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MEMBER OF

WATER OPTIMIZATION CONFERENCE & AWARDS

DROUGHT PROOFING INDIA’S THERMAL POWER PLANTS

BY COOLING SYSTEM CONVERSIONS

PRESENTATION TOPICS

1. SPG Dry Cooling – brief intro

2. Global water stress – recent losses in India

3. Water consumption for cooling thermal power plants

4. Stress-relief by Cooling system conversions

5. Q&A

SPEAKER:

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Mr. Andras BaloghVice President of SPG Dry Cooling, Engineered Retrofits

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SPG DRY COOLINGYOUR WATER CONSERVATION SOLUTIONS PROVIDER

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SPG DRY COOLINGWORLDWIDE DRY COOLING INSTALLATIONS

Hexacool®

State of the art ACC with SRC© tubesOther types of finned tubes available

BoxAir ACC®

Induced Draft Forced Draft Induced Draft

SPX DC Unique and patented

<30 MWe <50 MWe All size All size

Induced Draft

Air Cooled Condenser

ModuleAir ® W-Style ACC®

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SPG DRY COOLINGDRY COOLING SOLUTIONS PORTFOLIO

Indirect Dry Cooling

State of the art plant flexibility with SPX DC MCTtubes; Other types of finned tubes available

GLOBAL WATER STRESSRESOURCES PLUMMETING

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Number of months in which water is scarce

Global water availability – resources are plummeting

India is among the regions with highest water scarcities

GLOBAL WATER STRESSDEMAND GROWS

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Developing countries will require more water to sustain their growing power generation

GLOBAL WATER STRESS RECENT LOSSES IN INDIA

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India lost 30TWh output (equivalent with 1,7 bn USD revenue) between 2013-16

GLOBAL WATER STRESS WATER USE IN VARIOUS POWER GENERATION TECHNOLOGIES

• Example: the daily make-up water consumption by a wet cooling tower of a 500MW steam turbine – catering for 600 000 public

electricity consumers - equates the public water consumption of 150 000 people (EU average≈ 5-700W/pers. & 200 l/d/pers.)

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Evaporative/wet cooling systems are the biggest water consumers in a thermal power plant:

Open Loop CoolingConsumption1,100 L/MWh

Withdrawal130,000 L/MWh

Wet Cooling TowerConsumption> 1,800 L/MWh

Withdrawal> 2,100 L/MWh

GLOBAL WATER STRESS WATER CONSUMPTION FOR COOLING THERMAL POWER PLANTS

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Cooling systems are the thirstiest water consumers in a thermal power plantThey rob water from 30%-40% of the same people the plant provides electricity for

45% Electricity

47% Cooling/waste heat

8% Flue Gas

100% Fuel

Dry CoolingConsumption0 L/MWh

Withdrawal0 L/MWh

Reservoir CoolingConsumption1,500 L/MWh

Withdrawal1,700 L/MWh

Most common cooling methods in India; all consume water in large quantities

Any existing cooling system combined with an appropriately selected dry cooling will cut water dependence !!!

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SUSTAINABLE STRESS RELIEF BY COOLING SYSTEM

CONVERSION

GLOBAL WATER STRESSSUSTAINABLE RELIEF

COOLING SYSTEM CONVERSIONPURPOSE , METHOD AND VERIFICATION OF ECONOMY

Purpose :

• Reduce water consumption and find the optimum power generation/water consumption balance in the power plant, aiming at maximized drought resiliency

Method :

• Split cooling duty between the existing wet, and an add-on dry technology

Verification of economic feasibility:

• Simulate and compare the year-round operation of the plant with present all-water cooled versus the converted cooling system, and calculate Present Value of conversion for the remaning life of the plant

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Input data needed:

• Water availability / cost

• Power Plant load schedule

• Existing surface condenser

characteristics

• Dry and wet bulb temperatures:

maximum and distribution

• Turbine characteristic curve

• Available space for conversion

• Economics (interest rate,

commercial life left)

COOLING SYSTEM CONVERSIONINPUT DATA AND COMPONENTS USED

Proven components utilized:

EXISTING CONDENSER(RE-USED)

PLATE HEAT EXCHANGER

WET COOLING TOWER(RE-USED)

DRY COOLING ADD-ON

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COOLING SYSTEM CONVERSION THE SELECTION & OPTIMIZATION METHOD

=

Existing wet cooling system

Simulation of operation, selection of optimum based on Present Value

Input data collection+ + +

Investigation of all applicable dry cooling add-on solutions

Wet/dry conversion solution (example)

COOLING SYSTEM CONVERSIONDRY COOLING ADD-ON OPTIONS

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The conversions may fully, or partly rely on the following proven technologies:

• Direct steam condensing: ACC or NDACC• Relpaces existing SC, thus eliminating a heat transfer barrier

• Best positioned right next to turbine hall if site layout permits

• Dry/Wet operation possible

• Indirect steam condensing with closed water loop: M-IDCT or IDCT• Utilizing the existing surface condenser

• Implementation flexibility, anywhere inside or adjacent to site

• Dry/Wet operation possible

M

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Redirect the whole, or tap part of exhaust steam from surface condenser neck redirect steam from turbine outlet for dry-cooling by an add-on Air Cooled Condenser

Ideal, where the layout of the existing facility allows for the placement of an add-on ACC right next to the Turbine Hall, to ensure minimal steam-side pressure drop

COOLING SYSTEM CONVERSIONWITH ADD-ON DIRECT AIR COOLED CONDENSER

Full Dry

Wet / DryPCS

Present all-wet cooling orConverted to

COOLING SYSTEM CONVERSIONWITH ADD-ON INDIRECT AIR COOLED CONDENSER

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Interconnect a dry tower (mechanical, or natural draft) with the surface condenser, and enhance dry cooling in hot summer hours by the wet cooling tower

Fits all small to large conversion sizes; Can be built any distance from the

Turbine Hall, thus with no restriction by existing plant layout

Flexibly adapts to any existing plant layout, plant down-time forconversion is minimal

Converted to

Full Dry

Wet / Dry

Wet / Dry

Present all-wet cooling

or

or

Verification is through a year-round impact simulation: A, B, C…A. Atmospheric conditions specific to your plant

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1-Jan-2013 1-Feb-2013 1-Mar-2013 1-Apr-2013 1-May-2013 1-Jun-2013 1-Jul-2013 1-Aug-2013 1-Sep-2013 1-Oct-2013 1-Nov-2013 1-Dec-2013

Tem

pera

ture

[°C]

Monthes

Year round temperature variation

Dry Bulb Temperature

Wet Bulb Temperature

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1-Jan-2013 1-Feb-2013 1-Mar-2013 1-Apr-2013 1-May-2013 1-Jun-2013 1-Jul-2013 1-Aug-2013 1-Sep-2013 1-Oct-2013 1-Nov-2013 1-Dec-2013

Tem

pera

ture

[°C]

Monthes

Year round temperature variation

Dry Bulb Temperature

Wet Bulb Temperature

A

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COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY

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510

515

520

0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26

Gene

rato

r out

put,

MW

e

Backpressure, bara

Steam turbine characteristic curve

Design (0.0951 bara)Pgen = 500.253 MWe

ALARM point (0.2 bara)Pgen = ~475.8 MWe

Allowable backpressure range

Maximum output @ 0.05 bara)Pgen = ~508.6 MWe

Verification is through a year-round impact simulation: A, B, C… B. Backpressure evaluation with steam turbine curves

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0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26

Gene

rato

r ou

tput

, MW

e

Backpressure, bara

Steam turbine characteristic curve

Design (0.0951 bara)Pgen = 500.253 MWe

ALARM point (0.2 bara)Pgen = ~475.8 MWe

Allowable backpressure range

Maximum output @ 0.05 bara)Pgen = ~508.6 MWe

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1-Jan-2013 1-Feb-2013 1-Mar-2013 1-Apr-2013 1-May-2013 1-Jun-2013 1-Jul-2013 1-Aug-2013 1-Sep-2013 1-Oct-2013 1-Nov-2013 1-Dec-2013

Tem

pera

ture

[°C]

Monthes

Year round temperature variation

Dry Bulb Temperature

Wet Bulb Temperature

A B

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COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY

Verification is through a year-round impact simulation: A, B, C…C. Conversion Solutions

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0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26

Gene

rato

r ou

tput

, MW

e

Backpressure, bara

Steam turbine characteristic curve

Design (0.0951 bara)Pgen = 500.253 MWe

ALARM point (0.2 bara)Pgen = ~475.8 MWe

Allowable backpressure range

Maximum output @ 0.05 bara)Pgen = ~508.6 MWe

-40

-35

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-25

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-5

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1-Jan-2013 1-Feb-2013 1-Mar-2013 1-Apr-2013 1-May-2013 1-Jun-2013 1-Jul-2013 1-Aug-2013 1-Sep-2013 1-Oct-2013 1-Nov-2013 1-Dec-2013

Tem

pera

ture

[°C]

Monthes

Year round temperature variation

Dry Bulb Temperature

Wet Bulb Temperature

A B

Ci

Cii

Ciii…n21

COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY

Verification is throuigh a year-round impact simulation: A, B, C…Results: Annualized make-up water consumption & plant output

&(Wi…Wn) (Pi…Pn)

Year-round Impact Simulation COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY

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Actual case studies prove, the impact of conversion on power generation can be minimal, while plant cooling water consumption isdramatically reduced...see example

Targeted annual water consumption, 30% of original

Best solution within 0.4% net generation output while saving 70% of the annual waterAll solutions within 2.4% net generation output while saving 70% of the annual water

98.5%

97.6%

99.6%

98.4%

100%

~30%99.6% 100%

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COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY

The year-round simulation of plant operation with conversion cooling returns

• annual GWh/year output, and

• Tons/year water consumption

From which the Present Value of the Conversion, over the remainin g lifetime of the plant is calculated

PV = Revenue / A - I where

• I ($) total „cooling system conversion” related investment cost

• R ($ / year) annual revenue = balance of yearly electricity income and yearly water- and maintenance costs

• A (1 / year) annuity, function of interest rate % and commercial life in years

Sensitivity analisys can also be conducted upon request to see the impact of changing economic factors!

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COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY

Plant owner benefits include:

Optimized power generation/water consumption balance

Increased yearly availability/load factor of the power plant

Maximized drought resilience – less dependence on water

Reduced/eliminated cooling water-related costs

Leasable water rights to 3rd parties (where applicable)

Reduced plant maintenance and repair cost

COOLING SYSTEM CONVERSIONCUSTOMER BENEFIT

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• Seasonal or persistent water stress today can curtail your plant’s output and availability tomorrow.

• Control your water-dependency, ensure your asset is drought-proof.

• Eliminate vulnerability to rising water costs, growing and unknown future regulations, and speculation of a precious commodity.

• Ask SPG Dry Cooling, your heat-sink specialist, to optimize a hybrid, or all-dry cooling solution to meet your targeted water savings in a Wet-to-Dry conversion.

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COOLING SYSTEM CONVERSIONSUMMARY

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THANK YOU !Q & A