Howden Netherlands

A closer look to air side condenser performance

Martin Huis in ‘t Veld Date: 16 October 2013

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Air side condenser performance
Site assessment

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Air side condenser performance
Site assessment: Volume, pressure, temperature – system resistance curve

Unit A Unit B

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Air side condenser performance
Increased air side performance

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 Air side condenser performance
Condensing data relation to fan air supply
Temperature

Fan air supply

Pressure [a]

Fan air supply

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Air side condenser performance
Process data estimation

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Air side condenser performance
Process data estimation

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 Air side condenser performance
Process data

Measurement
Nom. air flow per fan Qair m3/s 465

Nom. fan static pressure pStatic Pa 106

Fan shaft power PFan kW 82

Generated output Eturb MW 293

Steam mass flow per unit ṁsteam kg/s 367.0

Condensing temperature tC °C 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 Efuel = (hturb - hc) x ṁsteam

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 Air side condenser performance
Process data

Measurement
Nominal air flow per fan 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 ṁsteam lb/s 809.2

Condensing temperature tC °F 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 Efuel = (hturb - hc) x ṁsteam

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 Air side condenser performance
Estimated savings

Measurement +10%
Nom. air flow per fan 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 ṁsteam kg/s 367.0 364.2

Condensing temperature tC °C 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 = (hturb - hc) x ṁsteam
Saving ∆Efuel MJ/day 407331
Heat density coal MJ/kg 25
∆CO2 = 3.667 x ∆CoalCons x Ccoal
Coal saving per day ∆CoalCons ton/day 16.3
Estimated carbon content % 70 3.667 = 44 kg [1kgmol CO2]
12 kg [1kgmol C]
CO2 saving per day ∆CO2 ton/day 41.8
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 Air side condenser performance
Estimated savings

Measurement +10%
ACFMx1
Nominal air flow per fan Qair 985 1081
03
Nominal fan static
pStatic In H2O 0.426 0.512
pressure
Fan shaft power PFan HP 112 147

Generated output Eturb MW

Steam mass flow per unit ṁsteam lb/s 809.2 802.9

Condensing temperature tC °F 121.8 116.6
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
Efuel = (hturb - hc) x ṁsteam
Fuel saving per day ∆Efuel btu 386333458
Heat density coal btu/lb 10755
∆CO2 = 3.667 x ∆CoalCons x Ccoal
Coal saving per day ∆CoalCons lb 35921
Estimated carbon content Ccoal % 70 3.667 = 44 kg [1kgmol CO2]
12 kg [1kgmol C]
CO2 saving per day ∆CO2 lb 92198
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 Air side condenser performance
Estimated savings

Measurement +10% +15% +20%

Nom. air flow per fan Qair m3/s 465 510 535 560

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 mass flow per unit ṁsteam kg/s 367.0 364.2 362.7 361.9
Condensing temperature tC °C 49.9 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
Saving ∆Efuel MJ/day 407331 644924 753895
Heat density coal MJ/kg 25
Coal saving per day ∆CoalCons ton/day 16.3 25.8 30.2
Estimated carbon content % 70
CO2 saving per day ∆CO2 ton/day 41.8 66.2 77.4
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 Air side condenser performance
Estimated savings

Measurement +10% +15% +20%

ACFMx10
Nominal air flow per fan Qair 3 985 1081 1134 1187

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 mass flow per unit ṁsteam lb/s 809.2 802.9 799.6 797.9
Condensing temperature tC °F 121.8 116.6 114.3 112.6
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 ∆Efuel btu 386333458 611678959 715032787
Heat density coal btu/lb 10755
Coal saving per day
∆CoalCons lb 35921 56874 66484
Estimated carbon content Ccoal % 70
CO2 saving per day ∆CO2 lb 92198 145976 170642
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Air side condenser performance
Costs versus incentives

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 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 ∆ PWL

% db(A)
120 2.4
115 1.8
110 1.2
105 0.6
100 0.0
95 -0.7
90 -1.4
85 -2.1

[m3/s]
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 Air side condenser performance
Increased air supply – More speed

[Pa] Exponential increased of blade load

Q2 n2
Volume: =
Q1 n1

2
p2  n2 
Pressure: =  
p1  n1 

3
Abs. Power: PFan 2  n2 
=  
PFan1  n1 

Noise: n 
∆PWL = 60 LOG  2 
 n1 

[m3/s]
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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

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Air side condenser performance
Retrofit – Extrapolating a new fan duty

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Air side condenser performance
Retrofit – Extrapolating a new fan duty

T ×n
P=
9550

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 Air side condenser performance
Costs versus incentives

Costs vary. Major question marks

are:

• Noise requirements?
• Power supply / Cabling capacity?

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 Air side condenser performance
Coal saving

Measurement +10% +15% +20%

Nominal air flow per fan Qair m3/s 465 510 535 560
Required fuel energy Efuel MJ/s 1170.0 1165.2 1162.5 1161.2
Saving ∆Efuel MJ/day 407331 644924 753895
Heat density coal MJ/kg 25
Coal saving ∆CoalCons ton/day 16.3 25.8 30.2
RMB 450
Price black coal / ton
USD 74

RMB 2,676,163 4,237,150 4,953,090

Saving in black coal/year
USD 438,715 694,615 811,982

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 Air side condenser performance
CO2 saving

Measurement +10% +15% +20%

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Nominal air flow per fan Qair m /s 465 510 535 560
Coal saving per day ∆CoalCons ton 16.3 25.8 30.2
Estimated carbon content Ccoal % 70
CO2 saving per day ∆CO2 ton/day 41.8 66.2 77.4
RMB 30
Costs CO2 emission per ton
USD 5

RMB 457,921 725,023 847,529

Saving in CO2 emission
USD 75,069 118,856 138,939

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 Air side condenser performance
Costs versus incentives

+10% +15% +20%

RMB 3,134,085 4,962,173 5,800,619
Total savings/year
USD 513,784 813,471 950,921

Major question marks are:

• Noise requirements.
• Power supply / Cabling capacity

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Howden Netherlands
Do take a closer look to air side condenser performance!
Martin Huis in ‘t Veld Date: 16 October 2013

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