Developing Potential Game Changing Water Treatment and Cooling Technologies...
Transcript of Developing Potential Game Changing Water Treatment and Cooling Technologies...
Developing Potential Game Changing Water
Treatment and Cooling Technologies for Power
Plant Water Conservation
Jessica Shi, Ph.D.
EPRI Sr. Project Manager
Technical Lead
for
Technology Innovation
Water Program
Sean Bushart, Ph.D.
EPRI Sr. Program Manager
Cross-sector Lead
for
EPRI Water Programs
EPRI TI Water Program Request for Information Informational Webcast
June 26, 2012
2/39 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Agenda
• EPRI Water Innovation Program Overview
• 2011 Request for Information (RFI) Response
Summary
• Reply to FAQ’s
• Current RFI Technology Overview
• Program Progress Summary and Plan
• Open Questions/Answers
Recording can be found here (at the right bottom).
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Core Team Members
Sean Bushart , Lead Sr. Program Manager, Env.
Kent Zammit Sr. Program Manager, Env.
Ammi Amarnath Sr. Program Manager, PDU
Bob Goldstein Sr. Technical Executive, Env.
Tom Mulford Technical Executive, Nuclear
Revis James Director, Gen.
Jeff Stallings Sr. Project Manager, Gen.
Jessica Shi, Technical Lead Sr. Project Manager, Env.
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More Core Team Members
Jeffrey Hamel
Sr. Program Manager, Nuclear
Jose Marasigan
Sr. Project Manager, Gen.
Sarah Inwood
Project Engineer/Scientist, PDU
Richard Breckenridge
Sr. Project Manager, Gen.
George Offen
Sr. Technical Executive, Gen.
5/39 © 2012 Electric Power Research Institute, Inc. All rights reserved.
About EPRI
• Founded in 1972
• Independent, nonprofit center for
public interest energy and
environmental research
• Collaborative resource for the
electricity sector
• Major offices in Palo Alto, CA;
Charlotte, NC; Knoxville, TN
– Laboratories in Knoxville,
Charlotte and Lenox, MA Chauncey Starr
EPRI Founder
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TI Water Conservation Program Overview and Objective
• Initiated in early 2011
• Funded by EPRI Office of Technology Innovation
• Collaborated by all EPRI Sectors (Environment, Nuclear, Generation, and Power Distribution Unit)
• Broadly distributed Request for Information (RFI) to solicit top technologies for development in Feb., 2011 and June 2012
Objective
Seek and develop “out of the box”, game changing, early
stage, and high risk cooling and water treatment ideas and
technologies with high potential for water consumption
reduction.
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Received More Than 70 RFI Responses in 2011
• Selected five cooling proposals for funding
• Success rate of 1/7 for cooling proposals
Technology Type Number of Proposals
Cooling/Thermal
Technologies35
Green Chillers 4
Thermal-Electric Cooling 1
Evaluation 3
Water Treatment 19
Membrane 7
Scrubber Water 9
35
29
7 3
Responding Organization Summary
Universities
Companies
National Labs
International
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Selection Criteria for TI Funded Projects
• Innovation (“out of the box”, game changer, cutting edge)
• Potential Impacts
– Significant reduction of water (especially fresh water)
consumption and/or withdrawals
– Improved thermal efficiency
– Economic potential in terms of water and energy
consumption, cost, and space
– Other
• Respondent’s capabilities and related experience
• Realism of the proposed plan and cost estimates
9/39 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Executive Advisory Committee Provides
Technical Peer Review
Invited representatives and experts on cooling,
and water treatment technologies from
• DOE
• Member Utilities
• Academia (National Labs and Universities)
• Others
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FAQ’s for 2012 RFI
• # of Proposals to be funded?
• Timeline for funding?
• Technology Readiness Level (or maturity) we are seeking?
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Industry Specific Needs: Strategic Water Management
Source: United States Geological Survey
• Thermal-electric power plants
withdraw 40% and consume 3% of
US fresh water.
• 90% of power plant water demand is
due to cooling systems.
• Water demand will continue in a
“Low Carbon World”
U.S. Freshwater Consumption (1995)
U.S. Freshwater Withdrawal (2005)
0
100
200
300
400
500
600
700
800
900
Nuclear Coal Oil Gas Simple CT
Comb. Cycle
IGCC Solar thermal
Solar PV Wind Biofuel
Wate
r u
se,
gal/
MW
h
Hotel
Fuel processing
CT injection
Inlet air cooling
Ash handling
Scrubbing
Boiler make-up
Cooling
Source: EPRI Report , “Water Use for Electric Power generation”, No. 1014026, 2008
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Opportunities for Power Plant Fresh Water Use Reduction
Innovation Priorities: Advancing cooling technologies, and applying novel water
treatment and waste heat concepts to improve efficiency and reduce water use
Additional 1000+ gpm water savings
possible through fuel moisture
recovery innovations
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Most Rewarding Opportunities for Energy Efficient
Water Treatment Technology Development
• Degraded and nontraditional water sources:
– Technologies which enable cost effective utilization of municipal
wastewater effluent and brackish water.
• Process cooling applications:
– Moisture recovery from cooling tower (more than 20%) or boiler
flue gas
– Post treatment of blowdown water from evaporative cooling
tower operations to enable reuse on site, preferably for cooling
system make-up water.
– Pre-treatment and side stream treatment in order to increase the
cycles of concentration in the cooling system.
– Technologies which leverage existing processes and
infrastructure – such as waste heat.
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Non-Traditional Water Sources
• Substitute alternative water
sources for freshwater
– Waste treatment plant
effluent
– Agricultural
drainage/runoff
– Produced water
– Saline aquifers
– Mine water
– Stormwater
15/39 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Considerations
• Considerations
– Quantity
– Quality
• Cooling tower operations
(scaling, corrosion, fouling)
• Public and environmental
health
– Acquisition
– Transport
– Regulations
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Example: Municipal Effluent
• Used by approximately 60 power plants
• Largest number in FL, CA, TX and AZ
• Amount used varies from 0.1mgd to 55mgd
• Municipal effluent
– Volume function of population density
– Quality function of treatment and technologies
• Individual treatment plant information at http://www.epa.gov/enviro/html/pcs/index.html
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Wastewater Effluent vs. Thermoelectric Water Use
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High energy use
Foul
Scale
Degrade with use
En
erg
y C
ost, ¢
/m3
50
0
10
20
40
30
Water treatment
demands energy
En
erg
y U
se,
MJ/m
3
*
* Calculated from calorimetric
properties of electrolyte solutions
using Pitzer’s equations
Existing technologies
suffer from:
Existing membranes
commonly:
Research Challenge: Treatment Technologies with Significant Efficiency Gains
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Summary- Where can Water Treatment be Applied to
Efficiently Achieve Water Use Reductions?
Alternative Water Resource Utilization Advancements
e.g. Utilizing Waste Heat to Drive Novel Water Treatment
Novel Moisture Recovery Processes
Novel Blowdown Treatment Processes
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Water Treatment Technologies of Interest to Other EPRI
Programs for General Water and Waste Water systems
• Regenerative waste, plant process streams and low volume
wastewater and plant sumps and collection systems.
• Cost effective tritium separation technologies for light water
reactor nuclear power plants;
• Treatment of flue gas desulfurization (FGD) wastewater for
removal of contaminants of concern for onsite reuse and/or
compliance with environmental discharge limits;
• Zero liquids discharge (ZLD) processes, including more cost
effective: concentrate management (concentrating, sorting,
disposal), re-use of RO reject and/or water from
demineralization processes.
Note: Key Measures of Merit” are not all applicable to ideas in this category as they may be funded at
different funding levels by other EPRI programs
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Current Cooling System Types
Water Cooling Air Cooling Hybrid Wet/Dry Cooling
Water Tower (42% in US)
Once Through Cooling
(43% in US)
Air Cooled Condenser
1% Usage in US
Cooling Pond
14%Usage in US
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
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Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
.
a
Potential for 5% (1st Order Estimate) more power production or $11M more annual
income ($0.05/kWh) for a 500 MW power plant due to reduced steam condensing
temperature from 50 °C to 35 °C.
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(°C
)
Entropy (kJ/kgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
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Once Through Cooling Pros/Cons
Pros:
• Most cost effective
• Lowest steam condensate temp.
Cons:
• Facing tightened EPA rules to
minimize once through cooling
(OTC) system entrance and
discharge disturbance to water
eco systems.
• Forced to or increasing pressure
to retrofit OTC systems to cooling
tower or dry cooling systems (19
power plans already affected by
CA retrofitting regulations)
43% Usage in US
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Cooling Tower Cooling System Pros/Cons
42% Usage in US Pros:
• Most effective cooling system due to
evaporative cooling
Cons:
• Significant vapor loss and makeup
water needs
• Shut down in drought seasons
• Twice as expensive as OTC
systems
• Less power production on hot days
due to higher steam condensation
temperatures compared to OTC
systems
Challenges: Vapor Capture and Cooler Steam
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Air Cooled Condenser Pros/Cons
Pros:
• Dry system
Zero water consumption and
water supply needed
Cons:
• Up to 10% less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC systems
• Up to five times more expensive
than cooling tower systems
1% Usage in US
Challenge: Reduce ITD from 30 °C to 10 °C >> 6% more Power Production
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Hybrid Cooling Pros/Cons
Pros:
• Full power output
even on hot days
due to full operation
of cooling tower
systems
• Potential for more
than 50% less
vapor loss
compared to
cooling tower
systems
Cons:
• Cooling tower shut down in drought
seasons
• As expensive as air cooled condensers
• Dual cooling components
Challenge:
Develop alternative more
cost effective hybrid sys.
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
27/39 © 2012 Electric Power Research Institute, Inc. All rights reserved.
* Steam Condensation Temperatures Based on TDB of 100° F and TWB of 78° F.
Current Cooling System Data Comparison
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtu/hr and
Steam Flow Rate of 2.5 Mlb/hr.
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia.
(in)
# of
Tubes
Tube
Length (ft)
Cost
(MM$)
No. of
Cells
Cell Dimensions
(ft x ft)
Tower/ACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175,000 -
350,000 1.125 - 1.25
17,000 -
35,00030 - 40 1. - 2.5 15 - 20 48 x 48 to 60 x 60 50,000 - 80,000 7. - 10.
Dry Direct n/a n/a n/a n/a n/a 40 - 72 40 x 40 64,000 - 120,000 60. - 100.
Once Through
Cooling
175,000 -
350,000 1.125 - 1.25
17,000 -
35,00030 - 40 1. - 2.5 n/a n/a n/a n/a
Hybrid 50,000 - 350,000 1.125 - 1.2510,000 -
350,00030 - 40 0.4 - 2.5
4 - 10/
15- 30
48 x 48 to 60 x 60/
40 x 40
10,000 - 36,000/
24,000 - 48,00030. - 80.
Steam Condenser Tower/ACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgal/MWh)
Steam
Condensation
Temperature* (°F)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20. - 25. 1.00 0.5 - 0.7 116 100,000 - 250,000
Dry Direct 60 - 100 2.5 - 5 0.00 155 0
Once Through Cooling 10. - 15. 0.4 - .75 0.2 - 0.3 100 150,000 - 350,000
Hybrid 40 -75 2 - 4 0.1 - 0.5 116 50,000 - 150,000
* Steam Condensation Temperatures Based on T of 100° F and T of 78° F.
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Cooling Technology Innovation Objectives
• Major breakthroughs needed
– Improve performance of current
water-conserving technologies such
as air-cooled condensers and
hybrid cooling
– Develop alternative cooling
technologies.
• Reductions in efficiency penalties,
reliability and maintenance challenges,
and capital costs needed
A suite of advanced cooling technology options would increase the viability of building new power plants (or long term operations of existing power plants) in
water constrained regions.
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Cooling Technologies Under Development
Recording with more detailed info. can be found here (at the right bottom).
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Key Potential Benefits
• Dry cooling system
Near Zero water use and consumption
• Reduced condensation temperature
As low as 10 °C
Potential for annual power production increase by up to 5%
• Waste Heat Utilization
Project 1: Waste Heat/Solar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Phase 1 Project Scope
• Explore best power plant system level approaches to utilize waste heat or solar heat for
desorption
• Perform system integration energy and mass flow balance analysis for a 500 MW coal-fired
power plant
• Perform technical and economic feasibility study(EPRI Patent Pending)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber
Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
31/39 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Project 2:Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
Thermosyphon Cooler Technology
• The Thermosyphon Cooler uses a combination of dry cooling and refrigerant cycling by gravity and buoyancy effect (no pumps) for cooling.
• The cooler pre-cools condenser water thus reducing cooling tower load.
• EPRI research will assess the feasibility and determine the most effective means to scale up the Thermosyphon Cooler technology.
Key Potential Benefits
• Potential annual water savings up to 75%
• Compared to ACC, full plant output is available on the hottest days
• Ease of retrofitting
• No increase in surface area exposed to primary steam
• Reduced operating concerns in sub freezing weather
• Broad application (hybrid, new, and existing cooling systems)
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TSC Condenser
Animation: Thermosyphon Cooler
110F
85F
* Patent Pending
Refrigerant Vapor
Refrigerant Condensate
Refrigerant Liquid Head
TSC Evaporator
Efficient, Reliable, and Cost Effective Dry
Cooling •Evaporator Designed For:
•Low Waterside Pressure Drop •Waterside Cleanability •Freeze Protection •Optimized Water to Refrigerant Heat Transfer
•Condenser Optimized for Refrigerant to Air Heat Transfer
•Natural Thermosyphon Refrigerant Circulation
•Controls Continuously Adjust Fan Speed to Provide Lowest Total Utility (Water + Electricity) Cost of Operation
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Hot Summer Day
Wet Cooling Tower
Handles 100% of the Heat
Load
TSC Handles 0% of the
Heat Load
Mild Weather Day
Wet Cooling Tower
Handles 50% of the Heat
Load
TSC Handles 50% of the
Heat Load
Cool Winter Day
Wet Cooling Tower
Handles 0% of the Heat
Load
TSC Handles 100% of the
Heat Load
Steam
Surface
Condenser
Steam
Turbine
TSC
Condenser
TSC
Evaporator
Boiler
Wet
Cooling
Tower
Generator
Plant Heat Rejection System Incorporating Thermosyphon Cooler (TSC) Technology
Condenser Loop Pump Steam Condensate Pump
TSC Loop
Pump OFF
85F
85F 110F
100F
110F
110F
97.5F
97.5F
85F
Plume
70F 40F
Make-up
700 gal/
MWh
No
Make-up
Required
No Plume
Normal
Water
Treatment
Chemicals
Reduced
Water
Treatment
Chemicals
Minimal
Water
Treatment
Chemicals
175
gal/MWh
Blowdown
No
Blowdown
* Patent Pending
Outside
Temp
Typical Power Plant Heat Rejection System Incorporating Wet Cooling Towers
-Typical Condenser Water
Loop-
Regardless of The Outside
Temperature
All the Heat Is Rejected
Primarily Through
Evaporating Water in the
Wet Cooling Tower
75
gal/MWh
Blowdown
Make-up
300 gal/
MWh
TSC Loop
Pump ON
Refrigerant
Vapor
Refrigerant
Condensate
Refrigerant
Liquid Head
Early TI Program
Result:
TSC Technology Demo
at WRC funded by GEN
- Will make for
successful handoff!
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Key Potential Benefits
• Potential for less cooling water consumption by up to 20%
• Lower cooling tower exit water temperature resulting in increased power production
• Ease of retrofitting
• Potential to enhance hybrid cooling
Project Scope
• Develop an advanced fill
• Perform CFD and other types of energy, mass, and momentum balance modeling
• Evaluate performance and annual water savings for several typical climates using simulation models
• Perform prototype testing in scaled down cooling towers
• Perform technical and economic feasibility evaluation
Project 3 : Advanced Dew Point Cooling Tower
(Collaboration with Gas Technology Institute)
Conventional fil
l
1
4
tDP=53°F tWB=65°F
Dry Bulb Temperature
Satura
tion lin
e
tDB=85°F
Abs
olut
e hu
mid
ity
2
dhA
dh
3
Advanced fillAir
Warm
water
2
1
3
Dry Channel
Wet Channel
Air
1
Air
Warm
water
1
4
Wet
Channels
Air
outlet
Air
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Cooling
Tower Steam
Condenser
Cool Water
Warm Water
Blo
wd
ow
n
Ma
ke
-up
W
ate
r
Evaporation & Drift
Breakthrough Project: Heat Absorption
Nanoparticles in Coolant
Nanoparticles with Heat Absorption Cores
-Argonne National Laboratory
• Particles provide increased surface tension/ latent heat 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.
Key Potential Benefits
• Up to 20% less evaporative loss potential
• Less drift loss
• Enhanced thermo-physical properties of coolant
• Inexpensive materials
• Ease of retrofitting
• Broad application (hybrid/new/existing cooling systems)
Phase Change Material (PCM) Core/Metal
Shell Nano-particles added into the coolant.
Shell
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Progress Since 2011 Program Initialization
• Received more than 70 responses from Request for Information.
• Started four projects.
Status/Plan for 2012
• Lunched second round of Request for Information on June 12.
• Starting exploratory project on Thermoelectric Cooling with Purdue.
• Co-host Joint workshop and 2013 solicitation with National Science
Foundation.
• Start contracting processes with new proposals.
EPRI Water Innovation Program: Summary and Future Plan
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Upcoming EPRI Conferences
• EPRI Cooling Tower Conference
– Aug. 8 to 9, 2012 at Hilton Pensacola Beach Gulf Front in FL
– Contact: Jeff Stallings at [email protected]
• EPRI/NSF Joint Workshop on Advancing Power Plant
Cooling Technologies for Water Conservation
– Tentatively on Nov. 15, 2012 , open to attendees of 2012 ASME
Congress Conference at Hilton Americas in Houston, TX,
– Contact: Jessica Shi at [email protected]
• EPRI Conference on Water Management Technology
Innovations for Electric Power Generation
– March 2013 in Georgia Tech Conference Center in Atlanta, GA
– Contact: Richard Breckenridge at [email protected]
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Questions & Answers: If you have a question during the webcast you can…
Type your question to the
presenters using the Q&A
Feature
Let us know
you have a
question
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Together…Shaping the Future of Electricity
Thank You!
Any Questions?
Please feel free to contact us:
Cooling: Jessica Shi at [email protected]
Water Treatment: Sarah Inwood at [email protected]
General Questions: Vivian Li at [email protected]