Howden Netherlands

A closer look to air side condenser performance

Martin Huis in t Veld

Date: 16 October 2013

1

Air side condenser performance

Site assessment

Air side condenser performance

Site assessment: Volume, pressure, temperature system resistance curve
Unit A

Unit B

Air side condenser performance

Increased air side performance

Air side condenser performance

Temperature

Condensing data relation to fan air supply

Pressure [a]

Fan air supply

Fan air supply

5

Air side condenser performance

Process data estimation

Air side condenser performance

Process data estimation

Air side condenser performance

Process data

Qair

m3/s

Measurement
465

Nom. fan static pressure

pStatic

Pa

106

Fan shaft power

PFan

kW

82

Generated output

Eturb

MW

293

steam
tC

kg/s
C

367.0
49.9

Condensing pressure

tp

bar a

0.123

Condensate enthalpy

hc

kJ/kg

207.5

Turbine inlet enthalpy

hturb

kJ/kg

3395

Required fuel energy

Efuel

MJ/s

1170.0

Nom. air flow per fan

Steam mass flow per unit

Condensing temperature

Efuel = (hturb - hc) x steam

Air side condenser performance

Process data
Measurement
Qair

ACFMx103

985

Nominal fan static pressure

pStatic

In H2O

0.426

Fan shaft power

PFan

HP

112

Generated output

Eturb

MW

Steam mass flow per unit

steam

lb/s

809.2

Condensing temperature

tC

121.8

Condensing pressure

tp

PSI

1.784

Condensate enthalpy

hc

btu/lb

89.3

Turbine inlet enthalpy

hturb

btu/lb

1461

Required fuel energy

Efuel

btu/s

1109645

Nominal air flow per fan

Efuel = (hturb - hc) x steam

Air side condenser performance

Estimated savings
Measurement

+10%

Qair

m3/s

465

510

Nom. fan static pressure

pStatic

Pa

106

128

Fan shaft power

PFan

kW

82

108

Generated output

Eturb

MW

293

293

Steam mass flow per unit

steam

kg/s

367.0

364.2

Condensing temperature

tC

49.9

47

Condensing pressure

tp

bar a

0.123

0.103

Condensate enthalpy

hc

kJ/kg

207.5

195.6

Turbine inlet enthalpy

hturb

kJ/kg

3395

3395

Required fuel energy

Efuel

MJ/s

1170.0

1165.2

Efuel

MJ/day

Nom. air flow per fan

Saving
Heat density coal
Coal saving per day

MJ/kg

25

CoalCons ton/day
%

Estimated carbon content

CO2 saving per day

407331

CO2

ton/day

Efuel = (hturb - hc) x steam

CO2 = 3.667 x CoalCons x Ccoal

16.3
70

3.667 =

41.8

44 kg [1kgmol CO2]
12 kg [1kgmol C]
10

Air side condenser performance

Estimated savings
Measurement

+10%

Qair

ACFMx1
03

985

1081

pStatic

In H2O

0.426

0.512

PFan

HP

112

147

Eturb

MW

steam
tC

lb/s
F

809.2
121.8

802.9
116.6

Condensing pressure

tp

PSI

1.784

1.494

Condensate enthalpy

hc

btu/lb

89.3

84.1

Turbine inlet enthalpy

hturb

btu/lb

1461

1461

Required fuel energy

Efuel

btu/s

1109645

1105173

Fuel saving per day

Heat density coal

Efuel

btu
btu/lb

Nominal air flow per fan

Nominal fan static
pressure
Fan shaft power
Generated output
Steam mass flow per unit
Condensing temperature

Efuel = (hturb - hc) x steam

10755
CO2 = 3.667 x CoalCons x Ccoal

CoalCons

lb

Estimated carbon content

Ccoal

CO2 saving per day

CO2

lb

Coal saving per day

386333458

35921
70

3.667 =

92198

44 kg [1kgmol CO2]
12 kg [1kgmol C]
11

Air side condenser performance

Estimated savings

Qair

m3/s

Measurement
465

Nom. fan static pressure

pStatic

Pa

106

128

140

154

Fan shaft power

PFan

kW

82

108

125

143

Generated output

Eturb

MW

293

293

293

293

steam
tC

kg/s
C

367.0
49.9

364.2

362.7

361.9

47

45.7

44.8

Condensing pressure

tp

bar a

0.123

0.103

0.100

0.0949

Condensate enthalpy

hc

kJ/kg

207.5

195.6

189.9

186.3

Turbine inlet enthalpy

hturb

kJ/kg

3395

3395

3395

3395

Required fuel energy

Efuel

MJ/s

1170.0

1165.2

1162.5

1161.2

Efuel

MJ/day

407331

644924

753895

16.3

25.8

30.2

41.8

66.2

77.4

Nom. air flow per fan

Steam mass flow per unit

Condensing temperature

Saving
Heat density coal
Coal saving per day

MJ/kg

CO2 saving per day

%
CO2

ton/day

+15%
535

+20%
560

25

CoalCons ton/day

Estimated carbon content

+10%
510

70
12

Air side condenser performance

Estimated savings

Nominal air flow per fan

Qair

Measurement

+10%

+15%

+20%

985

1081

1134

1187

ACFMx10

Nominal fan static pressure

pStatic

In H2O

0.426

0.512

0.563

0.617

Fan shaft power

PFan

HP

112

147

170

195

Generated output

Eturb

MW

steam
tC

lb/s
F

809.2

799.6

797.9

121.8

802.9
116.6

114.3

112.6

Condensing pressure

tp

PSI

1.784

1.494

1.450

1.376

Condensate enthalpy

hc

btu/lb

89.3

84.1

81.7

80.1

Turbine inlet enthalpy

hturb

btu/lb

1461

1461

1461

1461

Required fuel energy

Efuel

btu/s

1109645

1105173

1102565

1101369

Fuel saving per day

Heat density coal

Efuel

btu
btu/lb

386333458

611678959

715032787

Coal saving per day

CoalCons

lb

35921

56874

66484

Estimated carbon content

Ccoal

CO2 saving per day

CO2

lb

92198

145976

170642

Steam mass flow per unit

Condensing temperature

10755

70
13

Air side condenser performance

Costs versus incentives

14

Air side condenser performance

Increased air supply Blade angle

[Pa]

Increased power consumption to

compensate reduced efficiency.
Increased risk of stall due to
reduced pressure margin.
Air flow
%
120
115
110
105
100
95
90
85

PWL
db(A)
2.4
1.8
1.2
0.6
0.0
-0.7
-1.4
-2.1

[m3/s]
15

Air side condenser performance

Increased air supply More speed

[Pa]

Exponential increased of blade load

Volume:

Pressure:

Abs. Power:

Noise:

Q2 n2
=
Q1 n1

p2 n2
=
p1 n1

PFan 2 n2
=
PFan1 n1

n
PWL = 60 LOG 2
n1

[m3/s]
16

Air side condenser performance

Increased air supply More speed

Basic formula:

PWLFan = C + 30 LOG U Tip + 10 LOGPAero 5 LOGDWaaier + dB

Air flow PWL

%
120
4.8
115
3.6
110
2.5
105
1.3
100
0.0
95
-1.3
90
-2.7
85
-4.2

17

Air side condenser performance

Retrofit Extrapolating a new fan duty

18

Air side condenser performance

Retrofit Extrapolating a new fan duty

T n
P=
9550

19

Air side condenser performance

Costs versus incentives

Costs vary. Major question marks

are:
Noise requirements?
Power supply / Cabling capacity?

20

Air side condenser performance

Coal saving

Nominal air flow per fan

Qair

m3/s

Measurement
465

Required fuel energy

Efuel

MJ/s

1170.0

Efuel

MJ/day
MJ/kg

Saving
Heat density coal
Coal saving
Price black coal / ton

CoalCons ton/day
RMB
USD

Saving in black coal/year

RMB
USD

+10%
510

+15%
535

+20%
560

1165.2

1162.5

1161.2

407331

644924

753895

16.3

25.8

30.2

2,676,163
438,715

4,237,150
694,615

4,953,090
811,982

25
450
74

21

Air side condenser performance

CO2 saving
Nominal air flow per fan
Coal saving per day
Estimated carbon content
CO2 saving per day
Costs CO2 emission per ton

Saving in CO2 emission

Qair
CoalCons
Ccoal
CO2

m /s
ton
%
ton/day
RMB
USD
RMB
USD

Measurement
465

+10%
510
16.3

+15%
535
25.8

+20%
560
30.2

41.8

66.2

77.4

457,921
75,069

725,023
118,856

847,529
138,939

70
30
5

22

Air side condenser performance

Costs versus incentives

Total savings/year

RMB
USD

+10%
3,134,085
513,784

+15%
4,962,173
813,471

+20%
5,800,619
950,921

Major question marks are:

Noise requirements.
Power supply / Cabling capacity

23

Howden Netherlands
Do take a closer look to air side condenser performance!
Martin Huis in t Veld

Date: 16 October 2013

24