Condenser Cooling Systems

White Paper

November 2014
In a closed power cycle, maximum generation can be achieved if system allows working
fluid (Steam) to expand to its fullest potential i.e. expansion of steam (saturated, supercritical, ultra-super-critical) to lowest possible vacuum (below atmospheric pressure).
Many big companies in collaboration with world class universities are continuously
trying to improve inlet conditions/parameters of steam by means of changing geometry,
configuration and material of turbine blades. However, at turbine exhaust side, though
many past developments have provided us proven methods and equipments to
maintain exhaust steam/condensate flow at desired vacuum in order to achieve lowest
possible back-pressure but fluctuating condenser cooling cycle performance as a result
of change in environment conditions is still a concern and has a direct impact on output
generation as well.

333E Technology Private Limited

White Paper | Condenser Cooling System | November 2014

Broadly condenser cooling can be classified in four categories which
are listed below.
1. Once Through System (river/sea water)
2. Closed Condenser Cooling System (cooling towers)
3. Direct Dry Condenser Cooling System (Air Cooled Condensers)
4. In-Direct Condenser Cooling System

Direct Dry Condenser Cooling System (Air Cooled Condensers)

Favorable points

Almost zero make-up water requirement for

condenser cooling; Less maintenance throughout
the life cycle.

Unfavorable Points Highest auxiliary power consumption among all

choices (within plant boundary); High Heat Rate of

plant when compared with Closed Cycle.

Once Through System (river/sea water)

Favorable points

Lowest condenser pumping power (depends on

Water Level in River & Sea at intake and outfall)

Health &
Environment
Concern

No direct threat

Unfavorable Points Continuous supply of cold water from source;

Temperature rise restrictions in condenser

Health &
Environment
Concern

Marine life threat and Tsunamis

Pic3. Air Cooled Condenser

In-Direct Condenser Cooling System

Favorable points
Pic1. Once Through System

Closed Condenser Cooling System (cooling towers)

Favorable points

Lowest possible back-pressure; Small quantity of

make-up water required when compared to Once
Through System

Almost zero make-up water requirement for

condenser cooling; Less maintenance throughout
the life cycle.

Unfavorable Points Auxiliary power consumption is also high but

significantly lower than ACC (within plant

boundary); Highest Heat Rate
Health &
Environment
Concern

No direct threat

Unfavorable Points Frequent maintenance required (both at condenser

and cooling tower); Lot of Chemical consumption to

maintain desired water chemistry; Restriction of
temperature rise of circulating water in condenser
depending upon WBT and selected approach.
Health &
Environment
Concern

Threat of Legionnaires' disease or Mycobacterium

avium

Pic2. Closed Condenser Cooling

Pic4. Air Cooled Condenser

White Paper | Condenser Cooling System | November 2014

Summary:
It is to be noted that many studies have been carried out in past both
by government and private bodies independently and jointly and
subsequently different conclusions, based on different assumptions,
have been used for selection of condenser cooling system. Like,
1. Closed cycle with cooling towers is most preferred system over
other systems where abundant water is available. However,
single drought (non-availability of water) in plant life cycle of 25
30 years may change the preference.
2. Capex involved in In-direct dry system is significantly more than
Direct dry system. However,Auxiliary power savings, equipment
replacement & maintenance cost, etc have much more
significant savings than initial capex involved when compared
for life cycle cost)
3. Many more examples.
Therefore, it is highly recommended to carry out detailed
investigation by group of expert people who have hands on
experience in all the above fields before finalizing your choice of
condenser cooling systems. It just takes a few weeks time and a
correct decision may save hundreds of millions in future.

About the Author

Vishal Roat is Director (Technical) at 333E Technology, based in New
Delhi, India. He can be reached at td@333e.co.in

333E Technology Private Limited

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