060301-Sea Water Cooling - March 2006-Islamabad

Sea-Water Cooling
For Air-Conditioning Systems

BY
Fahim I. Siddiqui
Partner / Principal Mechanical Consultant FND Consulting Engineers
13th Annual Conference Pakistan HVACR Society March 2006
You cannot discover oceans unless you have the courage to leave the shore.
Sea-Water Cooling
Presentation Overview:
What is Sea Water?
Thermal Impacts Environmental Concerns Materials of Construction
Fahim I. Siddiqui Paper At 13th Annual Conference Pakistan HVACR Society March 2006
Sea-Water Cooling
Presentation Overview:
How can sea-water be used for cooling?
Using sea-water as make-up water in sea-water cooling towers. OR Using sea-water to remove condenser heat. OR Using cold sea-water to directly cool buildings (SWAC).
Sea-Water Cooling
Why sea-water cooling?
BecauseAn air-conditioning system uses a lot of fresh water, which is a very expensive resource today, & Using fresh water is not a adopting a policy of environment sustainability. & Using sea-water reduces operational expenses
What is Sea Water?

Seawater is water and various dissolved salts.
3.7, 4%
Six elements and compounds

comprise about 99% of sea salts. The quantity of these salts is constant in all seawater, however the amount of salt will vary due to runoff and precipitation.
7.7, 8%
Na
30.6, 31%
CI SO4 Mg Ca K Minor Salts
55, 54%
What is Sea Water?

Seawater is typically defined in terms of salinity.
Salinity is defined as the total amount of solid material dissolved
in a kilogram of seawater when all the carbonate has been converted to oxide, all bromide and iodine replaced by chlorine, and all organic matter is completely oxidized.
Average Seawater - Salinity is 35,000 ppm, Alkalinity of 115 ppm, and
a pH of around 8.
For Cooling Towers, Sea Water is Circulating Water with a Salinity of 10,000 ppm or greater. Since the circulating water is typically concentrated, the cooling tower could also be exposed to salt water service even if the makeup water has a salinity below 10,000 ppm.
Sea-Water Cooling Towers
Sea-Water Cooling Tower Schematic
Impacts on Thermal Performance

Salt has Four Physical Effects Upon Water That Impacts Thermal Performance.
1. Increased Density - Average Seawater Density is 2.8% Greater than Fresh Water (1,028 vs. 1,000 kg/m3)
- Use caution when specifying cooling tower flow rates (1 m3/hr is not equal to 1 ton/hr)
2. Lower Vapor Pressure - Average Seawater Vapor Pressure is 0.5% to 2.0% Lower than Fresh Water.
- The increased density and lower vapor pressure result in a decreased Latent Heat transfer
- Latent Heat transfer, or the energy of evaporation, accounts for most of the
temperature drop in a cooling tower.

3. Seawater Provides Less Surface Tension, Which Effects Water Film
- This will have a minor impact if film fill is used
4. Reduced Heat Capacity - Seawater Heat Capacity at 38C is 7.1% Less than Fresh Water
- This increases the Sensible Heat transfer, or the energy of a temperature change, within the cooling tower - Reduced heat capacity actually serves to increase the performance of a salt water cooling tower, however it is not enough to offset the other physical effects

The Result is Reduced Thermal Performance
10,000 ppm Salinity 1% Reduction 35,000 ppm Salinity 3% Reduction
70,000 ppm Salinity 5% Reduction
Due to Decreasing Thermal Performance, the Practical Limit of Salinity is ~70,000 ppm
Two Cycles of Concentration Maximum for Typical Seawater
Reduced Performance Must be Offset with a Larger Footprint for the Cooling Tower and/or Increased Fan Motor Power
Environmental Impacts
Evaporation is Pure Water - No Environmental Concern
Drift
Salt May Collect on Nearby Facilities - Buildings, Power Lines, Cars - Corrosion is Major Concern Majority (99%) of Drift Droplets will be 20 Microns or Smaller for Atmospheric Distribution Less than 5% are 10 Microns or Smaller Cooling Tower Should be Placed Downwind from the Rest of the Plant/ Building
Blowdown - Depending on Concentration and Return Location,
Blowdown May be a Concern
Materials of Construction-1
Due to the Corrosive Environment, Special Consideration Must be
Given to all Materials that will be in Contact with the Water

Structure Hardware / Reinforcement Fill Distribution System Fan Stacks Mechanical Equipment & Supports
Structure:
Structure Can be Wood, Fiberglass, or Concrete
With proper treatment, the use of Douglas fir or redwood is possible. However, if the tower is to be used for intermittent service problems could arise from the continual wetting and drying of the wood. If a fire protection system is required, a wood tower is more expensive than a fiberglass tower. Fiberglass has a high resistance to corrosion and drying, a long service life, and lower cost than concrete. However, the cost of fiberglass may exceed that of concrete when freight is considered.
Concrete is the best overall option for saltwater towers in India & Pakistan.
Longest service life of all materials, and could be cheaper too in Pakistan due to low labour cost.
Structure Concrete:
Additional Performance Impacts due to Increased Air Blockage from Larger Support Beams - 3 to 5%
Longest Service Life
Lower maintenance requirements than wood or fiberglass
Installation Requires More Man-Hours

Typically offset by low labor rates in India & Pakistan
Concrete Materials Selected to Reduce Chance of Water Penetration Emphasis on American Concrete Institute (ACI) Design Codes
Hardware:
For Wood and Fiberglass Structures the Connecting Hardware is a Concern
Silicon Bronze or is recommended unless high levels of sulfides are present Silicon bronze hardware is 2X the cost of 316SS. Titanium, Monel or another nickel alloy can also be used Titanium hardware is 6X the cost of 316 SS. High molybdenum metals such as Super Duplex (254SMO) or Super Austenitic Stainless Steel (AL6XN UNS S31254 and N08367) are also acceptable.
In Concrete Towers Exposed Hardware and Reinforcement Bars are a
Concern
Exposed hardware should be silicon bronze, titanium, monel, or a high molybdenum metal Rebar should be stainless steel or epoxy coated carbon steel
Fill:
Depending on Water Source and Treatment, Suspended Solids Levels May be High - Sand, Debris, Oil, Biological
TSS levels will impact fill selection TDS has no effect on fill selection
Circulating Water Temperature

PVC Sheets - Temperatures < 60oC Polypropylene Sheets - Temperatures < 77oC
Fill:
Film Fills
Low TSS Levels (<70 ppm for High Efficiency, <120 ppm for Low Fouling) Very Low Biological Level & Less Than 5 ppm of Oils Can be used in salt water towers if the makeup water is properly treated to remove biological matter and other debris
Splash Type Fills

TSS > 120 ppm, No upper limit on TSS
Lower efficiency, results in a larger tower Far less susceptible to fouling
Water Distribution:
The Distribution System is the Same For Salt Water and Clean Water Towers
Materials are inert and will not be harmed by salt water Headers - Fiberglass Laterals - PVC Spray Nozzles Polypropylene
Care should be taken when selecting the connecting hardware
Materials of Construction
Fan Stacks:
Velocity Recovery Design Can be Made of Fiberglass or Concrete Fiberglass Fan Stacks
Segmented - 15 to 20 segments Bolting hardware should be 316 SS, Silicon Bronze, or Monel 316 SS is Recommended - Hardware is not in contact with water and Silicon Bronze tends to gaul easily
Concrete Fan Stacks

Can be cast-in-place or pre-formed Lower Maintenance Higher Cost
Materials of Construction
Mechanical Equipment:
Standard motor, gearbox, and fan hub can be used, but at least one layer of epoxy coating should be applied Fan blades should be fiberglass, but marine grade or epoxy coated aluminum
can be used
Drive shafts are typically a carbon composite material. The couplings should be 316 SS or monel The mechanical supports should be epoxy coated carbon steel. Several layers are recommended. Stainless steel supports can be used, but are cost prohibitive.
Sea-Water Condenser Cooling
Sea-Water Condenser Cooling Schematic
Problems of direct & indirect cooling

Piping and equipment blockage by marine animals and semi-floating debris. Growth of small marine organisms on condenser tubes, piping and HX surfaces. Erosion, corrosion, pitting and cracking associated with the quality of sea water
Sea-Water Air-Conditioning System Components

A sea-water intake piping.
Intake water filtration system. Sea water supply pumps, pipeline, and discharge pipeline. Heat exchangers transferring heat from the fresh water circulation loop to the seawater. A fresh water circulation network, including pumps. This network provides chilled water that circulates through each building. Because of the economy of scale, the seawater A/C system is most appropriate for large or multiple buildings in coastal areas.
Sea Water Intake,Filtration & Pumping Station
Sea Water Intake,Filtration & Pumping Station
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake
Sea Water Intake-backwash
Sea Water Intake
Bar Screens
Prevent the ingress of large floating debris only Low cost Frequent maintenance required
Hi down time
Rapidly clogged by seaweed, jellyfish, plastic bags and other fibrous materials Clogging restricts the flow and increases pump power consumption
Traveling Band Filter
Traveling Band Filter

Intake Works & Filtration is critical to the success of sea-water cooling.
Band screens are equipped with a
back-washing spray system discharging all removed debris into baskets for collection / removal or into a tough to be sluiced away for disposal.
Drum Filter
Drum Filter
Plate Heat Exchanger

Preferred Material is Titanium.
Easy to maintain as the whole heat exchanger can be opened up plate by plate.
The Natural Energy Laboratory of
Hawaii has conducted years of testing on heat exchangers.

This long-term testing has shown that fouling is not a problem with deep seawater, and corrosion can be eliminated with either titanium or aluminum.
Sea-Water Cooling (SWAC)
Sea-Water Cooling
Central air conditioning systems circulate water at temperatures of 40F to 50F. These temperatures are commonly found in the deep ocean at about 1000ft to 1500ft depth, even in tropical & sub-tropical climates.
The use of this cold water for direct cooling of buildings was previously hindered by lack of knowledge on deep-water pipelines,& heat exchanger fouling and corrosion.
During the last decade, research has provided the required knowledge for its application.
Depth-wise Temperature in Ocean
Generally, water at 42F can be found between 1800ft- to 2100ft depths and water as cold as 39F can be obtained at 2500ft. For applications on the coastline, an unlimited supply of cold water is often a few kilometers offshore.
Sea Water Cooling

An experts comment: The single most effective measure for reducing carbon dioxide emissions on a global basis would be the substitution of deep ocean water air conditioning and industrial cooling wherever and whenever it is feasible.
Sea Water Cooling

Deep, cold seawater has long been recognized as a valuable ocean energy resource. Over the past 20 years research and experimentation has been conducted on ocean thermal energy conversion (OTEC). Out of this research, one clear economic winner emerged: Sea-Water Air-Conditioning (SWAC).
It is technically and economically feasible today;
Once installed, the energy is inexhaustible and There are no adverse environmental impacts.
Sea-Water Cooling Design Considerations

Location and layout of site (survey and investigate the hydraulic and hydrographic conditions at the proposed site). Sea water intake level and tidal& storm level considerations. Intake sump and pump model test: important as the screens, intake channels, penstocks, etc. affect the smooth flow of the water to the pumps. Environmental and local regulations. Structural costs. The sea-water intake must be designed to catch & remove jelly fishes, plastic bags and other floating and semi-floating debris .
Seawater A/C is suitable for coastal developments with large air conditioning demand and reasonable access to deep, cold seawater. The main factors that influence the economic viability of a seawater air conditioning system are:
Distance offshore to cold water in the 38F to 48F range,
Size of the A/C load, Percent utilization of the A/C system, Local cost of electrical power, Size of the onshore distribution system,
Local seafloor bathymetry,

Continued
Wave and storm data,
Local climate,
Existing vs. new buildings, Environmental requirements,
Secondary uses of the seawater.
Larger seawater A/C systems are more economical than small systems. In general, a system smaller than 1.000 tons is not economical
Economic Viability
Economic Viability
Savings afforded by the seawater air conditioning system are defined as the value of chiller energy demand in a conventional air conditioning system minus the value of electrical demand for the seawater pumping in a seawater system. The savings are typically 80 percent or better, resulting in payback periods of 2.5 to 5 years, depending on specific factors. The payback values only provide a general guideline relative to the economic merits of seawater air conditioning. The construction and application benefits and challenges of the cold seawater system are very sitespecific.
Site Specific Analysis

Utilizing the seawater air conditioning system can be very attractive for large users needing a base load system and with adequate access to deep, cold seawater.
The economic payback period can be quite small, specially for new structures, where credit can be taken for not installing conventional chillers, the payback is significantly better. Energy savings with the seawater system can be as large as 80 percent,
so there is less dependence on conventional fuels and energy-cost increases.

Coastline of Pakistan is a suitable candidate for cold sea water application.
Alternate usage of cool sea-water

In some locations the seawater available may not be sufficiently cool to completely lower the freshwater to its optimal temperature. In these cases, a chiller unit can be installed with the cold sea-water cooling the freshwater first, followed by chiller units. Alternately the cool sea-water can cool the condensers of chillers,
maintaining a high efficiency at low condensing temperatures.
Power savings realized by seawater air conditioning can be significant, and studies show that a saving of about 80% are possible against a conventional electric operated system.
Sea Water Piping Material

The preferred material for the sea-water pipeline is high-molecular-weight polyethylene. This material is ideal for cold water pipelines as it is:
rugged,
Flexible, Completely inert in seawater, Its flexibility allows for fast and easy installation,
Expected lifetimes of 20 to 30 years.

Capitalizing on polyethylene's flexibility, these pipelines can be safely deployed to depths reaching 3,000ft, and for the maximum polyethylene pipe diameter available5ft.
Pipelines have been buried, bolted to the bottom, gravity weighted, pendant-supported, and floated over the bottom in long, continuous buoyant spans.
Combinations of these techniques can be used to reliably deploy polyethylene pipelines over a wide variety of bottom and environmental conditions.
Sea-Water Treatment
CHLORINATION:
Most practical procedure for sea water treatment.
Minimizes maintenance.
Most reliable, economical and efficient method for preventing the growth of mussels and other marine
organisms.
Sea-Water Treatment
Hypochlorite Generation by Electrolysis of Sea Water
Most popular method.Higher initial cost. Sodium Hypochlorite is generated on site by electrolysis of sea water.No problem of supply, storage and transport.
NaOCL Solution Dosing

Simple method. Lowest capital outlay Cost is comparatively higher than other methods. NaOCL solution is not stable at higher temperatures.
Gas Chlorination
Traditional method. Hazardous to personnel and environment in bottle gas storage and injection room. Permission and approval are required from the dangerous goods division of explosives / fire service department.
Costs
As with most alternative energy systems, the heaviest expenses for seawater air conditioning system would occur in the initial capitalization. Total capital costs include the cold water intake pipe, the pumping station, the onshore heat exchangers, the onshore distribution system, and the effluent pipeline. The largest cost is in the seawater supply system (intake pipe, pumps, effluent pipe). This segment typically represents 45 to 75 percent of the total capital costs. On average, approximately half the capital costs is in the seawater supply system, 15 percent is in the heat exchanger, and the last 35 percent, in the distribution system.
Project References
1. In 1975, the US Department of Energy funded a program entitled "Feasibility of a District Cooling System Utilizing Cold Seawater." The two most favorable sites identified were Miami/Ft. Lauderdale and Honolulu. 2. In 1999, the Cornell Lake Source Cooling Project installed a 63 diameter pipeline into nearby Lake Cayuga. This pipeline was 10,000ft in length and installed to a depth of 250ft. Cold water from this pipeline, at approximately 4C, provides 20,000 tons of air conditioning for the Cornell University Campus. 3. Two Buildings known as Purdys Wharf are cooled by cold sea-water at Halifax, Nova Scotia. 4. The Lake Water Supply Project, New York State: establishing a cold-water district as part of a proposed lake water supply project for the town of Webster New York along the shores of Lake Ontario. This project would require 3- 63 HDPE pipelines, each 3miles in length. Estimated cost of this project is $120 million. 5. Deep Water Cooling Project, Toronto, Ontario, Canada: The city of Toronto, Ontario, Canada is developing a district cooling plan that will utilize cold water from Lake Ontario to provide air conditioning to Toronto. Construction has already begun for the cold water distribution system throughout the city. 6. In 1995, Stockholm Energy started supplying properties in central Stockholm with cooling from its new district cooling system, using cold water from the Baltic Sea. 7. Ontario, Canada is developing a district cooling plan that will utilize cold water from Lake Ontario to provide air conditioning to Toronto. Construction has already begun for the cold water distribution system throughout the city. 8. In 1995, Stockholm Energy started supplying properties in central Stockholm with cooling from its new district cooling system, using cold water from the Baltic Sea. Fahim I. Siddiqui Paper At 13th Annual Conference Pakistan HVACR Society March 2006
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060301-Sea Water Cooling - March 2006-Islamabad

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Sea-Water Cooling

For Air-Conditioning Systems

13th Annual Conference Pakistan HVACR Society March 2006

What is Sea Water?

Six elements and compounds

CI SO4 Mg Ca K Minor Salts

What is Sea Water?

Sea-Water Cooling Towers

Sea-Water Cooling Tower Schematic

Impacts on Thermal Performance

Impacts on Thermal Performance

Impacts on Thermal Performance

70,000 ppm Salinity 5% Reduction

Blowdown - Depending on Concentration and Return Location,

Blowdown May be a Concern

Given to all Materials that will be in Contact with the Water

Installation Requires More Man-Hours

In Concrete Towers Exposed Hardware and Reinforcement Bars are a

Circulating Water Temperature

Splash Type Fills

Care should be taken when selecting the connecting hardware

Concrete Fan Stacks

Sea-Water Condenser Cooling

Sea-Water Condenser Cooling Schematic

Problems of direct & indirect cooling

Sea-Water Air-Conditioning System Components

Sea Water Intake,Filtration & Pumping Station

Sea Water Intake,Filtration & Pumping Station

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake

Sea Water Intake-backwash

Sea Water Intake

Sea Water Intake-backwash

Sea Water Intake-backwash

Sea Water Intake-backwash

Sea Water Intake-backwash

Sea Water Intake-backwash

Traveling Band Filter

Traveling Band Filter

Plate Heat Exchanger

Hawaii has conducted years of testing on heat exchangers.

Sea-Water Cooling (SWAC)

Depth-wise Temperature in Ocean

Sea Water Cooling

Sea Water Cooling

Sea-Water Cooling Design Considerations

Distance offshore to cold water in the 38F to 48F range,

Local seafloor bathymetry,

Wave and storm data,

Secondary uses of the seawater.

Site Specific Analysis

so there is less dependence on conventional fuels and energy-cost increases.