Development of CFBC concepts and problem solution with the aid of - - PowerPoint PPT Presentation

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Development of CFBC concepts and problem solution with the aid of - - PowerPoint PPT Presentation

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Development of CFBC concepts and problem solution with the aid of simulation programs CFB Workshop 24.9.2014, Jyvskyl Hannu Mikkonen, VTT Technical Research Centre of Finland 2 02/10/2014 Why to invest for Where does the modelling?

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Development of CFBC concepts and problem solution with the aid of simulation programs

CFB Workshop 24.9.2014, Jyväskylä Hannu Mikkonen, VTT Technical Research Centre of Finland

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2 02/10/2014

Why to invest for modelling?

Support for boiler investment plans Increasing of plant efficiency Decreasing of operating costs Optimization of the boiler life time Education by using process simulator

Where does the modelling is used for?

An environment for process simulation models building. Evaluation of process phenomena and problems Optimize production Use as a training simulator Design and testing environment

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Simulation Information Management Engineering Information Management Simulation Engineers Design Engineers

Simulation and process design integration

Plant design systems: SmartPlant Foundation, Comos, … 3D design Process design Automation design

Simantics

Apros Process Simulation Common user interface environment Other simulators: Balas, DEVS, sd, Fluent, Modelica, company specific

Process simulation

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Dynamic process simulation

Integrated process level Basic component level

Elementary components branches, nodes, structures, sources

Process component level Conservation equations for mass, momentum and energy

Control circuits Logic circuits Sequences Change-over automation Measurements Device controls Actuators

Set points

Position

The automation can be included in the model ... Or real/virtual automation application can be connected to the process model.

Control system model Process model

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Apros modelling program

The model libraries have been comprehensively validated against data from physical process experiments. Besides the process, also automation and electrical systems can be modelled in detail. The simulation environment aims at meeting the requirements for testing, design, analysis, and training simulator applications The Apros provides easy on-line access for:

  • configuring and running the

simulation models

  • solution algorithms and model

libraries for full-scale modelling

  • dynamic simulation of processes,

such as conventional power plants, nuclear power plants, and pulp and paper mills.

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Aspen Plus - modelling program

Aspen Plus and Dynamics are focused on process engineering and optimization. Optimize process designs for energy use, capital and operating costs, and product yield through the use of activated energy, economics, and equipment design during the modeling process. Due the different features of Apros and Aspen VTT uses both platforms to model large complex processes.

Hierarc h y

H

Hie r a rchy Hierarc h y

H

63 .9 1.0 5 6 99 .8 0 33 7 .7 31 2 .40 0 22 9 .87 63 .9 1.0 5 6 15 2.86 25 .0 1.0 0 0 37 .5 2 1.5 20 70 .00 41 5.7 31 0.40 0 22 9.87 62 .8 1.0 1 2 25 2.67 4 3 8.6 3 0 1.70 0 2 2 9.87 46 0.0 46 2.3 0 0 22 9.8 7 46 0.0 46 2.30 0 22 9.87 51 7.8 29 2.30 0 22 9.87 51 7.8 29 2.3 0 0 22 9.8 7 55 0.8 28 5.60 0 22 9.87 60 0.0 27 8.50 0 22 9.87
  • 92 .52 7
35 3.2 58 .5 00 38 .0 0 35 3.2 58 .500 19 2.00 60 1 .0 57 .000 19 2 .00
  • 28 1.1 75
18 0.3 2.2 00 9.0 0 35 3.4 10 .000 5.0 0 42 7.1 17 .100 1.0 0 90 .0 0.7 00 17 0.76 90 .0 0.7 00 6.2 4 23 .5 0.0 29 85 .38 23 .5 0.0 29 72 .88
  • 34 2 .0 53
W 20 .0 1.0 00 0.0 0 22 .000 15 8.13 70 .1 0.3 1 3 12 .5 0 11 3.8 16 .000 71 .37 18 6.1 31 2.90 0 22 9.87 20 4 .6 17 .100 39 .00 S21 26 9.1 31 2.9 0 0 22 9.8 7 25 .0 1.0 12 30 .10 1 .0 00 7 .4 2 LIM E 17 9.7 10 .00 0 22 9.8 7 1 7 9.9 1 0 .00 0 2 2 9.8 7 10 .0 00 0.0 0 60 0.0 27 8.50 0 22 9.87 Q=-6 9.76 0 Q=- 1 6 3.7 9 8 Q=2 9 .61 1 W=9.8 11 Q=0. 196 Q=- 8 1.30 7 Q=63 .93 6 Q=38 .29 5

HP-turbine

BOILER TURBINE

Total electric power IP-turbine LP-turbine Condensation tank LP-Preheating HP-Preheating Feedwater tank Feedwater pump HP-Intrex 4 HP-Intrex 3 Spraying 2 Spraying 1 Superheater 2 Superheater 1 Cross over duct and Convection cage Eco

Furnace

Reheating Lime feed Fuel feed

O2
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An example of a modelled case: Coal plant evaporator analysis

  • Target: 315 MW pulverized coal power plant of Fortum,

located in Naantali, Finland. Origin in the 1970’s.

  • Motivation: Suffered of evaporator tube damages. Recent

change in control strategy. Does the new way increase risk for tube ruptures?

  • Approach in modelling: detailed model of the evaporator

tubes, minimum scope of the surrounding process, rough model of the combustion heat power

  • Analysis of the temperatures of the individual tubes when

different operational scenarios are practised

Ref: Lappalainen, J., Blom, H, Juslin, K., Dynamic process simulation as an engineering tool – A case of analysing a coal plant evaporator, VGB Powertech, 1/2 2012, pp. 62-68.

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APROS

Combination of Apros and Aspen models

ASPEN PLUS DYNAMICS

Oxygen production plant CO2 pressurizing and separation CFB boiler Turbine and water circulation

SIMULINK

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Simulation examples (Apros)

Load change: oxygen 100% - 40% - 100% Mode change: air – oxygen - air

500 1000 1500 2000 2500 3000 10 20 30 40 50 60 70 80 Flue gas CO2 Time, s mol% 500 1000 1500 2000 2500 3000 4 6 8 10 12 14 16 18 20 22 Flue gas H2O Time, s mol% 500 1000 1500 2000 2500 3000 1 2 3 4 5 6 Flue gas O2 Time, s mol% 500 1000 1500 2000 2500 3000 10 20 30 40 50 60 70 80 Flue gas N2 Time, s mol%

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Conclusion

VTT has powerful modelling tools for researching, analysing, design, testing and education. Apros is capable to dynamic evaluation of large process areas. Aspen Plus is capable to steady state studies and is powerful tool for chemical process evaluations. At VTT there are made several years process modelling in different kind of projects Modelling projects on-going at VTT:

  • Apros furnace model development
  • Boiler and CCS-process heat integrations
  • Combined use of the solar field power and boiler
  • Controlling of the whole concept including process and control

development

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VTT 2014