Overview of RecentOverview of RecentAccomplishments and Accomplishments and
Work in ProgressWork in Progress
Edward S. Rubin Carnegie Mellon University
Project Review Meeting National Energy Technology Laboratory
April 2, 2001
Outline of TodayOutline of Today’’s Presentations Presentation
Brief History of the Project Recent Accomplishments
IECM technologiesToward Vision 21
Work in ProgressFuture PlansOpen Discussion
Project HistoryProject History
“Development of the Integrated Environmental Control Model”
– CORs: C. Drummond, L. Gould, P. Rawls, T. Feeley, G. Gibbon
– September 1992 - April 2000
“Development and Application of Optimal Design Capability for Coal Gasification Systems”
– CORs: K.Williams, G. Gibbon– September 1992 - present
Because of the . . .
Increasing complexity of advanced processesMultiple options for component design & selectionStrong interactions among system componentsSignificant performance and cost uncertainties
Advanced Design and Analysis Advanced Design and Analysis Methods Are NeededMethods Are Needed
ObjectivesObjectives
Develop a comprehensive modeling framework to estimate the performance, environmental emissions, and cost of coal-based power generation technologies
Develop a method for comparing alternative options on a systematic basis, including the effects of uncertainty
ApproachApproach
Process Technology ModelsEngineering Economic ModelsAdvanced Software CapabilitiesSystems Analysis Framework
Integrated EnvironmentalIntegrated EnvironmentalControl Model (IECM)Control Model (IECM)
CoalCleaning
CombustionControls
Flue Gas Cleanup & Waste Management
NOxRemoval
ParticulateRemoval
CombinedSOx/NOxRemoval
AdvancedParticulateRemoval
SO2Removal
Calculate detailed mass and energy flowsEmploy empirical relationships and models based on available dataPredict component and system efficiencyPredict multi-media environmental emissions
Process Performance ModelsProcess Performance Models
Direct capital cost of major process areasTotal system capital costFixed operating costsVariable operating costsTotal cost of electricityLinked to process performance models
Process Cost ModelsProcess Cost Models
Probabilistic Software CapabilityProbabilistic Software Capability
Can specify parameter values as distribution functions to reflect uncertainty or variability in model input data
Explicitly quantifies the effects of uncertainty on predicted performance, emissions, and cost, yielding confidence intervals for uncertain results
IECM Software PackageIECM Software Package
PowerPowerPlantPlantModelModel
GraphicalGraphicalUserUser
InterfaceInterface
Plant andPlant andFuelFuel
DatabasesDatabases
Fuel PropertiesFuel PropertiesHeating ValueHeating ValueCompositionCompositionDelivered CostDelivered Cost
Plant DesignPlant DesignFurnace TypeFurnace TypeEmission ControlsEmission ControlsSolid Waste MgmtSolid Waste MgmtChemical InputsChemical Inputs
Cost DataCost DataO&M CostsO&M CostsCapital CostsCapital CostsFinancial FactorsFinancial Factors
Plant & ProcessPlant & ProcessPerformancePerformance
-- efficiencyefficiency-- resource useresource use
EnvironmentalEnvironmentalEmissionsEmissions
-- air, landair, land
Plant & ProcessPlant & ProcessCosts Costs -- capitalcapital
-- O&MO&M-- COECOE
The IECM is Publicly AvailableThe IECM is Publicly Available
Web Access:
ftp://ftp.netl.doe.gov/pub/IECM
Preliminary IECM User GroupPreliminary IECM User Group
ABB Power Plant ControlAmerican Electric Power Consol, Inc.Energy & Env. Research Corp.Exportech Company, Inc.FirstEnergy Corp.FLS Miljo A/SFoster Wheeler Development Corp.Lehigh UniversityLower Colorado River AuthorityMcDermott Technology, Inc.Mitsui Babcock Energy LTD.
National Power Plc.Niksa Energy AssociatesPacific Corp.Pennsylvania Electric AssociationPotomac Electric Power Co.Savvy EngineeringSierra Pacific Power Co.Southern Company Services, Inc.Stone & Webster Engineering Corp.Tampa Electric Co.University of California, BerkeleyUS Environmental Protection Agency
Overview of Overview of Recent AccomplishmentsRecent Accomplishments
Combustion NOx controls (v 3.3)Mercury control technologies (v 3.4)IGCC systems (current and advanced)Solid oxide fuel cells CO2 capture and sequestration systemsFlexible fuel optionsEnhanced software capabilities
Newest Versions ofNewest Versions ofthe IECM ...the IECM ...
n
New IECM Modules for New IECM Modules for Combustion Combustion NONOxx ControlsControls
Version 3.3Selective Non-Catalytic Reduction (SNCR)Low NOx Burners (LNB)LNB + Overfire airLNB + SNCRNatural Gas ReburnTangential, Wall & Cyclone Firing
New IECM Modules for New IECM Modules for Mercury ControlsMercury Controls
Version 3.4Carbon injection systemsFlue gas humidification optionEffects of coal type (eastern vs. western)Effects of control technology selection
– Particulate collector– FGD system– SCR system
MultiMulti--Pollutant InteractionsPollutant Interactions
CriteriaAir
Pollutants
PMSO2
NOx
HazardousAir
Pollutants
HgHClH2SO4
A Special AnnouncementA Special Announcement
n
Model ApplicationsModel Applications
Process designTechnology evaluationCost estimationR&D management
Risk analysisEnvironmental complianceMarketing studiesStrategic planning
Current Activities and PlansCurrent Activities and Plans(PC plants)(PC plants)
Refine existing models for mercury control and other pollutants as new data become available Couple the IECM to a database of U.S. power plant and fuel characteristicsAnalyze options, costs and emission reductions associated with use of control technologies for criteria pollutants and air toxicsExplore IECM applications to the DOE Power Plant Improvement Initiative
Toward Vision 21 ...Toward Vision 21 ...
n
Model Software ImprovementsModel Software Improvements
Increased FlexibilityMultiple fuel types (coal, oil, gas)Multiple plant types (combustion, IGCC, fuel cells, gas turbines, etc)Easy and fast integration of new modules
Additional FeaturesPlant configurationsResults tools
User Interface ImprovementsUser Interface Improvements
Increased FlexibilityConfiguration of flowsheetsTwo-dimensional flowsheetsInterface database compiler
Additional FeaturesMultiple technology navigation menuMultiple session results
– Comparisons of up to six sessions– Differences between two cases
Comparisons of Competing OptionsComparisons of Competing Options
Select Gasification Combined Select Gasification Combined Cycle (IGCC) OptionsCycle (IGCC) Options
Select Select GasifierGasifier
Select Oxygen PlantSelect Oxygen Plant
Select Gas Cleanup SystemSelect Gas Cleanup System
Select Byproduct RecoverySelect Byproduct Recovery
Current Status of IGCC ModelsCurrent Status of IGCC Models
Response surface model of advanced IGCC system (KRW gasifier + hot gas cleanup) is completed; implementation in the IECM framework is nearing completion.Response surface model of baseline IGCC system (Texaco gasifier + cold gas cleanup) is under development; expected completion in June.
Set IGCC Process ParametersSet IGCC Process Parameters
IGCC Process AreasIGCC Process Areas
Coal HandlingLimestone HandlingOxidant FeedGasificationSulfationZinc Ferrite
Boiler Feedwater SystemGas TurbineHeat Recovery Steam GenerationSelective Catalytic ReductionSteam TurbineGeneral Facilities
IGCC Fixed O&M CostsIGCC Fixed O&M CostsFuels
Coal CostFuel Oil CostLPG - Flare Cost
ReagentsSulfuric Acid CostNaOH CostHydrazine CostMorpholine CostLimestone CostLime CostSoda Ash Cost
SCR SystemSCR Catalyst CostAmmonia Cost
Zinc Ferrite SystemZinc Ferrite Sorbent CostPlant Air Adsorbent Cost
Waste Water SystemCorrosion Inhibitor CostSurfactant CostChlorine CostBiocide CostWaste Water CostRaw Water Cost
ByproductsSulfur Byproduct CostSulfuric Acid Byproduct Cost
ASPEN Model of an IGCC SystemASPEN Model of an IGCC System
CoalHandling
Gasification,Particulate &Ash Removal,Fines Recycle
GasTurbines
BoilerFeedwaterTreatment
SteamTurbine
SteamCycle
& SCR
SulfurRemovalProcess
SulfuricAcid Plant
SulfuricAcid
Rawwater
Coal Coal
CleanSyngas
Exhaust Gas
Gasifier Steam
Boiler Feedwater
Exhaust Gas
Shift & Regen.Steam
Cyclone
RawSyngas
Cyclone
Blowdown
Return Water
CoolingWater
Makeup
CoolingWaterBlowdown
Air
NetElectricityOutput
InternalElectricLoads
Ash Gasifier Air
AirTailgas
Off-GasCaptured Fines
Response Surface Model DevelopmentResponse Surface Model Development
Range of ParameterInputs, Ii
DetailedPerformance
Model
PerformanceOutputs (Oj)
PerformanceOutputs
(Oj)
Response SurfaceModel
Oj = f (Ii)
RegressionAnalysis
Response Surface ModelResponse Surface Modelfor an IGCC Systemfor an IGCC System
0.39
0.4
0.41
0.42
0.43
0.39 0.4 0.41 0.42 0.43
Actual Efficiency
Pred
icte
d Ef
ficie
ncy
Desktop Model of a ProcessDesktop Model of a Process
ResponseSurface
Model (RSM)
CostModel
InputAssumptions
Performance
Emissions
Cost
Additional Fuel and Technology Additional Fuel and Technology OptionsOptions
Simple Cycle Gas PlantSimple Cycle Gas Plant
Combined Cycle Gas PlantCombined Cycle Gas Plant
NGCC Plant with SCR SystemNGCC Plant with SCR System
Open Vision 21 Plant OptionsOpen Vision 21 Plant Options
Vision 21 WorkbenchVision 21 Workbench
Select Existing Select Existing Flowsheet Flowsheet -- 11
Water
Air
Air
GT
GT
ST
GC
HRSG
GA
ASU
FC
FC
Select Existing Select Existing FlowsheetFlowsheet -- 22
Air
Water
PFBC
ASU
CBTC
HRSG
GTST
FCGC
GC
GT
Configure a New SystemConfigure a New System
Air
H2
CO2
New Modules Under New Modules Under Development ...Development ...
n
Tubular SOFC DesignTubular SOFC Design
Air
ElectrolyteCathodeAnode
FuelInterconnect
SOFC Voltage vs. Current DensitySOFC Voltage vs. Current Density
0 100 200 300 400 500 600 700 800 900
10.90.80.70.60.50.40.30.20.1
0
Current Density (mA/cm2)
Vol
tage
(V)
COCO22 Capture TechnologiesCapture Technologies
MEACausticOther
Chemical
SelexolRectisolOther
Physical
Absorption
AluminaZeoliteActivated C
Adsorber Beds
Pressure SwingTemperature SwingWashing
Regeneration Method
Adsorption Cryogenics
PolyphenyleneoxidePolydimethylsiloxane
Gas Separation
Polypropelene
Gas Absorption
Ceramic BasedSystems
Membranes Microbial/AlgalSystems
CO2 Separation and Capture
Flas
h
MEAStorage
Flue Gas
CoolerCooler
Pump
Pump
ReboilerLean-hot
rich-hotrich-cool
lean-cool
MEAmakeup
CO2 productExhaust
Gas
Blower
SpentSorbent
H-Ex*
COCO22 Capture Using AmineCapture Using Amine--Based SystemBased System
Absorber
Regenerator
MultiMulti--Pollutant InteractionsPollutant Interactions
CriteriaAir
Pollutants
PMSO2
NOx
HazardousAir
Pollutants
HgHClH2SO4
CO2
CH4
GreenhouseGas
Emissions
Cost of COCost of CO22 AvoidedAvoided
0.00.10.20.30.40.50.60.70.80.91.0
45 50 55 60 65 70 75 80 85 90 95Mitigation cost ($/ton CO2 avoided)
Cum
ulat
ive
prob
abili
ty
Deterministic
Probabilistic
Application to MajorApplication to MajorPower Generation OptionsPower Generation Options
Combustion-basedGasification-based
Coal
Direct CombustionGas Reforming
Natural Gas
Fuel
Air
Oxygen
Oxidant
Pulverized CoalGas Turbines
Simple Cycle
Gas TurbinesCoal GasificationFuel CellsOther
Combined Cycle
Technology
Power Generation Technologies
IGCC Plant with COIGCC Plant with CO22 CaptureCapture
NGCC Plant with CONGCC Plant with CO2 2 CaptureCapture
To Succeed We Need ...To Succeed We Need ...n
Recipe for SuccessRecipe for Success
Talented Researchers
DOE Collaboration
Continuity of Funding
(blend in equal parts)
Comments andComments andDiscussionDiscussion
n
Configure Base PlantConfigure Base Plant
Select Select NONOxx ControlsControls
Select Particulate ControlsSelect Particulate Controls
Select SOSelect SO2 2 ControlsControls
Set Coal PropertiesSet Coal Properties
Set Base Plant ParametersSet Base Plant Parameters
Specify Input UncertaintiesSpecify Input Uncertainties
Results: Plant Mass FlowsResults: Plant Mass Flows
Results: Plant Cost SummaryResults: Plant Cost Summary
Control Technology DetailsControl Technology Details
Probabilistic ResultsProbabilistic Results
IECM CapabilitiesIECM Capabilities
A comprehensive modeling framework to estimate the performance, emissions, and cost of coal-based power plants
A tool for comparing alternative options on a systematic basis, including the effects of uncertainty in performance and cost
A Hierarchy of Models for A Hierarchy of Models for Technical and Policy AnalysisTechnical and Policy Analysis
Design options for a single
facility (tech. feasibility, cost,
efficiency,emissions)
Multi-facility(or multi-sector)optimization or
simulation (dynamic)
Integrated assessment
models(including
measures of impacts)
Detailed (mechanistic)
models or codes for specific processes or components
Conventional Process ModelingConventional Process Modeling(Deterministic Simulation)(Deterministic Simulation)
ProcessModel
ParameterValues
ResultsResults
Parameter UncertaintyParameter UncertaintyDistributionsDistributions
NORMAL UNIFORM LOGNORMAL
FRACTILETRIANGULAR BETA
Stochastic SimulationStochastic Simulation
StochasticModeler
SAMPLINGLOOP
ProcessModel
ParameterUncertainty
DistributionsResultsResults
Example of a Probabilistic ResultExample of a Probabilistic ResultC
umul
ativ
e Pr
obab
ility
Cum
ulat
ive
Prob
abili
ty
Total Capital Requirement ($/kW)Total Capital Requirement ($/kW)1000 1100 1200 1300 1400 1500
ProbabilisticResult
0.0
0.2
0.4
0.6
0.8
1.0
SorbentSulfur
Loading
GasifierFines
Carryover
CarbonRetention inBottom Ash
353025201510500.0
0.1
0.2
0.3
Sorbent Sulfur Loading, wt-%20151050
0.0
0.1
0.2
0.3
Carbon Retention in Bottom Ash% of coal feed carbon
3025201510500.00
0.05
0.10
0.15
0.20
Fines Carryover, % of coal feed
Expert Judgments on Expert Judgments on Key Model ParametersKey Model Parameters
Calculated Plant EfficiencyCalculated Plant Efficiency
444342414039380.0
0.2
0.4
0.6
0.8
1.0
ProbabilisticDeterministic
Net Plant Efficiency (%, HHV basis)
Cum
ulat
ive
Prob
abili
ty
Total Plant Capital CostTotal Plant Capital CostC
umul
ativ
e Pr
obab
ility
Total Capital Requirement ($1994/kW)1000 1100 1200 1300 1400 1500
DOE (1989)Probabilistic
0.0
0.2
0.4
0.6
0.8
1.0
524 MW net
Value of Targeted ResearchValue of Targeted Research
1201101009080706050400.0
0.2
0.4
0.6
0.8
1.0
Base Case UncertaintiesReduced Uncertainties inSelected Performanceand Cost Parameters
Levelized Cost of Electricity, Constant 1989 mills/kWh
Input Uncertainty Assumptions
Cum
ulat
ive
Prob
abili
ty
NETL 2001 Award CeremonyNETL 2001 Award Ceremony
March 28, 2001
Silver Awardto
NETL 2001 Award Ceremony
March 28, 2001
Silver Awardto
Mercury Control PerformanceMercury Control Performanceand Cost Model Teamand Cost Model Team
Developed a model that evaluated mercury control options for 12 different coal-fired plant configurations which EPA used in their final determination to regulate mercury.
Descriptor - include initials, /org#/date
Mercury Control Performanceand Cost Model Team
• Developed a model that evaluated mercurycontrol options for 12 different coal-fired plantconfigurations which EPA used in their finaldetermination to regulate mercury.
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