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Commercialisation of a Novel Modular Air Cooled Condenser for Steam Cycle Power Generation

Periodic Reporting for period 1 - COMACC (Commercialisation of a Novel Modular Air Cooled Condenser for Steam Cycle Power Generation)

Reporting period: 2014-10-01 to 2015-03-31

RR Projects (RRP) strategy includes moving from being a provider of services such as installation and maintenance of equipment to providing its own product with a global market potential, estimated at $50m in 2030. This feasibility study assesses RRPs capability to progress with the commercialisation of the Modular Air Cooled Condenser (MACC™) . The MACC has been developed through the successful FP7 funded MACCSol project (Project No 256797).

The feasibility study has identified the need to establish a division with the goal of delivering the MACC to market, focusing on all elements from design through to aftersales. This will enable RRP to focus on its core business and continue successful operations as a service provider. It is envisioned that this scale up and first MACC commercial installation will be assisted by funding as part of Phase 2 and potentially Phase 3 of the SME Instrument under Horizon 2020.

Unique Selling points:
• Speed controllability of fans, speed control algorithms and ability to mitigate against adverse wind affects. These features combined results in an increased net power output.
• Modular design results in minimised onsite assembly, reducing installation and capital costs.

Continuing research and integrating technological developments will ensure that MACC continues at the forefront of the state of the art. Implementing robust protection for the MACC concept is vital to safeguard its competitive advantage and profitability. The MACC concept is currently in the patent application phase.

Under typical operating conditions, using the MACC rather than a conventional air cooled condenser (ACC) the net power generation plant’s annual net energy output is increased. This should result in a corresponding revenue increase, as more energy is delivered to the grid. Moreover, by achieving higher efficiency through the use of the MACC, power generation plants will be awarded priority to sell electricity into the market for a greater percentage of time, compounding the revenue increase.

Relative to RRP’s existing business, by 2020 revenue generated by the MACC will provide a significant increase in RRP’s projected profit compared to 2014. It is anticipated that having demonstrated the first commercial scale MACC in 2016, RRP will begin sales in 2017.

This COMACC project is aimed at progressing the existing MACC pilot from demonstrator to full scale commercialisation on 30 MW plant, having successfully completed performance testing. Scaling up the business with resource capabilities for commercial installation will enable performance validation at full scale and determine the benefits which MACC can offer over existing inferior ACC technology.
1.1 Cost Structuring
• Identified the costs associated with commercial volume manufacturing, distribution and installation.
• Identified cost savings which can be made in manufacturing, distribution and sales
• Identified appropriate sub-contracting options
• Benchmarked MACC costs against conventional ACCs and water cooling technologies

1.2 Market Study
• Quantified accurately the size of the current ACC market and forecasted ACC market
• Quantified the breakdown of the market between the main players
• Set targets on the percentage of the market which can realistically be captured

1.3 End User Involvement
• Disseminated data from MACCSol demonstrator trials to potential end users through one on one meetings
• Disseminated the MACC benefits by exhibiting at events such as Gas and Oil Expo, the Renewable Energy World Conference and Expo and Power Gen International

1.4 IP Management
• Performed a freedom to operate analysis
• Assessed the protection provided by the existing MACC patent
• Assessed the patentability of the suite of IP which was developed throughout the MACCSol project
• Assessed other forms of protecting foreground IP from the MACCSol project

1.5 Strategy Development
• Identified most appropriate revenue sources. As well as sales and installation, these could include for example, remote performance monitoring, remote continuous optimisation, maintenance contracts and licencing in selected regions.
• Identified the most profitable cost structures for the company.
• Identified technology development requirements.

1.6 Partner Search
• RRP will further developed relationships with existing partners, and seek new partnerships with suppliers, end users, Steam Turbine manufacturers, sub-contractors and financiers
The MACC will enhance the profitably of RRP through MACC sales and indirectly with additional erection and installation contracts resulting from the increased contact with steam turbine manufacturers. The establishment of the MACC division has been deemed the most effective way to successfully market the MACC. There will be significant employment opportunities to design, manufacture, market, install and service the MACC.
The MACCs waterless condensation capability and increased efficiency over traditional ACCs sustainably tackles many of the H2020 Societal Challenges regarding “Secure, Clean and Efficient Energy” with a particular emphasis on:
• “Reducing energy consumption and carbon footprint by smart and sustainable use”
The MACC reduces the parasitic consumption of ACC in a power plant, through intelligent control of fan speed and mitigation against adverse weather conditions. This will increase the net plant power output, reducing emissions.
• “Low-cost, low-carbon electricity supply”
Through intelligent control, the MACC improves power plant efficiency, increasing power plant output. This reduces Levelised Cost of Electricity and carbon emissions.
• “New knowledge and technologies”
The modularity achieved by the MACC is novel to the ACC industry. RRP believe and have support from steam turbine manufacturers, that it could potentially revolutionise cooling in the power industry.