ACC User Group Presentation
Direct Air Cooled Condensing vs. Indirect Air Cooled
Condensing Comparison Studies
GEA Heat Exchangers
Topics of Discussion
Heller Process Diagram
Major Components of Heller
Cooling Systems Case Studies
GEA Heat Exchangers
Flow Diagram
GEA Heat Exchangers
Topics of Discussion
Heller Process Diagram
Major Components of Heller
Cooling Systems Case Studies
GEA Heat Exchangers
Direct Contact DC Jet Condenser
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Forg Heat Exchanger
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Heat Exchanger Assembly & Erection
GEA Heat Exchangers
Air Cooled Heat Exchanger: Natural Draft
The NDCT can be built either with a conventional reinforced concrete
shell or with a steel structure covered by corrugated aluminum clad.
GEA Heat Exchangers
Air Cooled Heat Exchanger: Mechanical Draft
GEA Heat Exchangers
Topics of Discussion
Heller Process Diagram
Major Components of Heller
Cooling Systems Case Studies
GEA Heat Exchangers
Illustrative Case Study 1
1. Aux Power Benefit (NDT)
2. Cold Condensing
GEA Heat Exchangers
Comparison of Cooling Systems: Case I
HELLER SYSTEM
DIRECT ACC
OCCUPIED AREA
9130 m2
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Copyright by GEA EGI
5030 m2
GEA Heat Exchangers
Comparison of Cooling Systems: Case I
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Copyright by GEA EGI
GEA Heat Exchangers
Comparison of Cooling Systems: Case I
Main technical and
budgetary price data
HELLER SYSTEM
DIRECT ACC
Auxiliary power consumption
1900 kWe
3610 kWe*
Minimum backpressure
<0.035 bar(a)
>0.065 bar(a)
Area occupied by limit noise
60%
100% (BASE)
Material & Equipment Price
0.98
0.88
I&C and electrical items related to
the cooling system
0.04
0.12
Cooling system related material
& equipment prices together **
1.02
1.00
* Does not include aux power requirement for condensate extraction pumps
** Does not include cost impact due to civil works
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Copyright by GEA EGI
GEA Heat Exchangers
Illustrative Case Study 2
1. Aux Power Benefit (NDT)
2. Efficient Use of Limited Wet Evaporative Cooling
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PAC SYSTEM
SSC & ACC are condensing steam in parallel
Steam turbine
steam
ACC
Cooling tower
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Dry/Wet Separate Circuit For Combination System
Hybrid Condenser
Dry ACHE Tower
Wet Cooling Tower
(Mechanical Draft or Natural Draft)
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GEA Heat Exchangers
Cold Condensing Capability
COLD END HEAT DISSIPATION CAPABILITY AT FULL TURBINE LOAD
(considering varying heat input into the steam-cycle)
350
All dry Heller System
Heller System with Spraying
Turbine back-pressure, mbara
300
Heller System with 2 wet cells
ACC
250
WET Cooling Tower
200
150
100
50
0
-20
-15
-10
-5
10
15
20
25
30
35
40
Ambient Dry Bulb Temperature, C
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GEA Heat Exchangers
Comparison of Cooling Systems:
2 x 7FA Blocks (Combination Wet/Dry System)
Main technical and
budgetary price data
HELLER SYSTEM
DIRECT ACC
Auxiliary power consumption
4864 kWe
8064 kWe*
Area occupied by limit noise
60%
100% (BASE)
Material & Equipment Price
0.99
0.91
I&C and electrical items related to
the cooling system
0.03
0.09
Cooling system related material
& equipment prices together **
1.01
1.00
* Does not include aux power requirement for condensate extraction pumps
** Does not include cost impact due to turbine hall height, and auxiliary equipment for fast start
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Copyright by GEA EGI
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Illustrative Case Study 3
1. Footprint / Layout Flexibility (MDT)
2. Rapid Response
GEA Heat Exchangers
Rapid Response CCPP Case Study: Heller Option
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Copyright by GEA
CPC
23.6 MBTU/hr/F
Auxiliary power
consumption
3660 kWe
Occupied area by
tower
36,950 sq-ft
GEA Heat Exchangers
Rapid Response CCPP Case Study: ACC Option
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Copyright by GEA
CPC
23.6 MBTU/hr/F
Auxiliary power
consumption
2910 kWe
Occupied area by
tower
43850 sq-ft
GEA Heat Exchangers
Rapid Response Plant Case Study: Layout
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Copyright by GEA
GEA Heat Exchangers
Rapid Response Study: Comparison Cooling System Options
1.
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Main technical and
budgetary price data
HELLER SYSTEM
DIRECT ACC
Auxiliary power consumption
3660 kWe
2910 kWe
Minimum backpressure
<0.035 bar(a)
>0.06 bar(a)
Material & Equipment Price 1
0.97
1.00
Does not include: (i) electrical and civil works, and mechanical erection (ACC >
Heller), (ii) O&M impact (Heller < ACC)
Copyright by GEA
GEA Heat Exchangers
Rapid Response Study: Comparison Cooling System Options
Three Rapid Response Power Plants have been permitted with
Heller despite 0.75MW aux power penalty. Why?
Unless extreme/expensive measures are taken, an ACC would
delay a warm/hot start by 8 minutes
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To overcome an 8 minute delay, a rapid response CCPP would
need to run 26 hours.
Super Peak Periods average 50 minutes in duration
Copyright by GEA
GEA Heat Exchangers
When Indirect Dry Cooling (Heller)
Should Be Considered vs. an ACC
Large Power Plants where reduction in Parasitic Load / Aux
Power Consumption is desired/evaluated
Life Cycle Evaluation (vs. Installed Costs) is taken into
considerationincluding efficiency benefits, maintenance costs
and increased availability
Need for Site Arrangement flexibility
Revenues generated during winter operation are significant
Power Plant is designed around a Fast-Start concept
Regions that are vulnerable to wind gusts
Installation where labor is very expensive or unskilled
Re-Powering/Retrofits requiring conversions of Wet-Cooled
Systems to Dry-Cooled Systems
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GEA Heat Exchangers
GEA Cooling System Evaluations/Studies
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GEA Heat Exchangers
Appendices, Enclosures, Attachments, etc
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GEA Heat Exchangers
Cold Condensing Capability
COLD END HEAT DISSIPATION CAPABILITY AT FULL TURBINE LOAD
(considering varying heat input into the steam-cycle)
350
All dry Heller System
Heller System with Spraying
Turbine back-pressure, mbara
300
Heller System with 2 wet cells
ACC
250
WET Cooling Tower
200
150
100
50
0
-20
-15
-10
-5
10
15
20
25
30
35
40
Ambient Dry Bulb Temperature, C
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GEA Heat Exchangers
Noise Generation Study
Impact of cooling systems on noise emmission
Sound pressure levels around the 800 MWe CCPP equipped with functionally
equivalent dry cooling systems: natural draft HELLER System and mechanical draft
direct ACC :
Direct ACC
90 ha occupied by noise > 45 dB(A)
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HELLER System
54 ha occupied by noise > 45 dB(A)
GEA Heat Exchangers
Heller Indirect Dry Cooling References
Intergen (Developer) and Bechtel (EPC)
2400 (3800) MW Gebze & Adapazari CCPP:
Largest CCPP with Dry Cooling
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GEA Heat Exchangers
Select References, Mechanical Draft Heller Systems
800 MWe Modugno CCPP, Italy (EPC: Alstom, owner: Energia SpA)
Heller System with DC Jet condenser
No bypass stack for gas turbines, cooling system supports plant reliability
24 main cooler cells with single fan
2 auxiliary cooler cells with four fans each
This document is proprietary to GEA EGI Contracting/Engineering Co. Ltd. All rights reserved.
GEA Heat Exchangers
Natural Draft Tower Design Flexibility
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GEA Heat Exchangers
Wet-to-Dry Conversions
Pre-Conversion
Wet Cooling Tower with Surface Condenser
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GEA Heat Exchangers
Wet-to-Dry Conversions
Post-Conversion
Dry System utilizing existing Surface
Condenser and supplement spraying
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GEA Heat Exchangers
Wet-to-Dry Conversions
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GEA Heat Exchangers
