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CLOSED-LOOP, EVAPORATIVE
COOLING SYSTEMS
Agenda
• Wet Surface Air Cooler (WSAC™) System Specifications
• Water Use
• Case Study
Niagara Blower
Heat Transfer Solutions
• Founded in 1904
• In-house engineering/fabrication
Cooling water
in
4.) Air is induced over tubes in
3.) Spray water directly over the exposed tubes the same direction as the water
SPECIFICATIONS
Unit Configurations
Tube Bundles
Serpentine or Straight Through
General Specifications for WSAC™ Systems
Tube Bundles •Serpentine
•Straight Through
– Serpentine
• Constructed with a continuous tube
circuit
• Various tube materials available
• Carbon steel bundles all H.D.G.A.F.
• Lowest cost arrangement
• Highest pressure rating - up to 2500
psi
• ASME Code design available
General Specifications for WSAC™ Systems
Tube Bundles •Serpentine
•Straight Through
– Straight Through/Cleanable
• Complete internal access for
inspection and cleaning
• Offers lowest process side pressure
drop
• Various tube materials available
• Tube sheet thickness designed to
TEMA standards
• Bundles can be retubed using existing
headers
• ASME Code design available
General Specifications for WSAC™ Systems
•Metal
Basins •Concrete
•FRP
– Metal
• Most economical
• Constructed of heavy
gauge carbon steel
H.D.G.A.F
• Drain pan arrangement for
lower operating weight
• Fully factory assembled
and tested
General Specifications for WSAC™ Systems
•Metal
Basins •Concrete
•FRP
– Concrete (erect in place)
• Lowest cost for larger
installations
• Maintenance free
• Completely fireproof
• Concrete designed
• Local supply
• Reduced noise
– FRP (erect in place)
• Fan plenum or entire basin
• Corrosion resistant
• Can be cheaper alternative to
concrete
General Specifications for WSAC™ Systems
Fan System
– Direct Drive
• 5 ft. diameters and smaller
• 5 ft. diameters and smaller
• Plastic fan blade construction
• Plastic fan blade construction
• Carbon steel construction of all fan
• Carbon steel construction of all fan
supports, motor brackets, and fan
supports, motor brackets, and fan exhaust
exhaust rings
rings
• Adjustable pitch design
• Adjustable pitch design
• Fans directly connected to Totally
• Fans directly connected to Totally Enclosed
Enclosed Air Over (TEAO) motor
Air Over (TEAO) motor
General Specifications for WSAC™ Systems
Fan System
– Low-pressure/high-flow design
– Fully flooded spray pattern
– Heavy duty construction
• PVC pipe for site assembled units
• Galv. CS for factory assembled units
• Large orifice non-clogging nozzles
Water Issues
• Evaporation
• Cycles of concentration
• Drift
• Plume
• PM10
• Water makeup
Water Issues
EVAPO R ATION
M A KEUP
W ATER
BLO W DO W N
• Drift
– Based on spraywater rate
– “Standard” drift .02%
– Drift eliminators easily incorporated
• .005% standard (with drifts)
Water Issues
• Plume
– Visual discharge: vapor condensing in atmosphere
– Plume abatement available for visually or
environmentally sensitive areas
• Plume Control
– Cold air introduction
– Partial wet/dry operation
– Reheat coils
Water Issues
• PM10
– Particles up to 10 micrometers in size
– WSAC meets or exceeds PM10 requirements
– Lower total emissions/lower discharge height
• Water Makeup
– Blowdown from cooling towers and boilers
– Waste streams from demineralizers, HRSG and RO
– Waste treatment plant effluent
– Brackish, seawater
Resource Conservation
• Wet/dry systems
• Capacity enhancement
• Limitations
Wet/Dry System Options
for Water Limited Plants
PARALLEL FLOW SERIES FLOW COMBINED FLOW
IN IN
IN
W ET /
DRY
ACC SECTION WSAC
W SAC
(FINNED
COILS) System
ACC WSAC
WSAC System
OUT
WSAC
WSAC System
OUT
OUT
IN
DRY
SECTION
W SAC System
WSAC
W ET
SECTION
OUT
Water Usage Graph
Percentage Water Use
Conventional
Dry / Wet
Dry Only
EVAPORATION
4,800 gpm
200,000 gpm
OPEN
COOLING
FRESH Plant Cooling 104
TOWER
MAKEUP 81 Load
5,350 gpm
200,000 gpm
BLOWDOWN
550 gpm
5% Fresh Water Reduction
EVAPORATION
4,560 gpm
190,000 gpm
OPEN
COOLING
FRESH Plant Cooling 104
TOWER
MAKEUP 81 Load
5,100 gpm
200,000 gpm
EVAPORATION
240 gpm
81 10,000 gpm
WSAC 104
BLOWDOWN
AS MAKEUP
BLOWDOWN
540 gpm 300 gpm
5% Fresh Water Reduction
MAKEUP WATER SAVINGS
5,350 gpm 5,100 gpm = 250 gpm
120 MILLION gal/yr
-----------------------
BLOWDOWN WATER REDUCTION
550 gpm 300 gpm = 250 gpm
120 MILLION gal/yr
-----------------------
$$ COSTS FOR:
WATER…DISPOSAL…TREATMENT
De-Bottlenecking/Adding Capacity
in Existing Open-Loop Systems
EVAPORATION
BLOWDOWN EVAPORATION
COOLING TOWER
BLOWDOWN FOR
MAKEUP NEW WET
SURFACE AIR
COOLER
BLOWDOWN
Advantages of the WSAC™ System for
Sites with Poor Quality Makeup Water
OPEN
COOLING STEAM
RIVER
TOWER SURFACE
WATER
MAKEUP CONDENSER
EVAPORATION
BLOWDOWN
WSAC
“OTHER” WATER
CT BLOWDOWN
AS MAKEUP MAKEUP
BLOWDOWN
WSAC™ Demonstration Project
New Mexico Power Plant
•Operating at 35 – 50 cycles of concentration using cooling
tower blowdown as WSAC™ makeup
•CT blowdown contains phosphonate inhibitors to control
Calcium Sulfate
•Controlling pH in the range of 7.3 - 7.7
•Calcium at saturation (in solution) as fed to WSAC™ system
•Phosphate level 2 – 4 ppm (from phosphonate inhibitor)
•Conductivity 5,000 ppm
•Produced water will be used as makeup in 2006
•Chlorine residual maintained at 0.05 to 0.10 mg/lCl2
NO DEGRADATION OF THERMAL PERFORMANCE
Cost Analysis
Water Quality & Tube Material
Exotic
Good
TUBE MATERIAL
$ WATER
Cost
Poor Std.
Quality
Design Considerations
Makeup
Water
Water
Treatment
Quality
WSAC™
System
Tube Operation
Material
NIAGARA
Niagara Blower Heat Transfer Solutions
673 Ontario St., Buffalo, NY 14207
Phone: (716) 875-2000 ~ Fax: (716) 875-1077
sales@niagarablower.com / www.niagarablower.com