Advanced Low Cost and Compact Utility Dry Cooling System

Utilizing a dry cooling system for power plant condensers can reduce cooling system water need by over 90%, versus a wet cooling system, thereby reducing permitting and associated water use problems. However, by shifting from a wet to a dry cooling system, the volume, weight and cost of the cooling system are substantially increased. To realize the water use reduction benefits of dry cooling, lower cost dry cooling condensers are needed. The proposer has developed a highly efficient condenser heat exchanger technology that increases the performance of air cooled condensers, reducing condenser volume and weight by 63% and 65%, respectively, while also reducing fan power requirements by 52% and achieving the same heat transfer as competing technologies. These characteristics make the technology more economically competitive with classical water based approaches, and will allow utilities to meet constraints on water use, at an affordable cost. Condenser heat transfer and pressure drop models were developed and utilized to design full scale and test article condensers that have optimal performance, size, weight and cost. A subscale condenser test article was then manufactured and tested and test results showed volume reductions of 63% and pressure drop reductions of 52%, versus conventional dry cooling condensers. These advantages result in a 43% to 48% reduction in condenser total cost, versus conventional dry condensers. Under the Phase II project, a prototype partial condenser panel of 400 kWt capacity will be manufactured and tested, under simulated operational conditions, to demonstrate the technology. In addition to showing that the technology has better heat transfer and pressure drop characteristics than conventional dry cooling condensers, economic analyses will be used to show that costs are substantially lower. Lastly, a transition plan will be created to guide the subsequent commercialization of the technology. Commercial Applications and OtherBenefits: Given the performance and cost advantages of the technology, the commercial opportunity for applying the technology to the utility industry is large, and with the cost advantage the proposed concept will save $29 billion per year, versus conventional dry condenser technology.