Investment cost
Induced Draught
Cell Evaluation
CT
parameters:
specific energy price:
Erection - installation Cooling Tower
15.100.000
8.700.000
Erection-installation power supply
485.000
Total investment
15.100.000
9.185.000
5.915.000
0.07 $/kWh
annual operating hours:
8 000 h/a
Operating cost
Pumping power consumption (only CT)
kW
2.500
1.750
Fan power consumption
kW
2.088
kW
2.500
3.838
Evaluated power consumption
$/a
1.400.000
Maintenance, repair, spare parts
$/a
15.000
Annual cost
$/a
1.415.000
Total power consumption
$/a
2.149.280
480.000
2.629.280
1.214.280

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BALCKE-DRR GmbH
Break-even of Compared CTs
$/a
Simplified pay-back time

Necessary annuity
/ * 100
Interest rate
0,05 $/kWh
0,07 $/kWh
7 500 h/a
8 000 h/a
5.915.000
5.915.000
966.750
1.214.280
6,1
4,9
%/a
16,4
20,5
%/a
14
12
Commercial calculated pay-back time
annuity
14,8
7,8
IndiaComparison.xls

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BALCKE-DRR GmbH
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!!
Rel. 1.2 - 28.12.2002
BALCKE-DRR GmbH
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
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BALCKE-DRR GmbH
Conclusion
For basic load

and
long time investment ( 15 years)
the

is always
the most rigid
and most economic
solution !
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BALCKE-DRR GmbH
The End
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BALCKE-DRR GmbH
Splash
muddy water
Typesfilloffor
Cooling
Fill

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BALCKE-DRR GmbH
Foil fill for clean water

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BALCKE-DRR GmbH
Annuity for Transfer from Investment to Annual Payment

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

Rel. 1.2 - 28.12.2002

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BALCKE-DRR GmbH

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

Comparison Mechanical <-> Natural Draught

Rel. 1.2 - 28.12.2002

What is "Best Available Technique"?

Taking into account individual parameters:

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

The Power Generation Process

Rel. 1.2 - 28.12.2002

Alternative Systems: recooling systems

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

Preference on Recooling Systems (2)

Rel. 1.2 - 28.12.2002

To answer the Question,

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

Basics of Heat and Mass Transfer (1)

basic equation by Merkel

Solving of this equation needs an iterative computer calculation!

wet bulb temperature

hot water temperature

cold water temperature

Rel. 1.2 - 28.12.2002

Basics of Heat and Mass Transfer (2)

Choosing a cooling fill

The quality of a cooling fill

air-water mass flow ratio

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

Basics of Heat and Mass Transfer (3)

air-water mass flow ratio

afflux velocity v [m/s]

Each fill has a thermal and an aerodynamic characteristic,

Rel. 1.2 - 28.12.2002

The thermal design data and the chosen fill

& w the absolute air

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

Design Data for a 500 MW Power Station

water flow rate

dry bulb temperature

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

Dimensions of the Possible Solutions

Rel. 1.2 - 28.12.2002

Dimensions of the Possible Solutions

Rel. 1.2 - 28.12.2002

Dimensions of the Possible Solutions

Rel. 1.2 - 28.12.2002

Induced Draught In-Line Cell CT

high demand in ground area

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

Induced Draught Back-to-back Cell CT

high pumping head

BALCKE COOLING TECHNOLOGY

Rel. 1.2 - 28.12.2002

Natural Draught Cooling Tower

simple and cheap pipeline