Post on 12-Sep-2021
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AVESTARTM Center for the Operation
and Control of Clean Energy Plants
Stephen E. Zitney, PhD.
Director, AVESTARTM Center
National Energy Technology Laboratory
Morgantown, WV
www.netl.doe.gov/avestar
Energy Systems Initiative (ESI)
Carnegie Mellon University
Pittsburgh, PA
March 11, 2012
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Presentation Outline
• U.S. Energy Challenges
– Electricity Generation, Modern Grid Era, and
Clean Energy Plants
• Advanced Virtual Energy Simulation
Training And Research (AVESTARTM)
– Mission and Goals
– Meet Our People, Partners, and Trainers
– Integrated Gasification Combined Cycle (IGCC)
with CO2 Capture
• Dynamic Simulator/Operator Training System (OTS)
• 3D Virtual Immersive Training System (ITS)
– Simulator Facilities
– Training, Education, and R&D Programs
– Future Directions
• Concluding Remarks
3
U.S. Energy Challenges Electricity Generation
• Maintain generation and optimize efficiency of coal-fired plants,
while taking full advantage of carbon capture, utilization, and
storage (CCUS)
– Exploit CO2 capture advantages and
fuel/product flexibility of gasification-
based systems (e.g., IGCC)
• Grow gas-fired generation driven
by increase in shale gas
– Accelerate deployment of post-
combustion CO2 capture
• Maintain generation from nuclear
• Grow share of generation from
renewables (e.g., wind, solar)
Source: DOE/EIA-0383, Annual Energy Outlook 2011
Bil
lio
n k
Wh
U.S. Electricity Generation by
Fuel Type
Meet increasing demand for clean, affordable, and secure energy
by developing a diversified portfolio of power generation plants
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U.S. Energy Challenges
Modern Grid Era
• Variable demand from active
participation of consumers
• Variable and non-storable supply
from renewable energy resources,
such as wind and solar
• Combine renewable energy forms
with clean fossil fuel power plants
and energy storage
• Produce reliable, near-constant
baseload power
Renewables
Clean Energy Plant
with Energy Storage
Fast-Ramping CAES
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U.S. Energy Challenges Clean Energy Plants
• Clean energy plants (e.g., IGCC) require effective operation
of large, highly-integrated, multipurpose power and process
systems
• CCUS adds CO2 capture and utilization processes,
as well as CO2 transport and sequestration platforms
• Modern grid requirements increase need for cycling, load-
following, and faster startups/ramp rates
• Optimize dynamic plant performance using advanced
automation and control technologies to achieve operational
excellence
• Minimize plant derates, emissions, equipment damage,
downtime, and safety hazards
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AVESTARTM Center
Advanced Virtual Energy
Simulation Training And Research
• Mission
– Accelerate progress toward achieving Operational Excellence for
Clean Energy Plants
• 1) Asset, 2) Control, 3) Environment & Safety, and 4) People
• Goals
– Develop portfolio of high-fidelity real-time dynamic simulators with
full-scope operator training systems (OTSs) and 3D virtual
immersive training systems (ITSs)
– Bring together advanced simulation-based technologies, state-of-
the-art facilities, and leading energy experts
– Conduct collaborative, innovative, internationally-recognized R&D
on dynamics, control, and virtual plant simulation technologies
– Train workforce and educate students using experiential learning
www.netl.doe.gov/avestar
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AVESTARTM Center – Meet Our People
Dr. Stephen E. Zitney, NETL
Director, AVESTAR Center
Prof. Richard Turton
ChE Dept., WVU
Manager, AVESTAR Center
at National Research
Center for Coal & Energy
(0.5 PhDs)
George Darakos, NETL
Business Manager,
AVESTAR Center
Prof. Debangsu Bhattacharya
ChE Dept., WVU
R&D Manager,
AVESTAR Center
(2.5 PhDs, 1 Post-doc)
Terry E. Jordan Jr., NETL
Sr. Computer Engineer,
AVESTAR Center
Eric Liese, NETL
Sr. Research Engineer,
AVESTAR Center
Dr. Priyadarshi Mahapatra
URS/NETL
Sr. Research Engineer,
AVESTAR Center
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AVESTARTM Center
Meet Our Partners Meet Our Trainers
Industrial Collaborators
Graham Provost
Fossil Consulting
Services
Michael McClintock
Fossil Consulting
Services
Victor Madison
Fossil Consulting
Services
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De
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Tra
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Presentation Outline
• U.S. Energy Challenges
– Electricity Generation, Modern Grid Era, and
Clean Energy Plants
• Advanced Virtual Energy Simulation
Training And Research (AVESTARTM)
– Mission and Goals
– Meet Our People, Partners, and Trainers
– Integrated Gasification Combined Cycle (IGCC)
with CO2 Capture
• Dynamic Simulator/Operator Training System (OTS)
• 3D Virtual Immersive Training System (ITS)
– Simulator Facilities
– Training, Education, and R&D Programs
– Future Directions
• Concluding Remarks
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IGCC Power Plant with CO2 Capture
Coal
O2
Gasifier Water Gas
Shift
Cryogenic
ASU
Syngas Cooler
Steam
Acid Gas
Removal
Claus Plant
Sulfur
CO2 Comp
CO 2 2200 psig
CO 2
Steam
Reheat / Humid.
Fuel Gas
Syngas
Cooler /
Quench
Particulate Removal
Gas
Turbine
HRSG Steam
Steam
Turbine Power
Power
H2S
Syngas
CO
H2
Syngas
CO2
H2 (High P,T)
N2
Dilution
N2 for
Dilution
IGCC Case #2, Cost and Performance Baseline for Fossil Energy Power Plants Study, Volume 1: Bituminous Coal
and Natural Gas to Electricity, www.netl.doe.gov, DOE/NETL-2010/1397, November 2010.
Plant Section Description
Gasification Entrained-flow Gasifier
Air Separation Elevated-P Cryogenic ASU (95% vol O2)
H2S Separation Physical Solvent AGR 1st Stage
Sulfur Recovery Claus Plant
CO2 Separation Physical Solvent AGR 2nd Stage
CO2 Compression Four stage (2200 psia)
Gas Turbines Adv. F Class (232 MW output each)
Steam Cycle Subcritical (1,800 psig/1,000ºF/1,000ºF)
Power Output 746 MW gross (556 MW net)
• IGCC operates at high pressure with
oxygen instead of air
• Volume of gas to be treated is nearly
two order of magnitude lower
• CO2 is removed before combustion
• CO2 is easier to capture and is
produced at higher pressures
• Increased power plant efficiency
• Lower cost of electricity
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IGCC Dynamic Simulator/OTS
Capabilities and Features
• Full-Scope, High-Fidelity, Real-Time
Dynamic Simulator (DYNSIM)
• Modular: IGCC with CO2 Capture,
Process (Gasification), Power (CC)
• Fuels: Coal, Petcoke, Biomass
• OTS: HMI (InTouch), Trends, Alarms
• Instructor: ICs, RFs, Malfunctions
• Controls: Regulatory (PID),
Coordinated (Gasifier/Turbine Lead)
• Operations: Normal Baseload, Startup,
Shutdown, Load Shedding, Abnormal
Situation Handling
Deployed at AVESTAR Center in March 2011
DYNSIM Gasifier Model
InTouch Gasifier HMI
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IGCC Immersive Training System/ITS Capabilities and Features
• 3D Virtual Plant Model
– 3D computer-aided design (CAD)
– Plant photos for photorealism
• 3D Immersive Interaction/Content
– Avatar represents field operator
– Navigation using game pad
– Remote field functions
– Collision geometry and sound
– Popup trends (variables vs. time)
– Transparent equipment objects
– Highlighted virtual content/scenarios
• Benefits
– Added dimension of plant realism
– Plant familiarization and walkthrough
– OTS/ITS for control room and plant
field operators, promoting teamwork
Scheduled for deployment at AVESTAR Center in June 2012; Invensys EYESIM software
Distillation
Column
Gasifier
Gas
Leak
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Presentation Outline
• U.S. Energy Challenges
– Electricity Generation, Modern Grid Era, and
Clean Energy Plants
• Advanced Virtual Energy Simulation
Training And Research (AVESTARTM)
– Overview
– Meet Our People, Partners, and Trainers
– Integrated Gasification Combined Cycle (IGCC)
with CO2 Capture
• Dynamic Simulator/Operator Training System (OTS)
• 3D Virtual Immersive Training System (ITS)
– Simulator Facilities
– Training, Education, and R&D Programs
– Future Directions
• Concluding Remarks
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AVESTAR Center Facilities
AVESTAR Center at AVESTAR Center at
• Locations
– NETL: R&D
– WVU: Education, Training
– Both in Morgantown, WV
• Facilities
– OTS Room: Control Room
Divider for 2 Simulators
– ITS Room: Plant/Field
– Local area network
• Training Systems
– IGCC OTS
8 Operator Stations
2 Instructor Stations
2 Engineering Stations
– IGCC ITS
2 Field Stations
1 Instructor Station
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AVESTAR Training Program
For more information on AVESTAR training, please visit: www.netl.doe.gov/avestar/training.html
• Comprehensive, hands-on, dynamic
simulator-based training
• Experienced power plant trainers
• IGCC with CO2 capture courses
– Orientation to advanced operations
– Registration inquiries and fees online
– ITS integrated into training in June 2012
• Customized courses/programs
available for industry
• CEUs through West Virginia Univ.
• Collaborating with regional technical
colleges on Power Plant Technology
certificate/degree programs
– Partnering with electric utilities to assure
availability of well-qualified workforce
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AVESTAR Education Program
• Leverage real-time OTS/ITS technology
• Enhance engineering education in process
simulation, dynamics, control, and safety
• Example courses at WVU include:
– Process Control for Chemical Engineers
• Seniors in Chemical Engineering
• 4-6 hours on IGCC dynamic simulator
• Learn how plant responds dynamically to changes in
manipulated inputs, as well as how control system
impacts plant performance, stability, and robustness
– Process and Dynamic Simulation
• New course for ChE juniors and seniors
• Theory of steady-state/dynamic process simulation
• Development of operator training simulators
• 3-4 weeks on IGCC dynamic simulator
• Learn key OTS features and capabilities
• Practice start-up and malfunction scenarios
• Extend to other NETL-RUA universities
Prof. Bhattacharyya
(WVU, ChE)
Prof. Turton
(WVU, ChE)
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AVESTAR R&D Program
• Dynamic Modeling/Simulation
– High-fidelity dynamic models
• Gasification/ROMs (Turton/Bhattacharyya/
Kasule, WVU)
• CO2 capture (Bhattacharyya/Modekurti, WVU)
– Load following and ramp rate
• (Bhattacharyya, WVU); (Mahapatra, URS)
• Advanced Process Control/Sensors
– Advanced regulatory/coordinated control
• (Mahapatra, URS)
– Model predictive control (MPC)
• (Bhattacharyya/Jones, WVU); (Mahapatra, URS)
– Optimal sensor placement
• (Bhattacharyya/Paul, WVU)
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AVESTAR Center Future Directions for Virtual Energy Simulation
• Clean Energy Plants
– Derivative versions of IGCC with CO2 Capture
• Air Separation, Gasification, CO2 Capture
• Generic OTS/ITS for Acid Gas Removal (AGR – H2S/CO2) and
Sulfur Recovery Unit (SRU – Claus)*
– Natural Gas Combined Cycle (NGCC) with CO2 Capture**
– Supercritical Pulverized Coal (SCPC) with CO2 Capture*
• U.S. DOE Carbon Capture Simulation Initiative
– Solid sorbent post-combustion capture
– Virtual Carbon Capture Center
• Carbon Capture, Utilization, and Storage (CCUS)
– CO2 Pipeline/Transport, CO2 Utilization, CO2 Injection
• Shale Gas Processing Facilities
• Modern Power Grid
– Energy Plants, Variable Generators, Energy Storage
* - Project is planned; ** - Project is underway
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AVESTARTM Center
Concluding Remarks
• Increasing demand for clean, affordable, and secure energy
requires diversified portfolio of power generation plants
• Clean energy plants with CCUS require operation and
control of large, highly-integrated, power + process systems
• Modern grid requirements increase need for load-following
and faster startups/ramp rates
• Changing demographics and rapidly evolving technologies
necessitate training the next generation of engineering and
operations professionals
• High-fidelity dynamic simulators with OTSs and 3D virtual
ITSs are well suited for training, education, and R&D
• AVESTAR Center brings together simulation technology,
energy experts, and innovation to address challenges to
achieving the operational excellence of clean energy plants
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Thank You / Questions?
For more information on AVESTAR’s simulators, facilities, training,
education, and R&D, please visit us at www.netl.doe.gov/avestar
or contact us at avestar@netl.doe.gov.
Disclaimer
"This report was prepared as an account of work sponsored by an agency of the United States
Government. Neither the United States Government nor any agency thereof, nor any of their
employees, makes any warranty, express or implied, or assumes any legal liability or
responsibility for the accuracy, completeness, or usefulness of any information, apparatus,
product, or process disclosed, or represents that its use would not infringe privately owned
rights. Reference herein to any specific commercial product, process, or service by trade name,
trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any agency thereof. The
views and opinions of authors expressed herein do not necessarily state or reflect those of the
United States Government or any agency thereof."