The invention relates to a cooling delta applicable for a dry cooling system.
It is known that dry cooling towers are frequently applied for cooling the condensers of power plants. These cooling towers include a large number of finned heat exchangers, providing very high airside surface area. Most frequently, these heat exchangers are installed along the circumference of the cooling tower, in a so-called delta arrangement exemplified in
The deltas, of which each consists of two heat exchanger bundles 1 arranged at an angle relative to each other, are assembled by means of a common steel structure 8, each delta thereby forming an individual assembly unit.
Inlet and outlet chambers 4, adapted for inletting and outletting the medium to be cooled, are mounted at the bottom portion of the heat exchanger bundles 1 installed in the delta, and return chambers 5, adapted for reversing the flow direction of the medium, are mounted at the top of the bundles.
This solution is satisfactory and efficient as long as the water flow of the cooling tower does not exceed a critical limit value.
This critical water flow value is determined by two factors. One of these is the water-side resistance of the cooling tubes 2, the other factor (closely related to the first one) is the inlet velocity at which erosion may begin to occur at the cooling tube inlets.
To better understand this, consider that the larger the extracted thermal power is, the larger the water flow will be. In proportion to the increasing thermal power, the air flow should also increase, which goes hand in hand with the increasing combined front surface area of the heat exchanger bundles 1 that have to be built in. This increased front surface area may be provided by increasing the circumference of the cooling tower, as well as the height of the cooling column 7.
Assuming a twofold target increase of cooling power, it is obtained—somewhat simplified—that in case the geometrical proportions are kept, both the base diameter of the cooling tower and the height of the cooling columns 7 should be increased by a factor of √2.
Therefore, if the thermal load increases e.g. twofold, the water flow also increases by the same amount.
From the above it follows that, since the area of the cooling tower is increased only by a factor of √2, the water flow of the heat exchangers at a given section of the circumference also increases by a factor of √2. This, in turn, results in that the velocity of water at the inlets of the heat exchangers—having a height increasing √2 times with the increasing water flow—increases √2 times in proportion to the increasing cooling power.
According to our calculations, the critical inlet velocity is reached in case of a conventional power plant of 500-700 MW, and a nuclear power plant of 300-500 MW.
The tube velocity may of course be reduced by applying multiple tube rows. This solution is, however, limited by the increasing airside resistance of the heat exchanger, which in case of natural draft necessitates an increase of tower height, and in case of using fans the energy expenses of the self-consumption increase.
The tube velocity may also be reduced by applying larger diameter tubes, as illustrated in the top drawing of
It could also be possible to increase the number of the applied cooling towers. However, this option is much more costly compared to single-tower solutions.
It becomes apparent that, in case a single cooling tower is applied, some provisions have to be made in case power is to be further increased, since the above mentioned limitations may in certain cases put in question the feasibility of indirect cooling systems.
Returning now to the variant comprising a single cooling tower having vertically arranged cooling deltas disposed along the circumference in a conventional manner, two options suggest themselves for solving the problem.
One of these options is known from prior art, namely that, by vertically dividing the heat exchanger surface area of the tower to two or more storeys, and increasing the number of the inlet and outlet chambers 4, as well as of the return chambers 5, to twice or multiple times the original, the height of the individual cooling columns—and in proportion to that, their water load—is reduced.
This solution has the disadvantage that, on the one hand, a significant amount of ascending and descending distribution tubing has to be installed, and, on the other hand, the number of the inlet and outlet chambers 4 (arranged at the bottom), as well as of the return chambers 5 (arranged at the top) increases in proportion to the number of storeys.
This solution is based on the hitherto unquestioned presupposition that the axis of the cooling tubes 2 has to be arranged vertically.
The primary object of the invention is to provide a cooling delta which are free of the disadvantages of the prior art solutions to the greatest possible extent.
The objects of the invention can be achieved by the cooling delta according to claim 1. Preferred embodiments of the invention are defined in the dependent claims.
The cooling delta according to the invention is adapted for cooling liquid, gaseous or steam media to be cooled (in the following: media). The cooling delta according to the invention comprises cooling panels arranged at an angle relative to one another, in which cooling panels cooling tubes are arranged. In the cooling delta according to the invention the cooling tubes extend horizontally or substantially horizontally, the cooling delta further comprises a first media flow header—arranged preferably vertically or substantially vertically—being connected to the cooling tubes at a junction of the cooling panels, and providing a flow communication space for the cooling tubes, and second media flow headers—arranged preferably vertically or substantially vertically—connected to opposite ends of the cooling panels with respect to the first media flow header, and providing a flow communication space for the cooling tubes. The media flow headers are preferably implemented as chambers. According to the invention, the cooling tubes extend horizontally or substantially horizontally, which is to be meant that the cooling tubes may have a maximum inclination of a few degrees. In some embodiments, a slight inclination is explicitly required; however, in conventional cooling deltas the cooling tubes are arranged vertically, from which the horizontal or substantially horizontal arrangement of the cooling tubes is fundamentally different.
In an embodiment of the invention, the first media flow header and/or the second media flow headers are formed as columns.
In an embodiment of the cooling delta according to the invention, loading forces arising from the weight of the cooling columns and from wind load act on the outside and inside support columns partly via the steel structure, and partly via the flat surfaces of the support columns, which surfaces comprise openings or bores and are adapted for holding together the cooling tubes.
Preferred embodiments of the invention are described below by way of example with reference to the following drawings, where
The solution according to the invention provides an alternative of the prior art solutions (see
While in conventional cooling deltas the length of the cooling tubes reaches 25-30 m, in the cooling delta according to the invention the tubes may be much shorter. The reduced tube length involves reducing the flow speed of water in the heat exchanger tubes, with the water side resistance also decreasing according to the third power. The horizontal width of the heat exchanger bundles built into conventional cooling deltas is 2.5-2.7 m. The bundles of the cooling delta according to the invention may exceed that by a factor of 3 to 5.
The combination of these features allow that the 600-700 MW power limit for single-tower dry cooling systems applied for conventional power stations may be raised to 1200-1600 MW, also allowing the application of the single-tower system for 800-1200 MW PWR or BWR nuclear power station blocks.
The inventive solution has further important advantages, namely that it reduces the sensitivity to wind and the danger of freezing damage that conventional cooling towers having vertically arranged tubes are subjected to. This may be understood contemplating
On a top sectional view of the delta, the flow pattern in wind is shown for a cooling delta arranged at the side of the tower. Since in the air flowing around the tower the wind speed increases to twice the speed measurable further from the building structures, according to the Bernoulli equation air pressure drops, which results in a reduced air flow entering into these deltas. However, this reduced air flow enters the air space of the delta at high velocity at an oblique angle, and is distributed unevenly along the width of the cooling columns 7. Thereby, the outside portions 20 (from the perspective of the centre of the tower) of the downwind cooling column 7 receive wind at high speed, while other portions of the column receive wind at low speeds. The outside corner of the cooling column 7 being in leeward is in a vortex 27, with no or slight inflow, while further inside the space of the delta the inflow speed is higher due to the stronger vertices. As a result of that—assuming a vertically arranged tube axis—the tubes situated at the outside portion 20 of the cooling column shown in the right of the drawing may be overcooled, or, in winter, may be damaged by freezing. This is related to the vertical arrangement of the tubes, as the high air flow density affects the entire length of the cooling tubes in question. The same holds for the cooling tubes 2 situated in the inside portion 21 of the left-side cooling column. Conversely, due to the depression, the cooling tubes 2 of the outside portion of the upwind column provide little or no cooling. As a result of the uneven airflow distribution illustrated above, the heat exchanger tubes are prone to freezing damage, and, in addition to that, the cooling power of the cooling tower is also reduced, which poses problems of operation especially in case of winds occurring in the hottest summer period.
The situation is completely different in the case of the horizontal tube arrangement implemented according to the invention. Referring also to
Since the suggested dimensions and weight of the cooling deltas is several times bigger than that of conventional deltas, and no suitable lifting equipment is available any more after construction is completed, it would not be possible to dismount and remove a completed cooling delta. Therefore, it should be provided for that the heat exchangers built into the deltas may be removed in smaller units. The invention also contains provisions, explained below, addressing this problem.
The deltas illustrated in
A possible embodiment of the invention is presented as follows. A solution extensively applied in conjunction with dry cooling towers is sealing the ends of the cooling tubes 2 by means of rubber rings 17. Such a solution is shown in
This, however, would not be sufficient to provide for the removability of the cooling columns if axial displacement were not allowed at the other side of the column (shown in the right side in
A loose tube bundle sheet 13, adapted for receiving in a non-fixed manner the cooling tube ends extending over the fixed tube bundle sheet 12, is placed on the tube ends of the cooling column. Rubber rings 17 are placed on the distal side of the loose tube bundle sheet, on the ends of the cooling tubes 2. In the assembled state, the rubber rings 17 situated between the loose tube bundle sheet 13 and the flat wall 14 functioning as the sealing surface of the inside support column 10 are constricted by inserting such transition pieces 15 between the fixed tube bundle sheet 12 and the loose tube bundle sheet 13 that are resilient, but fixed enough to transfer a pressure force to the loose tube bundle sheet 13 that is sufficient to provide the required sealing effect by deforming the rubber rings 17. In case this transition piece 15 is removed, and the fixed tube bundle sheet 12 is pressed against the flat wall 14 functioning as the sealing surface of the inside support column 10 by tightening the tube bundle sheet screws 16, the cooling column 7 may be longitudinally displaced towards the inside of the inside support column 10 by an extent corresponding to the thickness of the transition piece 15. To achieve that, all that has to be done is to loosen the screws 23 of the loose tube bundle sheet 22 situated at the opposite side. The thickness of the transition piece 15 is chosen such that on the other side the ends of the cooling tubes 2 may come out from bores of the outside support column 11. After that, provided that the tube bundle sheet screws 16, 23 are removed at both sides, the cooling column 7 may be removed by first lifting it at the—now freed up—side facing the outside support column 11, and then pulling and lifting it out at the side facing the inside support column 10. To allow for that, the spatial steel structure of the delta (not shown) is configured such that the side through which the damaged cooling columns 7 are to be removed is free, or arranged to be able to be freed up.
A major advantage of this solution should be mentioned here, i.e. that this sealing and tube bundle sheet attachment method does not require high manufacturing accuracy. It is not important that the flat walls 14 of the inside and outside support columns 10, 11, being adapted for sealing, fall perfectly in the same plane. It is also not a problem if the sealing flat walls 14 of the respective inside and outside support columns 10, 11 facing each other are not perfectly parallel, and there can even be an angle allowance in their perpendicular angle relative to the cooling tubes 2. There can also be difference in the distances between the sealing flat walls 14 of the inside and outside support columns 10, 11. What is important is the positional accuracy of the bores disposed on the cooling columns, and the bores of the tube bundle sheets 12, 13, 14, but this requirement is not different from requirements set for conventional heat exchangers.
The connections between the cooling tubes 2 and the inside and outside support columns 10, 11 may be implemented as welded connections. In that case, the components designated by reference numerals 12, 13, 15, 16, 17, 22, 23 in
Another possible embodiment of the invention is illustrated in the top drawing of
The above described solution may also be realised (see the drawing at the bottom of
The circuit connection options of the heat exchangers implemented according to the invention are not different from those of conventional heat exchangers; full cross-flow being the simplest to implement. In this case, the medium to be cooled flows in the same direction in all of the tubes of a given cooling column. According to the examples illustrated in
Further connection options may also be carried out, some of these embodiments being shown in
An alternative arrangement is also possible (top right drawing,
In a further possible solution (bottom left drawing) that one of the support columns is divided in two by a divider member 24 along a plane perpendicular to the longitudinal axis of the column, while the opposite column is left undivided. Thereby, two flow paths may be configured along the column's axis by installing inlet and outlet stubs on only the divided columns but not on the opposite ones, which latter columns therefore become adapted for only reversing the flow direction of the media. By including multiple vertical divisions, more than two flow paths may also be formed.
Applying a longitudinal division 25 to the inside support columns 10 in a direction parallel with their axis, a cross-counter-flow connection of the cooling columns may also be realised, as it is shown in the bottom right drawing in
A solution for filling and draining the cooling deltas should also be found which provides that air can flow out from the cooling tubes during filling and water can flow out therefrom during draining. This may be achieved by raising to a small extent the axis of the cooling tubes 2 (seen from the direction of the inlet support column). The same effect may be obtained for instance by disposing the bores of the inside support column 10 a few centimeters higher, which is allowed by the resilient sealing method described above. According to this solution, the draining ports of the cooling delta are disposed at the bottommost portion of the inlet support columns.
Such an arrangement is also possible wherein the cooling tubes 2 descend towards the direction of oufflowing air (taking into account the filling direction). In this case, the draining means is disposed at the bottommost portion of the outlet support column. In such an embodiment, the hydraulic resistance of the cooling tube 2 must exceed the hydrostatic pressure difference caused by the height difference resulting from the tube's inclination.
In case of this example, the media enters the outside support column 11 at the bottom, and is let out at the top of the inside support column 10. The deltas are filled also in this direction, such that air is let out at the top portion of the inside support column 10. Draining may be carried out in the opposite direction.
The invention is, of course, not limited to the preferred embodiments described in details above, but further variants, modifications and developments are possible within the scope of protection determined by the claims.
Number | Date | Country | Kind |
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P1300085 | Feb 2013 | HU | national |
Filing Document | Filing Date | Country | Kind |
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PCT/HU2014/000016 | 2/11/2014 | WO | 00 |