Advanced Process Engineering Co-Simulation of the ...

Advanced Process Engineering Co-Simulation of the

FutureGen Power and Hydrogen Production Plant

National Energy Technology Laboratory

Morgantown, WV

Sustainable Energy II (TE003)AIChE 2005 Annual Meeting,

October 30-November 4, Cincinnati, OH

Stephen E. ZitneyResearch Group Leader

Process & Dynamic Systems [email protected]

SEZ/NETL/Clearwater 2005 Conference, April 17-21, 2005

Presentation Outline

• Vision for Energy Plants of the Future

• DOE FutureGen Project

−Concepts and features

−Process description

• FutureGen Modeling and Simulation at NETL

−Goals and objectives

−Advanced Process Engineering Co-Simulator

• APECS FutureGen Demonstration

• Summary


Vision for Energy Plants of the Future

• Remove environmental concerns associated with the use

of fossil fuels for production of electricity, transportation

fuels, and chemicals through technology development

• Characteristics of future energy plants

− “Near-zero” emissions (coal as clean as gas)

− CO2 sequestration-ready

− Flexible (Feed stocks, co-products, and siting)

− Highly energy efficient

− Affordable (competitive with other energy options)

− Industrially ecological (waste into by-products)

− Reduced water requirements

− Timely deployment of new technology

− Sustainable

Electricity

Hydrogen

Chemicals


FutureGen

• One-billion dollar, 10-year U.S. DOE project to

create world’s first coal-based, near-zero

emission electricity and hydrogen plant

• Addresses four Presidential Initiatives focused

on the environment and sustainability

− Hydrogen

− Clear Skies

− Climate Change

− Clean Coal Power


FutureGen Project Concept


Features of the FutureGen Project

• Coal-fueled gasification process that co-produces electricity and hydrogen – 275 MWe

• Near-zero emissions

− Capture and sequester > 90% CO2 with potential for 100%

− > 99% sulfur removal

− < 0.05 lb/million Btu NOx emissions (~5ppm)

− <0.005 lb/million Btu particulate emissions

− > 90% mercury removal

• 1 million tons/year of CO2

captured and sequestered

• High-efficiency performance

• Platform for testing advanced technology components and integration concepts


Coal

O2

SyngasH2 and CO

CoalGasifier

O2

Plant

Sulfur

GasCleanup

TransportationFuel CellsIC Engine

GeologicSequestration Distributed

PowerFuel Cells

FutureGen Based on Integrated Gasification Combined-Cycle (IGCC) Technology

Shift

O2

H2CoalGasifier

O2

Plant

CO2

Sulfur

GasCleanup

Central PowerGas Turbine Combined

Cycle

Syngas

H2/CO H2/CO2


Nanoscale

Microscale

Mesoscale

Macroscale

Megascale

Computational

Fluid Dynamics

Process Simulation

Computational

Chemistry

Plant Optimization

Grid Modeling

NETL Office of Science & Engineering ResearchFutureGen Plant Modeling and Simulation

• Goal

− Reduce the time, cost, and technical risk of developing the FutureGen plant using advanced modeling and simulation technology

• Objectives

− Apply wide range of modeling and simulation technology

• Process simulation, CFD, PDE multiphysics

− Develop integrated, multiscale simulation capabilities

• Co-simulation frameworks

• Open standards

− Couple with advanced visualization and high-performance computing

− Demonstrate virtual power plant simulations Multiscale Modeling and Simulation


Advanced Process Engineering Co-Simulator (APECS)

APECS Software Integration Framework

• Combines process simulation with

custom engineering models and

computational fluid dynamics (CFD)

• Complies with the process industry

CAPE-OPEN software standard

• Offers fast reduced order models

(ROMs) and parallel computing for

improved performance

• Exploits advanced visualization for

equipment and process analysis

• First of a kind development by

NETL and its R&D technology

partners

• Recognized with 2004 R&D 100

Award

2-3D

Equipment Model Database

Aspen Plus Process Model CFD Viewer

CO

Integration Controller(CAPE-OPEN Interface )

Configuration

Wizard

Reduced

Order Model

CO

Nu

a RebPrc

FLUENT CFD

CO

Configuration

Wizard

Custom

Device Model

CO

Configuration

Wizard

2-3D

Equipment Model DatabaseEquipment Model Database

Aspen Plus Process ModelAspen Plus Process Model CFD ViewerCFD Viewer

CO


CO


Configuration

Wizard

Reduced

Order Model

CO

Nu

a RebPrc

Configuration

Wizard

Reduced

Order Model

CO

Nu

a RebPrc

Reduced

Order Model

CO

Reduced

Order Model

CO

Nu

a RebPrc

FLUENT CFD

CO

Configuration

Wizard

FLUENT CFD

CO

FLUENT CFD

CO

Configuration

Wizard

Custom

Device Model

CO

Configuration

Wizard

Custom

Device Model

CO

Configuration

Wizard

Custom

Device Model

CO

Custom

Device Model

CO

Configuration

Wizard

http://www.fluent.com/

http://www.iastate.edu/


APECS Power Generation Applications

• ALSTOM Conventional Steam Plant (250MWe) with 3D CFD Boiler

ThrottleSH Outlet Steam Turbine Extractions

Condenser

Deaerator

Feedwater HeatersAir Preheater

Boiler

Volatile Feed Stream

Coal Moisture Feed Stream

Venturi Air Feed Stream

Tertiary Air Feed

Secondary Air Feed

Primary Air Feed

CFD

Block


Condenser

Deaerator


Boiler




Tertiary Air Feed

Secondary Air Feed

Primary Air Feed

CFD

Block


Condenser

Deaerator


Boiler




Tertiary Air Feed

Secondary Air Feed

Primary Air Feed

CFD

Block

• Fuel Cell Auxiliary Power Unit (APU) with 3D CFD SOFC

• FutureGen Plant (250MWe) with 3D CFD Gasifier and 2D CFD Turbine Combustor

FC-AIR-A C-DEPLET

E-O2

AN-ANHTR

CAT-OUTA

DCOUT

Q

AN-OUT

CAT-OUT

QATR-CMB

PRODUCTS

PAIR

COLDPROD

R-FUEL

SULFUR

AN-IN

FC-AIR

ATR-AIR

WATER

H2ODUMP

H2ORECYC

P-WATER

CP1

STEAM

AIRIN

WAPW

FUELIN

P-FUELIN

WFP

W

WWPW

CP3

CHILLOUT

Q

AN-IN-A ANODEIN2

AN1-AN2

AN-OUT-A

CAT-IN-F

AN-IN-F

CAT-I-F2

AN-IN-F2

FSPLIT

O2-SEPC-HTR COMBUST

AIR-HX

DESULF

FS PLIT

AIRSPLIT

FSPLIT

H2OSPLIT

H2OHX

AIRPUMP

FUELPUMP

H2OPUMP

CHILLER

ATR

INTREF

ANODE

DUPL

CAT-DUPL

DUPL

AN-DUPL

MULT

CAT-REDU

MULT

AN-REDU

AN-SEL

CAT-SEL

MULT

CAT-MULT

MULT

AN-MULT

FC-HOLD

AN-SPLIT

AN2CMB

AN-RECYC

0

0.2

0.4

0.6

0.8

1

1.2

0 5 10 15 20

Current (A)

Voltage (V) Fuel Utilization

Power Density (W/cm2) System Efficiency (LHV)

• ALSTOM NGCC (250MWe ) with 3D CFD HRSG

Gas Turbine

LP Turbine

FW

Economizers

Air

Natural Gas

Once-

Through

Separator

IP Turbines

SH Outlet

Steam

LP

Evaporator

LP Pump

LP Drum

HP PumpHP Turbine

Condenser

HP

Evaporator

GT Exhaust Gas to HRSG

SH

RH

HP

Economizer

GT

EconomizerGT Cooler

Gas Turbine

LP Turbine

FW

Economizers

Air

Natural Gas

Once-

Through

Separator

IP Turbines

SH Outlet

Steam

LP

Evaporator

LP Pump

LP Drum

HP PumpHP Turbine

Condenser

HP

Evaporator


SH

RH

HP

Economizer

GT

EconomizerGT Cooler

Gas Turbine

LP Turbine

FW

Economizers

Air

Natural Gas

Once-

Through

Separator

IP Turbines

SH Outlet

Steam

LP

Evaporator

LP Pump

LP Drum

HP PumpHP Turbine

Condenser

HP

Evaporator


SH

RH

HP

Economizer

GT

EconomizerGT Cooler


FutureGen Power/Hydrogen Production Plant

• IGCC with CO2 capture and H2 generation

− Air separation unit (ASU) integrated with gas turbine

− Entrained-flow, coal-slurry, oxygen-blown gasifier

− Water gas shift

− Gas cleanup for particulates, Cl2, and S2

− Selexol for CO2 capture with compression to liquid

− Pressure-swing adsorption (PSA) for generating H2

− GE 7FB gas turbine

− Steam cycle with three pressure levels and HRSG

FutureGen Process Diagram

• IGCC plant with advanced technology modules and aggressive integration, performance, and environment goals


APECS FutureGen Plant Demonstration

• FutureGen Plant Model

− Aspen Plus® steady-state

− All major plant sections, over 250 unit operations

− Calculates M+E balances, power, efficiency, etc.

− Design specifications, e.g., gas turbine inlet temperature

• CFD Models

− Entrained Flow Gasifier

• FLUENT® - 3D

• DPM for coal slurry

− Gas Turbine Combustor

• FLUENT® - 2D / ROM

• Embedded in design specification loop

Gas Turbine

Combustor

Gasifier

FutureGen Plant

Simulation


Summary and Conclusions

FutureGen Power Plant

• Described DOE’s vision for energy plants

of the future and the FutureGen Project

• Highlighted NETL’s APECS system for

coupling high-fidelity equipment models

with process simulation

• Demonstrated application of the APECS

technology to the FutureGen plant

• Illustrated how the APECS system:

− Helps engineers better understand fluid

dynamics and related phenomena that

impact overall power plant performance

− Provides necessary level of detail and

accuracy essential for advanced

power plant design and optimization

• Reducing the time, cost, and technical risk

of developing high-efficiency, near zero-

emission plants will speed the transition to

a sustainable energy future

Gas Turbine

Combustor

Gasifier

Gas Turbine

Combustor

Gasifier

APECS Co-Simulation

Advanced Process Engineering Co-Simulation of the ...

Documents

Transcript of Advanced Process Engineering Co-Simulation of the ...