Developing Potential Game Changing Water Treatment and Cooling Technologies …mydocs.epri.com/docs/PublicMeetingMaterials/0313/RFI... · 2013-07-03 · Developing Potential Game

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).

http://mydocs.epri.com/docs/PublicMeetingMaterials/0313/RFI_Informational_Webcast.wmv


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.


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.


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


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.

http://my.epri.com/docs/AdvancedCooling/FINAL_RFI.pdf


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


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


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


FAQ’s for 2012 RFI

• # of Proposals to be funded?

• Timeline for funding?

• Technology Readiness Level (or maturity) we are seeking?


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


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


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.


Non-Traditional Water Sources

• Substitute alternative water

sources for freshwater

– Waste treatment plant

effluent

– Agricultural

drainage/runoff

– Produced water

– Saline aquifers

– Mine water

– Stormwater


Considerations

• Considerations

– Quantity

– Quality

• Cooling tower operations

(scaling, corrosion, fouling)

• Public and environmental

health

– Acquisition

– Transport

– Regulations


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

http://www.epa.gov/enviro/html/pcs/index.html

http://www.epa.gov/enviro/html/pcs/index.html


Wastewater Effluent vs. Thermoelectric Water Use


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


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


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


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


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


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


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


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


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


* 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.


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.


Cooling Technologies Under Development

Recording with more detailed info. can be found here (at the right bottom).

http://my.epri.com/portal/server.pt?open=512&objID=397&&PageID=226168&mode=2&in_hi_userid=241438&cached=true


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


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.


• 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)


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


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


Load


Heat Load

Cool Winter Day

Wet Cooling Tower


Load


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!



• Potential for less cooling water consumption by up to 20%

• Lower cooling tower exit water temperature resulting in increased power production


• 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


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.


• Up to 20% less evaporative loss potential

• Less drift loss

• Enhanced thermo-physical properties of coolant

• Inexpensive materials


• Broad application (hybrid/new/existing cooling systems)

Phase Change Material (PCM) Core/Metal

Shell Nano-particles added into the coolant.

Shell


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

http://my.epri.com/docs/AdvancedCooling/FINAL_RFI.pdf


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]

mailto:[email protected]

http://www.asmeconferences.org/Congress2012/index.cfm

http://www.asmeconferences.org/Congress2012/index.cfm




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


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]




Documents

Developing Potential Game Changing Water Treatment and Cooling Technologies …mydocs.epri.com/docs/PublicMeetingMaterials/0313/RFI... · 2013-07-03 · Developing Potential Game