Computer optimization of dry and wet/dry cooling tower systems for large fossil and nuclear power plants

This study determined the cost of dry cooling compared to the conventional cooling methods. Also, the savings by using wet/dry instead of all-dry cooling were determined. A total optimization was performed for power plants with dry cooling tower systems using metal-finned-tube heat exchangers and surface condensers. The optimization minimizes the power production cost. The program optimizes the design of the heat exchanger and its air and water flow rates. In the base case study, the method of replacing lost capacity assumes the use of gas turbines. As a result of using dry cooling towers in an 800 MWe fossil plant, the incremental costs with the use of high back pressure turbine and conventional turbine over all-wet cooling are 11 and 15%, respectively. For a 1200 MWe nuclear plant, these are 22 and 25%, respectively. Since the method of making up lost capacity depends on the situation of a utility, considerable effort has been placed on testing the effects of using different methods of replacing lost capacity at high ambient temperatures by purchased energy. The results indicate that the optimization is very sensitive to the method of making up lost capacity. It is, therefore, important to do an accurate representation of all possible methods of making up capacity loss when optimizating power plants with dry cooling towers. A solution for the problem of losing generation capability by a power plant due to the use of a dry cooling tower is to supplement the dry tower during the hours of peak ambient temperatures by a wet tower. A separate wet/dry cooling tower system with series tower arrangement was considered in this study, and proved to be an economic choice over all-dry cooling where some water is available but supplies are insufficient for a totally evaporative cooling tower