International Conference

N
N
Nu
u
uc
c
cl
l
le
e
ea
a
ar
r
r E
E
En
n
ne
e
er
r
rg
g
gy
y
y f
f
fo
o
or
r
r N
N
Ne
e
ew
w
w E
E
Eu
u
ur
r
ro
o
op
p
pe
e
e 2
2
20
0
00
0
09
9
9
Bled / Slovenia / September 14-17




706.1
Feasibility Study and Optimization of Cooling Towers for
New Nuclear Power Plant at the Krko Site
Ale Buri, Robert Bergant
GEN energija, d.o.o.
Cesta 4. julija 42
SI-8270 Krko, Slovenija
ales.bursic@gen-energija.si, robert.bergant@gen-energija.si
ABSTRACT
Since the cooling capability of Sava river is already exploited due to the once through
cooling of existing nuclear power plant, cooling towers as a closed third cycle are predicted
for the new nuclear power plant which will be located next to the existing one. Therefore,
feasibility of different cooling tower (CT) designs and their adequacy to meet the plant and
environmental parameters were examined. At two generator output power levels 1200 MWe
and 1700 MWe, three cooling tower designs representing three basic cooling air philosophies
forced-, induced- and natural draught were applied. The feasibility evaluation for cooling
towers analyzed two separate nuclear power plant systems: Circulating Water system (CWS)
and Service Water system (SWS).
1 INTRODUCTION
When selecting a wet cooling tower, there are many factors to consider. The weighting
for the selection criteria for a cooling tower application are always dependant on the local
conditions and preferences of the end user. The considered factors at selecting appropriate wet
cooling tower might include:
Technical factors: cooling tower performance over a range of ambient conditions,
flexibility of operation and maintenance of desired water temperatures, space
requirement including provision for air inlets and shape;
Economic factors: capital cost, operating costs, lifetime cost and reliability;
Environmental factors: noise, plume generation, visual impact.
In accordance with NPP Krko II pre-preparation phase studies, the use of the following
cooling tower designs for two generator output power levels, 1200 MWe and 1700 MWe,
were examined:
Natural draught,
Cell-type (Multi-cell) and
Round forced draught hybrid.
There are of course other designs such as Fan Assisted Natural Draught (FAND) and
Hybrid Cell-type. These three were chosen because each is indicative of one of the three
basic wet cooling tower air philosophies (forced-, induced- and natural draught). For example
the layout of a FAND tower is similar to the Round Forced Draught Hybrid. The natural
draught cooling towers have been selected as a single unit where possible, with an alternative
where appropriate for two or more smaller units being limited in height to 150 m.
706.2
Material of construction for all types is expected to be reinforced concrete; however, it
is also possible to offer the multi-cell induced draught models in FRP (fiber-reinforced
plastic) material.
The heat loads for the SWS applications are too low for the use of natural draught or
round forced draught hybrid cooling towers. For these applications only cell-type is
considered.
2 COOLING TOWER APPLICATIONS AND EFFECT OF TEMPERATURE
At cooling tower applications there are some terms frequently used and therefore some
explanation is needed.
Wet bulb air temperature is the minimum temperature which may be achieved by purely
evaporative cooling of a water-wetted, ventilated surface.
Dry bulb air temperature is the temperature of air measured by a thermometer freely
exposed to the air but shielded from radiation and moisture;
Range indicates the difference between the hot and cold circulating water temperatures, while
approach indicates the difference between the wet bulb and cold water temperatures.
Heat load is the amount of the heat that the cooling tower is required to dissipate.
The ambient conditions at the design point for cooling tower were defined in order to
meet the required thermal performance. For this study following main ambient conditions
with respect to local psychrometric measurements and experience with recent installed
cooling cells at existing power plant NEK were selected: dry bulb air temperature 26.0 C and
wet bulb air temperature 23.6 C at 76.9 % relative humidity (r.H.) [1]. At other ambient
conditions the cooling tower performance will vary in a predictable manner. These variations
are presented with cooling performance characteristic diagrams. Each of cooling tower
types and applications have their own cooling performance characteristic with respect to
ambient wet bulb temperature. Cooling performance characteristic diagrams were calculated
by SPX Cooling Technologies GmbH with dedicated software compliant with Acceptance
Test Codes CTI ATC-105 and ATC-105S.
Tables 1, 2 and 3 are representing respective cooling solutions for two generator output
power levels, i.e. 1200 MWe and 1700 MWe. Footprint differences at the same power level
emerging mainly from selected different process parameters in CWS by different power plant
suppliers: condenser back pressure, circulating water flow and respective inlet/outlet and
condenser saturated temperatures. Differences at these parameters are resulting different
power efficiency and accordingly different dimensions of cooling installation. For instance;
lower condenser saturated temperature means larger useful work on the one hand (thus
increasing power generation), but gives lower approach temperature moving cooling tower
outlet temperature or condenser inlet temperature closer to design air wet bulb temperature
and thus requires larger cooling tower installation on the other hand. The optimization of the
design is not straightforward; therefore some sort of compromise between two diametrical
parameters should be done. Based on the results and dimensions of CTs from Tables 1, 2 and
3, it is notable, in some cases additional preliminary cold-end optimization has to be carried
out by plant designers in order to reduce disproportion of CTs between larger and lower
generator output power levels.
2.1 Natural Draught (CWS)
Natural draught cooling towers (NDCT) shown in Fig. 1 rely on the difference in air
density between ambient air and the warm air leaving the cooling tower to induce a flow of
air through the cooling fill and thereby cool the circulating water flow. The buoyancy of air
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.3
leaving the cooling tower is enhanced during times of low ambient temperature and this result
in an acceleration of cooling efficiency as the ambient temperature falls. The flow of air
through the cooling tower varies according to the prevailing ambient conditions. Water is
either delivered to the cooling tower through one or more external riser pipes, or in some
cases through an internal central concrete riser duct, before being distributed over a network
of plastic pipes with spray nozzles. These nozzles ensure an even distribution of water over
the entire cooling fill surface.

Figure 1: Natural Draught Cooling Tower
Table 1: Natural Draught Cooling Tower dimensions
NDCT
solutions
per NPP
Power
range
[Mwe]
N of
cooling
towers
Total
Height,
rHges [m]
Eff.
Height,
Hw [m]
Air Inlet
Height,
Hle [m]
Process
Diameter,
Dr [m]
Outlet
Diameter,
Da [m]
GEN01 1 170 159,3 10,7 118 73
GEN02 2 130 122,5 7,5 89,3 55
GEN05 2 190 179 11 125,7 78
GEN06
1700
3 150 139 11 106,9 67
GEN10 1 175 164 11 119,5 75
GEN11 2 134 126 8 90,3 56
GEN14 2 188 177 11 124,3 78
GEN15
1200
3 155 145 10 105,6 66

Figure 2: Performance characteristic curve for Natural Draught Cooling Tower at
temperature range 14 K with water flow rate 181170 t/h
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.4
Cooling performance characteristic diagrams show the hot water temperature versus
wet bulb temperature for a selection of relative humidities (40%, 60%, 80% as different
design points and 90% as an extra one). Nine cooling performance characteristic diagrams
are generated for each NDCT cooling application. For each of three different cooling ranges,
three circulating water flow rates are considered, similar as shown in Fig. 2 as an
representative example.
2.2 Multi-cell Induced Draught (CWS)
In this type of cooling tower, shown in Fig. 3, fan machinery located on the roof deck of
the tower structure is utilized to deliver a constant volume of air through the cooling fill as
presented in Fig. 4. The cooling performance, shown in Fig. 5, still improves in response to
lower wet bulb temperature; however as result of the air flow being constant during summer
and winter, the cooling characteristic tends to be more resistant to temperature change than in
natural draught cooling. Although the volume of air delivered by the induced draught fans
remains constant throughout the year, the mass air flow increases as a function of exit air
density. This means that during colder ambient conditions the absorbed fan power rises, and
conversely during warm ambient conditions the fan power falls, within a range of 10% of
the nominal design point. Water is again delivered to the cooling towers through external riser
pipes (1 per cell), or in the case of back to back blocks (as in the CW layouts of this study) 1
per 2 cells.

Table 2: Multi-cell dimensions
Multi-cell
Induced
Draught
Power
range
[Mwe]
N
of
cells
Total cell
length, l x
w [m]
GEN03 38 313 x 33
GEN07
1700
62 510 x 33
GEN12 36 297 x 33
GEN16
1200
56 461 x 33
Base cell dimensions: 16,5m x16,5m x20m
Figure 3: Multi-cell Induced Draught CT

Figure 4: Cell-type Operation Principle
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.5

Figure 5: Performance characteristic curve for Multi-cell Induced Draught Cooling
Tower at 100% Fan Power with water flow rate 212731 t/h
2.3 Circular Fan Assisted Hybrid (CWS)
Fig. 6 shows the principle behind hybrid cooling towers in a Mollier diagram. The
principle of operation is based on maintaining (up to the plume-free point) the exiting air (M)
above the area of oversaturation. Warm water arriving from the process is first delivered to
the dry section of the cooling tower, arranged vertically around the periphery of the upper
floor. After passing through these finned tube heat exchangers, water is then delivered to the
wet section distribution system mounted below, where it is then sprayed over the entire
cooling fill area.

Figure 6: Hybrid Operation Principle
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.6

Figure 7: Circular Fan Assisted Hybrid
Table 3: Circular Fan Assisted Hybrid dimensions
Round
Forced
Draught
Hybrid
Power
range
[Mwe]
N of
cooling
towers
Total
Height,
Hges [m]
Outside
Diameter,
Dges [m]
Process
Diameter,
Dr [m]
Number of
Fans Wet /
Dry
GEN04 1 55 161 121 44 / 44
GEN08 1 55 188 144 56 / 56
GEN09
1700
2 55 143 103 32 / 32
GEN13 1 55 159 119 44 / 44
GEN17
1200
1 55 178 138 52 / 52

Figure 8: Performance characteristic curve for Circular Fan Assisted Hybrid at 100%
Fan Power and 100% water flow rate
Such plume abated cooling towers have two separate streams of process air, one for the
dry section and one for the wet section, as shown in Fig. 7. In the case of circular hybrid
tower designs, each section is equipped with forced draught axial flow fans arranged in two
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.7
levels around the periphery of the tower. The dry section fans deliver a warm stream of dry air
that mixes with saturated air leaving the wet section.
A series of mixer ducts then ensures the wet and dry air streams are thoroughly mixed
such that the air leaving the cooling tower does not produce a visible plume under pre-agreed
ambient conditions and plant load. For the hybrid cooling tower as an input a typical plume-
free point 5 C at 90% relative humidity was selected. This is the ambient condition up to
which the hybrid cooling tower has practically no visible plume. Below this point the plume is
abated (i.e. reduced) but clearly visible.
Since the air flows are delivered mechanically, the performance characteristic of this
cooling tower type, shown in Fig. 8, is very similar to the induced draught Multi-cell type
described above.
2.4 Cooling performance characteristic curves - conclusions
Cooling performance characteristic curves in general show dependence of cooling
performance according to ambient conditions. Wet Bulb Temperature changes result in
cooling performance changes; with temperature rise, cooled water in CWS exiting cooling
tower becomes warmer, consequentially decreasing cooling performance in condenser and
thus lowering plant efficiency.
Natural draught cooling towers are most dependent upon ambient conditions. This is
because at lower ambient temperatures the air density difference between the ambient air and
the warm air in the cooling tower is larger so the natural draught effect is increased. Due to
this effect NDCTs become more efficient at lower temperatures (and less efficient at higher
temperatures). The negative aspect of this is that these towers are more prone to icing than the
other types.
For the forced draught towers (Circular hybrid) and the induced draught towers
(Multicell-type) the difference is smaller because the air volumes entering the towers remain
constant. There is a slight difference because the fans of the induced draught towers pull
warmed air through tower, whereas the forced draught hybrid towers force cold ambient air
into tower. It causes the Multicell-type towers to be the least effected by cold ambient air
because the cold air is denser and hence the hybrid tower fans force a greater mass of air into
the tower at cold ambient conditions.
3 ECONOMIC FACTORS

Figure 9: Capital costs of different CT designs
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.8
The economic factors determining the choice of cooling tower depends on the interplay
of capital and running costs. Fig. 9 represents capital costs of different CT designs at different
applications in two specified power ranges. Specific application power ranges and CT designs
are described under appropriate designations (e.g. GEN01) in Tables 1, 2 and 3.
The cost of maintenance, as one of important contributors to running costs, is however
difficult to assess in this phase. For all types the cooling fill is equally subjected to wear and
tear. The additional mechanical components of the fan assisted towers (particularly the
hybrids) are a source of significant maintenance expense. During operation, power
consumption, as a sum of pump power and fan power, has a significant impact on running
costs and those are connected with CT design. Disposal costs reflect the quantity of concrete
used at construction and the difficulty of demolishing the tower after operation lifetime. In
Table 4 economic factors are evaluated over selected CT designs.
Table 4: Economic factors of cooling towers
Natural Draught Circular Hybrid Multi-cell
Capital costs ++ + ++
Maintenance +++ + ++
Power consumed +++ + ++
Disposal costs
+ ++ +++
+++Best ++Mid +Worst
For the Circular hybrid CT the proportion of the dry section electrical power required to
maintain plume-free operation to 5C, 90% r.H. was estimated, followed by plume-abated
operation if temperature sinks and/or relative humidity rises. Investigation indicates a year
round average power consumption of 41% of total installed dry section fan power for 1996
and 33% for 2000.

Figure 10: Representative data of Fan Power variations during the day (based on average
hourly ambient data, 1996)

Figure 11: Representative data of Fan Power variations during the day (based on average
hourly ambient data, 2000)
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.9
The year 1996 was taken as the average coldest year and 2000 as hottest year in last 20
year observation period. The figures of average power consumption presented in Fig. 10 and
11, by their nature, are independent of the application, being based on the environmental data
supplied for these years [3] and a modelling of the fan power requirement to counteract air
saturation. Figures 10 and 11 are representing calculations for two months period, but average
data were calculated for all 12 months of plume abated operation. It can be seen that warm
weather conditions require less power for plume abated operation compared to cold weather
conditions.
Comparison between combining the installed power for dry fan section and wet fan
section at Circular Fan Assisted Hybrid and installed power for multi-cell cooling towers is
shown on Figure 12. Energy consumption at hybrid CT is varying according to ambiental
conditions. Thus a year round average power consumption for plume-abated operation
(Figures 10 and 11) could be compared to multi-cell power consumption, especially at
GEN04 to GEN03 (1700 Mwe) and GEN13 to GEN12 (1200 Mwe) variants.


Figure 12: Installed Fan power for Circular Fan Assisted Hybrid and
multi-cell cooling towers
4 ENVIRONMENTAL IMPACTS
The environmental impacts of each cooling tower types are summarized in the Table 5.
When assessing the environmental impacts of footprint the round CT is more space efficient
due to the recirculation effects suffered by the Multi-cell layout. Visual Impact of height and
plume at the NDCT makes it the most exposed one. The Multi-cell has smallest visual impact,
because it is low and its plume does not reach high elevations. Impact of noise at NDCT is
most acceptable, because it does not require fans for operation, since Multi-cell CT has one
fan for each cell whereas Circular Hybrid is equipped with two sections of fans. For any given
degree of sound attenuation there, noise level will correspond to the number of fans installed
at each design. Assessing Plume impact on environment leads to conclusion that the Multi-
cells have the biggest impact, because the plume is emitted at a low height. The Circular
hybrid is plume abated, therefore its plume impact on environment is negligible. Drift
Losses due to water droplets escape in the cooling tower discharge are the smallest at Circular
hybrid CT. Circular hybrid has high performance drift eliminators in order to improve the
plume abatement performance and at the same time the best drift eliminating performance.
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.10
Table 5: Environmental Impacts of cooling towers
Natural Draught Circular Hybrid Multi-cell
Footprint/Size +++ +++ +
Visual impact + ++ +++
Noise level +++ + ++
Plume ++ +++ +
Drift losses ++ +++ ++
+++Best ++Mid +Worst
5 CONCLUSIONS
In a comparison, represented in this paper, where the design ambient data are the same for the
applications, the main influencers are:
Range For a given heat load the range is inversely proportional to the water flow rate,
i.e. the design can be a large range and a low flow rate or vice-versa. A larger range reduces
the size of cooling tower required (whichever type is chosen) but increases the size of the
condenser, assuming the steam pressure is constant. The optimal split between the cooling
tower and condenser sizing requires a cold-end optimisation to be carried out.
Approach As the required approach decreases, the size of cooling tower increases
intensively. The approach of 3 K is technically the lowest acceptable value.
Heat load changes in power, e.g. load follow operation of plant, results in changes of
heat that the cooling tower is required to dissipate.
Effect of temperature variation on different cooling tower types at ambient
conditions away from the design point the different types of cooling towers produce different
circulating water temperatures. This effect can be seen on the Performance Curves in Section
2.
Above presented effects influence the average annual power produced. They also
determine the sizing required for a specific type of cooling tower. All determining factors for
the type of cooling tower must reflect local considerations, including Space available, Height
restrictions and Acceptability of plume.
At the economic criteria capital cost versus running costs should be considered in
terms of a project time frame. With all costs amortized over this period a comparison can be
made. However, economically quantifying the value of plume-free operation is not
objectively possible here the value is in terms of the project acceptability.
For the three types of cooling towers considered in this paper the following conclusions
can be drawn: Natural Draught Cooling Towers use the least parasitic energy. They require
the least maintenance because they have no major moving parts, use space efficiently and
emit plume at a high height; Multi-cell Induced Draught Cooling Towers can be installed
quickly, they suffer from recirculation, require a lot of space and use a significant amount of
energy; Circular Hybrid Cooling Towers produce no plume up to certain ambient
conditions and thereafter abated plume, require extensive noise abatement measures, are most
expensive among considered cooling options, use an enormous amount of energy while their
maintenance is intensive.
This study clearly showed all cooling approaches are feasible. Decision in selecting
appropriate cooling option among presented ones and further balancing other process
parameters (cold end optimization) is indeed in hands of the owner and investor, normally
trying to drive optimization to the optimum, gaining most efficiency with respect to
investment cost and return rates leaving least impact on environment and ensuring best local
community acceptance.
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009
706.11
REFERENCES
[1] SPX GmbH, S. Phillips et al, Feasibility Study and optimization Of Cooling Towers For
The New Nuclear Power Plant at the Krko Site (NPP Krko II), Ratingen, Germany,
2009
[2] DMP-477-CT-L: CT cooling tower system extension, 2008
[3] ARSO, Meteorological data from AMP NEK for years 1996 and 2000, Ljubljana, Oct.
2008
[4] Black & Veatch, Drbal, Lawrence F., POWER plant engineering, Chapman & Hall;
Springer Science+Business Media, New York, 1996
[5] Robert C. Rosaler, Standard Handbook of Plant Engineering; Ch 3.4, McGraw-Hill, New
York, 2004
Proceedings of the International Conference Nuclear Energy for New Europe, Bled, Slovenia, Sept. 14-17, 2009