Post on 29-May-2018
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Advanced Dew Point Cooling Tower Fill Development
Presented by Yaroslav Chudnovsky, Ph.D. Gas Technology Institute End-Use Solutions Group
Houston, Texas June 19, 2013
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> Not-for-profit applied R&D company with 70+ year history
> Facilities ─ 18 acre campus near Chicago ─ 200,000 ft2,
28 specialized labs ─ Offices in AL, CA, MA, PA TX, Washington DC
> Staff of 250 > Market opportunities
are creating substantial growth
> Over 1,200 patents > Over 500 products commercialized
GTI Overview
Energy & Environmental Technology Center
Pilot-Scale Gasification Campus
Offices & Labs
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“NEW is Well-Forgotten OLD”
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General Approach
>Utilization of psychrometric energy available from latent heat of water evaporating into air
>The smart combination of the basic thermodynamic processes of heat exchange and evaporation that results in production of a temperature approaching the dew point of ambient air
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Process Psychrometrics
> Direct cooling
> Indirect cooling
> Dew-point cooling
Saturat
ion te
mperat
ure, °
F
60
70
90°F
80°F
70°F
40°F
20%
40%60
%
90
50
15
6
80
Twb
60°F50°F wet bulb temperature
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80%
10% Relative humidity
1 2Wet channelWaterAir
1 3Wet channel
Dry channel
Water
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Air
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Dry channel 1
Wet channel Hot Water
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Air
Add’l Heat
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Wet Bulb vs Dew Point Cooling
Conventional fill
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tDP=53°F tWB=65°F
Dry Bulb Temperature
Saturat
ion lin
e
tDB=85°F
Abs
olut
e hu
mid
ity
2
dhA
dh
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Advanced fillAir
Warm water
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1
3
Dry Channel
Wet Channel
Air1
Air
Warm water
1
4Wet
Channels
Air outlet
Air
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1
2
3 t1DB = 86°Ft1WB = 66°Ft1DP = 54.7°F
t2DB = 55.6°Ft2WB = 55.1°Ft2DP = 54.7°F
Dry
cha
nnel
Wet
cha
nnel
t3DB = 90°Ft3WB = 90°Ft3DP = 90°F
Humidified air Air
Hotwater90°F
Cooled waterto user (55.6°F)
Plate
Advanced Cooling Tower Fill
• Cooled water temperature: 55.6ºF • Water evaporated: 3.1% • Air humidity gain: dH = Hair out – Hair in = 0.0219 lb water per lb dry air
86 ° F 55 . 6 ° F
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2 t 1 DP = 54 . 7 °F
t 1 WB = 66 °F
Psychrometric Chart
Dry Bulb Temperature
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d H
A b s
o l u t
e H
u m i d
i t y
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500 MW Power Plant Benefits Estimate
Cooling Tower
Cold Water Basin
Ambient Air54,558 ton/hr29,454 ton/hr Steam
CondenserCool Water
25°F 45°F Rise
100°F
75°F 55°F
Warm Water187,600 gpm 104,222 gpm
Evaporation & Drift4,258 gpm 3,406 gpm
Blowdown Water1,063 gpm 851 gpm
Make-up Water5,322 gpm4,257 gpm
2,300 MMBtu/hr
83ºF db53ºF dp
96ºF db96ºF dp
1,900 MMBtu/hr
4,20
0 M
MB
tu/h
r
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> Water cools to lower temperature
> Potential to decrease evaporation loss > Water can be cooled at higher ambient %RH - while conventional tower has approached its design limit > Lower pressure drop at the same load - laminar flow in the fill due to smaller channels - lower flow rates compared to conventional fill - preliminary estimate 10.9 vs 11.3 mm H2O/m length
Technology Advantages
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Advanced Fill Flow Arrangement
Dry channelWet channel
Ambient air85°F
Warm water100°F
Cooled water
Condensingzone
Condensate
Exhaust air
Heat flow
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Development Status
• Process simulation – in progress • Preliminary design – in progress • Engineering and fabrication – Q1-2014 • Proof-the-concept testing – Q3-2014
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Thank you! Questions? Comments?