CONDENSER COOLING

HELLER COOLING SYSTEM

Heller System: Indirect dry cooling

Air is used as a secondary cooling medium. Water is still needed as primary coolant, however the cooling water flows in a closed cycle and is never in contact with the cooling air The heat transfer between air and cooling water is achieved by convection and not by evaporation like in a wet cooling tower.

The Main Components of HELLER SYSTEM

1. Direct contact (DC) jet condenser/Surface condenser 2. Hydro machine group ( a cooling water circulation extraction pump, a recovery hydraulic turbine and a driving electric motor; mounted on a common shaft.) 3. Air coolers ( Cooling Tower)

1. Condenser

1.

Direct contact (DC) jet condenser.

Mostly used; Low TTD (terminal temperature difference ) of 0.3-0.6K against usual 3-5 K for a given cooling tower rating, Better vacuum can be achieved

2.

Surface condenser.
Used in special cases such as nuclear power stations or various power units serving district heating networks

Jet Condenser

the cooling water is sprayed into the steam steam by mixing directly with cold water gets condensed part of the condensate equal to the turbine exhaust flow is sent back to the plant as feedwater the remainder is cooled in a dry cooling tower and then sprayed on the turbine exhaust

Jet Condenser( contd..)

y for the spray condenser, a mass balance

y y y y

and an energy balance give the following equations: w2=w4, w3=w2+w5 w2h2+w5h5=w3h3 from which w5/w2 = (h2-h3)/(h3-h5) Since h2-h3 is much greater than h3-h5, the circulating water flow (w5) is much larger than the steam flow (w2).

Jet Condenser in a Heller System

2. Hydro-machine groups

For CW systems with surface condenser, regular CW circulating pumps are used (for units larger than 600 MWe) identical hydraulic machine groups connected in parallel are used.

y For DC condensers two or three

Each group consists: a cooling water circulation & extraction pump, a recovery hydraulic turbine and a driving electric motor; mounted on a common shaft.

3. Cooling Towers
Draft options for air moving equipment. y Allows the use of either natural or mechanical draft (unlike the direct ACC, where only mechanical draft can be applied). y For medium and large capacity power units, natural draft results in significantly better economics. The natural draft tower shell can either be of the usual reinforced concrete type, or a structural steel tower with aluminum clad . y Flue gases can be exhausted through the natural draft tower using a stack of approx. 40-50 m high instead of a tall chimney Results in capital cost saving , reduces the ground level concentration of pollutants. y For mechanical draft cooling systems we prefer to supply induced draft fans instead of forced draft ones to reduce warm air recirculation.

Natural Draft
y Natural draft towers use very large concrete

chimneys to introduce air through the media . y Due to the large size of these towers, they are generally used for water flow rates above 45,000 m3/hr . y These types of towers are used only by utility power stations

Mechanical Draft
y Utilize large fans to force or suck air through

circulated water . y The water falls downward over fill surfaces, which help increase the contact time between the water and the air - this helps maximise heat transfer between the two . y Cooling rates of Mechanical draft towers depend upon their fan diameter and speed of operation

Air Flow Arrangement of Tower

y Counter flows induced draft. y Counter flow forced draft. y Cross flow induced draft.

Air coolers y A great variety of water-to-air heat exchangers applicable y For power cooling tasks the best is the Forg-type; y a plate-fin-and-tube, surface treated, all aluminum water-to-air heat exchanger; different geometries are available. y For some special applications Forg-type heat exchangers are also supplied with carbon or stainless steel tubes and aluminum fins. y Heat exchanger bundles, arranged in a V shape, form the assembly units, so-called cooling deltas. y The cooling deltas are grouped in parallel sections.

Factors Affecting Cooling Tower Performance

y Range Range is the difference between the cooling

tower water inlet and outlet temperature. y The range at the exchanger is determined entirely by the heat load and the water circulation rate through the exchanger and on to the cooling water. y Range oC = Heat Load in kcals/hour / Water Circulation Rate in LPH y Approach -Approach is the difference between the cooling tower outlet cold water temperature and ambient wet bulb temperature.

y A fraction of the warm circuit water (equal to the

condensate stream) is pumped forward to the thermal cycle while most of the warm circuit water is pumped via pipeline to a natural draft cooling tower where it cools down in Forgo-type water-toair heat exchangers arranged vertically around the towers circumference.

y A great variety of water-to-air heat exchangers

applicable for HELLER System. For power cooling tasks the best is the so-called Forg-type- a platefin-and-tube, surface treated, all aluminum waterto-air heat exchanger of which different geometries are available. y Heat exchanger bundles, arranged in a V shape, form the assembly units, so-called cooling deltas. The cooling deltas are grouped in parallel sections.

Forgo Type Heat Exchanger

Cooling delta washing equipment enables efficient online cleaning.

 A mono-metal all aluminum heat

exchanger with protective surface treatment. The hard plate Al-fin and normal Al-tube bond provides enduring metallic contact due to spring effect.  Minimum deposition and easy cleaning (cleaning once or twice a year).

Dry/Wet HELLER System Options

y GEA EGI has developed several cost effective dry/wet

combinations derived from the all dry HELLER System y Aimed at improving:
1. 2. 3. 4. 5.

Environmental compatibility and Water conservation issues relative to wet cooling Summertime heat rejection capabilities Turbine output reducing investment costs relative to dry cooling.

y HELLER System is well suited to dry/wet combinations,

as at lower ambient temperatures it is capable to establish in dry operation mode the same vacuum than a wet cooling plant.

Dry/Wet HELLER System Options

Dry HELLER System with Supplemental Spraying (1-3%)
y Used for peak-shaving in the

hottest summer hours ; improving plant availability at excessive conditions or in emergency cases

y Spraying is applied only for

limited time period with quality water needed.

Dry/Wet HELLER System Options

HEAD (Delugable) Cooling System (1-20%)
y y

y y

y y

A well-proven system The system operates fully dry for a significant part of the year except during the summer hours coinciding with peak power demand. An even water film (deluging) is applied on the special plate fins of the air cooled heat exchanger. The applied quantity of water is significantly more than the evaporation; therefore the excess water is collected and re-circulated after the addition of the necessary make-up. An interesting variant is when a large all-dry natural draft cooling tower is supplemented with mechanical draft dry/deluged HEAD cells to enhance summer capability. These cells can be located either inside or outside of the tower. In case of cells outside tower for plants operating in areas of severe winter climate, the same cells can be used as so-called pre-heaters during the start-up period, ensuring a freeze-proof start even under the most unfavorable winter conditions.

Dry/Wet HELLER System Options

HELLER System with assisting wet cells (5-40%) y A new brand of efficient dry/wet systems has been developed by integrating the dry HELLER System with evaporative cooling cells. y The integration can be in parallel through a combined surface and DC condenser or through a surface condenser having separate sections assigned for the closed dry cooled circuit and the wet cooled one. y Also they can be integrated either in parallel or in series via waterto-water heat exchangers for transforming the heat dissipation of the wet tower to the closed dry circuit. y Offer great operational flexibility, high availability and, much better environmental compatibility than the wet cooling tower y Offer remarkably lower investment cost and improved summertime heat rejection than all-dry cooling plants.

Summary
y A completely closed and pressurized cooling circuit, where vacuum y

y y y

is limited to the small space of DC or surface condenser. The intermediate cooling water circuit supports flexibility in tower when looking at distance and arrangement wise, without major cost or auxiliary power penalties. A sectioned air cooler arrangement is used and easy & efficient online air cooler cleaning is ensured. Air moving either by mechanical or natural draft as well as steam condensing by surface or DC condenser can be applied. Natural draft allows the exhaust of flue gases via the cooling tower (stack-in-tower and FGD in tower slutions) resulting in capital cost saving and meanwhile dramatically reducing ground level concentration of pollutants. The DC condenser and natural draft tower shell support high thermal efficiency and they are practically maintenance-free with 100% availability.

Summary
y A variety of air coolers (material and surface wise) are available. The

preference is for applying the FORGO-type mono-metal, all-aluminum air coolers for 40+ years life-span, withstanding external and internal corrosion, no flow accelerated corrosion (FAC), adequate for OT water chemistry. y The conventional condensate extraction pumps can be substituted by simple booster pumps with an alternative connection to the return cold line allowing to remain within resin temperature limit of CPP (i.e. in the most common cases 60 C) even at max. ambient temperatures. y The large volume of water in the dry cooling circuit provides buffering condensate capacity as well as adequate conditions for CPP; and by its high thermal inertia can efficiently counter the negative effects of wind gusts (stabilizing back-pressure, thus avoiding surprise turbine trip at excessively warm ambient conditions). y The extra condensate volume in the DC condenser hot-well allows primary frequency control of supercritical cycles by condensate throttling.

Case study was put together for investigating cooling systems serving a 900 MWe supercritical coal fired power unit. Here the final results presented in the form of a bar chart show a massive reduction in costs of the all-dry natural draft HELLER System compared to a direct ACC.

Advantages of Heller System

y Highest efficiency among dry cooling options y Supporting power cycle operational flexibility y Easing power cycle water chemistry y Backing improvement in power cycle reliability &

availability and reduced maintenance y Lower condenser pressure in winter y Flexibility in siting

..contd
y Low noise y Low parasitic power consumption y No hot air recirculation y Environment friendly y Lesser noise emission, CO2 emissions; greater

opportunity to reduce ground level concentration of pollutants y Economical aspect: massive reduction of present value costs (comparable capital cost w.r.t. ACC)

Environmental Impact: Comparison with ACC

Economic viability: Comparison with ACC

Disadvantages of Heller System

y Added complexity with the introduction of a

secondary loop to carry the rejected heat, and its necessary piping y Significant loss of temperature driving potential for the ACHX, which increases the heat exchanger surface area needed y Additional pumping power requirement for the fluid loop

Typical performance of 800MW TPP

Conclusions
y The indirect dry cooling HELLER System and its dry/wet

derivatives have successfully demonstrated their reliability and effectiveness. y Given the long lasting impact o a cooling method for a power plant and even on the surrounding area, iIs is important to compare the lifecycle v cost issue. y Evaluations show how the advanced HELLER System extends the economic viability of water conserving cooling. The natural draft HELLER System can be competitive on present value basis against wet cooling even at a medium cooling water make-up cost.

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