Post on 18-Apr-2018
EPSRC Future Conventional Power Plant Call
Flexible and Efficient Future Power Plant Consortium
Prof Rachel Thomson
Loughborough University
Presented at the 13th Annual APGTF Workshop, Feb 2013
Consortium Partners
Five of ‘the Big Six’ electricity generating companies
All major UK power OEMs
Includes SMEs and large RTOs in the power sector
Plus Energy Generation and Supply KTN as a Delivery Partner
Six leading UK Universities
Generators OEMs Others
EDF Alstom Emerson
Eggborough Doosan Power NPL
E.ON Goodwin Steel Castings R-MC
RWE npower Rolls-Royce TWI
SSE Siemens EG&S KTN
Industry Consultation and Contributions
Undertaken extensive industry consultation – Initially in July 2011
– In 2012…
– Extensive industrial survey May
– Full Consultation meeting June
– Follow up teleconference early August
– Consortium meeting November
Led to significant industrial support (£3.6M) – Cash, primarily for supporting research students (>£800k)
– Use of various industrial facilities and plant
– Materials, data and software
– Industrial staff time
– Other support
Universities also providing £560k for 18 part funded studentships
Drivers
Demand forecast to be relatively stable
Older plant being replaced by wind and biomass
Older coal and all oil will close due to legislation
Some nuclear ‘retired’
Some refurbishment & life extension of older combined cycle gas turbines (CCGT)
Proposal reflects conventional generation portfolio – CCGT
– Coal, with biomass
Source: Electricity Capacity Assessment,
Ofgem report to Government, October 2012
Overall Structure
PLANT
OPERATIONS
AND DESIGN
COMBUSTION
FUELS AND
OPERABILITY
STRUCTURAL
INTEGRITY &
ADVANCED
MATERIALS
PLANT EFFICIENCY
PLANT FLEXIBILITY
FUEL FLEXIBILITY
SUSTAINABILITY
Jihong Wang
Warwick Phil Bowen
Cardiff
Rachel Thomson / Catrin Davies
Loughborough / Imperial
Jon Wells Siemens
Emerson Cath Goy E.ON
Rolls-Royce
Scott Lockyer E.ON
Alstom
Sayee Raguhnathan
TWI
Chris Bagley
EG&S KTN
INTEGRATION
OF WORK
PACKAGES /
DELIVERY OF
IMPACTS
Co
ns
ort
ium
Ma
na
ge
r
WP1 – Power Plant Operations and Design
Operating strategies in the face of trade-offs
Techno-economic modelling to assess
influence of operating decisions on fuel burn
and consumption (CO2), operating cost, etc.
Adapt existing models for coal plant to predict behaviour
Feasibility study to apply to CCGT and biomass firing
Develop on-line control for coal mill monitoring for biomass
0 1000 2000 3000 4000 5000 6000 7000
-10
0
10
20
30
time (s)
dP load [MW/min]
dP genpower [MW/min]
-10
0
10
20
30
Power plant modelling
Controller analysis and
deployment
Simulation (off-line and real time)
Efficiency-Flexibility-Sustainability Map
WP2 – Combustion Fuels and Operability
SOLID FUELS / COFIRING
Interactions between
coal and biomass
New understanding of
ash chemistry for
dedicated and high
levels of biomass firing
to mitigate corrosion
GASEOUS / LIQUID / DUAL FUELS
Quantify effect of fuel type on combustion oscillations and emissions
Obtain optical measurements to understand fuel effects on combustion
performance at part and full loads using advanced laser diagnostics
Deliver guidelines for combustor design for improved fuel flexibility
X [mm]
Y[m
m]
0 50 100 150 200 250 3000
10
20
30
40
50
[m/s]
17
16
15
14
13
12
11
10
8
7
6
5
4
3
2
1
0
Oscillating flame in optical
gas turbine combustor
Laser diagnostics for flow-flame
interaction
Gas Turbine Research Centre
Generic
burner
NOVEL SENSOR DEVELOPMENT
Develop flame chemiluminescence sensors for
monitoring flame characteristics in industrial combustors
Develop sensor to monitor flow velocity at exit of the
combustor to increase efficiency at part and full loads
Deliver guidelines for sensors integration in power
generation control system OH*
CH*
C2*
WP3 – Structural Integrity and Advanced Materials
NOVEL PLANT MONITORING TECHNIQUES
New emergent ACPD sensor deployed on real
plant components, providing continuous
quantitative information on the extent of
strain/damage development in-situ
Novel combination of innovative strain/damage
monitoring and FEA techniques
Development of miniature specimen test methods
ACPD sensor on a pipe Automated assessment of creep voids
ADVANCED MATERIALS
Opportunity to link materials performance to
information gathered from monitoring techniques
Development of new steels and Ni-based alloys for
future generation plant, or retrofit
Develop methodologies for refurbishment / repair
of specific critical components
Focus on increased cyclic operation (e.g. TMF) and
more aggressive environmental degradation
1 mm
Modelling damage evolution in a header hanger
Coated Nickel Based Superalloys
Thermodynamic
engine (MTDATA)
Ni thermodynamic
parameter database
Ni diffusion
parameter database Finite-Difference diffusion calculation
Oxidation Moving boundaries
MODEL
Coating
composition
Thermal
history
Substrate
composition
Coating
thickness
Output
Input
Time to coating failure
β Al
Scale
thickness
Phase
profiles
Concentration
profiles
Metal
loss
Use HPC for this
Coated Nickel Based Superalloys Developed a comprehensive modelling methodology, linked to finite
element modelling
Shown that coatings must be ‘designed in’
Used model to design new multi-layered coating systems for gas
turbine blades, and optimise refurbishment processing for blades
Research Student Training 18 PhD studentships
Ensure there is a ‘cohort’ mentality
Organise at least 2 industrial visits / training activities per year
Students will have the opportunity to undertake modules from the Eng Doc
Centre in EFET & IC, and events organised by Energy CDT Network and MEGS
Attend the EFET International Summer School
Students will be supported by industrial mentors
Very good track record of research students being employed in the sector
Register of Equipment
Loughborough has been
leading on the development of
an Open-source web-based
system for equipment sharing
Now being used by ~20
Universities in the UK and
overseas, including some of
partners
Intend to use this across the
Consortium to develop an
awareness of facilities available
for use
KITCATALOGUE
®
Consortium Links
The Consortium is open to additional collaborative projects
We will engage with a range of other programmes as appropriate,
e.g. Network of Energy DTCs, including Efficient Fossil Energy Technologies, other
Supergen programmes, UKCCS Centre, CCS for gas projects
Hub
Industrial and Academic
Stakeholders
Europe - EU Technology Platforms,
Horizon 2020, KMM-VIN
International Collaborators
e.g. USA (EPRI), Japan (NIMS), China, Korea
Novelty “novelty lies in the scale and coverage of topics dealt with collectively…”
Excited by the opportunity for true integration of different skills
Combustion control based on
novel optical sensors
Higher temperature materials
On line control implementation
Plant Flexibility
Fuel Flexibility Sustainability
Plant Efficiency
Development of new materials
systems (↓ scarce elements)
Assessments of future
operating regimes
Monitoring methods for
particulate emissions
Fuel type
Cost
Emissions levels and penalties
Issues with high levels of biomass
Impact on downstream components
Dynamic full plant models
Condition monitoring
Techno-economic modelling
Load levels, rate of change of
load
Summary
A multidisciplinary, technically balanced, team of 6 Universities with a proven track record in conventional power generation
A carefully planned research programme, striking a balance between ambition, novelty and delivery
Working collaboratively with our extensive industrial collaborators to address real challenges
Support the EPSRC goals of Delivering Impact and Developing Leaders, and helping to provide a skilled and talented workforce
Working closely with our delivery partner, the EG&S KTN, to help create and sustain an integrated network for Future Conventional Power Plant research
Thank you