by Apros simulation Fuel Characterization Workshop Jyvskyl, 23 rd - PowerPoint PPT Presentation

Utilisation of results from pilot and bench scale studies by Apros simulation Fuel Characterization Workshop Jyväskylä, 23 rd September 2014 Matti Tähtinen VTT Technical Research Centre of Finland

Contents  Presentation  The utilities and targets of modelling  Quick introduction to Apros Combustion  Utilisation of experimental data in modelling  Recent project examples  Conclusions 23/09/2014 2 2

Utilisation of experimental data in Apros simulation 23/09/2014 3 3

Where modelling is utilised?  Modelling programs provide an environment for process simulation models  With process models can be evaluated: o Process phenomena o Optimize production of the plant by evaluating process connection points and alternatives before building the plant. o Use as a training simulator before the new plant is ready o Use as design and testing environment o Use as an analysis tool o Find process problems 23/09/2014 4 4

Steady state vs. Dynamic simulation  Terms: o Steady state = Simulation which is executed once. Program calculates once and gives results according to initial data. o Dynamic = Time depending simulation, where initial data can be changed during simultaneously calculation. Results are also changing during the simulation.  Apros Combustion is dynamic process simulation software 23/09/2014 5 5

Dynamic process simulation Control system model Process model Integrated process level Set points The automation can be included in the model ... Control circuits Logic circuits Sequences Change-over automation Process component level Measurements Device controls Actuators Position Basic component level branches, Elementary nodes, Or real/virtual automation components structures, sources application can be connected to the process model. Conservation equations 23/09/2014 6 6 for mass, momentum and energy

Simulation and process design integration Process simulation Design Simulation Engineers Engineers Common Process user interface design environment Apros Automation Process design Simulation Other simulators: Balas, DEVS, sd, 3D Fluent, Modelica, design company specific Plant design systems: Simantics SmartPlant Foundation, Comos , … Engineering Information Simulation Information Management Management 23/09/2014 7 7

Apros modelling program  Dynamic modelling program  Included processes components (pipes, heat exchangers, pumps, fans, valves and vessels etc.)  Includes automation and instrumentation (controls, switches, motor drivers, calculations etc.)  Includes electrical systems  For every block dimensions has to be defined. For example for the pipe-block needs to be defined cross-section area, length, flowing material and nominal flow  The blocks are combined together with so called calculation nodes and pipes which is a basis of all calculations 23/09/2014 8 8

Utilisation of experimental data in Apros simulation 23/09/2014 9 9

Utilisation of experimental data in modelling

Experimental combustion at VTT Pilot scale grate Pilot scale CFB/BFB combustor (100 kW) combustors (15-100 kW) GRATE COMBUSTOR (100 kW) Flue gas FLUE GAS Deposit probes Bench scale CFB/BFB to stack (0.1-1.0 kW) Bag house Gas cooler Cyclone DISTRICT HEAT filter District heat exchanger FLY ASH Secondary cyclone Primary cyclone Riser Solids circulation sample Secondary and Temperature, Tertiary air tertiary airs pressure and profile FUEL sampling along the combustor height Fuel and additive feed Fuel feeder Gas tanks Secondary air (air, N 2 , CO 2 , O 2 ) Loop seal material sample Primary air Rotating grate Primary air and grid PC control and data logging system Flue gas recirculation Bottom ash BOTTOM ASH  Bench scale (CFB/BFB) for reactivity, bed material analysis, fuel/material screening  Pilot devices for process dynamics, heat exchange, scale-up, fouling, etc. 23/09/2014 11 11

Apros CFB boiler development  VTT has long background on furnace modelling  CFB and BFB furnace model to Apros n n n n n n n n n n n n n n n n+1 n+1 n+1 n+1 n+1 n+1 n+1 n+1 n+1 n+1 n+1 n+1 n+1 n+1 n+1  CFB/BFB pilot experimental data combined to dynamic n-1 n-1 n-1 n-1 n-1 n-1 n-1 n-1 n-1 n-1 n-1 n-1 n-1 n-1 n-1 furnace model and implementation to Apros n-2 n-2 n-2 n-2 n-2 n-2 n-2 n-2 n-2 n-2 n-2 n-2 n-2 n-2 n-2  Combustion and hydrodynamics etc.  Combination of furnace model and Apros to provide scalable information for power plant  More accurate dynamic simulation of process 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 23/09/2014 12 12 1D dyn. CFB model

Boiler  Boiler and turbine models include: - Fuel, sand and limestone feeding - Oxygen feed - Furnace - All the heat exchangers of the water-/steam circulation - Steam turbine including HP-, IP- and LP-parts - Main condenser and main cooling pump - Condense water preheating - Feed water tank and pump - Feed water HP-preheating 23/09/2014 13 13

Combination of different process parts APROS CFB boiler Matlab SIMULINK Turbine and steam cycle 23/09/2014 14 14

Apros-model: Boiler, air pre-heat and fluegas heat recovery 23/09/2014 15 15

Apros-model: Boiler and steam cycle 23/09/2014 16 16

Apros-model: Turbine and feedwater pre- heating 23/09/2014 17 17

Recent project examples

EU-project Flexi Burn CFB (2009-2012)  Combines experimental pilot tests at Jyväskylä VTT, steady state and dynamic simulation. To produce enough information for 30MW demo plant at Spain 23/09/2014 19 19

Utilisation of experimental data  Flexi burn:  Dynamic once through CFB boiler was modelled by Apros (300MWe).  This boiler can be driven both in air and in oxy mode  Dynamic oxygen production- (Air Separation Unit, ASU) and carbon capture plants (CCS) were modelled by Aspen  Apros and Aspen were combined together by using Matlab Simulink – program  All these plants were simulated at the same time to test:  Load changes  Switching from air over to oxy firing and back  Special situations like feed water pump stop, fuel feed stuck, oxygen feeding stops etc. 23/09/2014 20 20

Utilisation of experimental data  O2GEN: Flexi burn – project follow-on project where:  Oxygen content in recirculation gas is increased  The boiler construction research because of the increased of O 2 : advantages – disadvantages  Heat capacity increasing has to be remarked in boiler construction.  Apros is used for modelling a dynamic oxygen fired CFBC (600MWe) and a steam turbine  Aspen is used for modelling a dynamic O 2 - production and CO 2 - purification plant.  All these plants will be simulated at the same time to test:  Load changes, process optimisation, upper level controls, etc. 23/09/2014 21 21

Utilisation of experimental data  Sandwish: Combination of a concentrated solar power and CFBC  Apros is used for modelling a dynamic air fired once through boiler (OTU 460MWe) and a steam turbine  Apros is used for modelling solar field. Linear Fresnel and Parabolic trough are the alternatives for solar field  From real life collected sun radiation data can fed into the solar field or solar irradiation can be simulated  The models are combined and from the solar field achieved hot steam is lead into the boiler  Turbine tapping's are substituted with solar field steam 23/09/2014 22 22

An example of a modelled case: Coal plant evaporator analysis • • Target: 315 MW pulverized coal power plant of Fortum, Approach in modelling: detailed model of the evaporator located in Naantali, Finland. Origin in the 1970’s. tubes, minimum scope of the surrounding process, rough model of the combustion heat power • Motivation: Suffered of evaporator tube damages. Recent • change in control strategy. Does the new way increase risk for Analysis of the temperatures of the individual tubes when tube ruptures? different operational scenarios are practised 23/09/2014 23 23 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.

Conclusion  VTT has powerful modelling tools for researching, analysing, design and testing  Apros is capable to dynamic evaluation of large process integrations  At VTT there are made several years process modelling in different kind of projects  Customers are very satisfied with project results  In the future we will focus on:  Apros furnace model development  Boiler and process heat integrations  Combined use of the solar field power and boiler  Control development for any integration to provide optimum operation conditions 23/09/2014 24 24

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