Development of CFBC concepts and problem solution with the aid of simulation programs CFB Workshop 24.9.2014, Jyväskylä Hannu Mikkonen, VTT Technical Research Centre of Finland
2 02/10/2014 Why to invest for Where does the modelling? modelling is used for? � Support for boiler investment � An environment for process plans simulation models building. � Increasing of plant efficiency � Evaluation of process � Decreasing of operating costs phenomena and problems � Optimization of the boiler life � Optimize production time � Use as a training simulator � Education by using process � Design and testing environment simulator
3 02/10/2014 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
4 02/10/2014 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 for mass, momentum and energy
5 02/10/2014 Apros modelling program � The Apros provides easy on-line access for: o configuring and running the simulation models o solution algorithms and model libraries for full-scale modelling o dynamic simulation of processes, such as conventional power plants, nuclear power plants, and pulp and paper mills. � The model libraries have been comprehensively validated against data from physical process experiments. Besides the process, also automation and electrical systems can be modelled in detail. The simulation environment aims at meeting the requirements for testing, design, analysis, and training simulator applications
6 02/10/2014 Aspen Plus - modelling program � Aspen Plus and Dynamics are focused on process engineering and optimization. � Optimize process designs for energy use, capital and operating costs, and product yield through the use of activated energy, economics, and equipment design during the modeling process. � Due the different features of Apros and Aspen VTT uses both platforms to model large complex processes. BOILER Q=38 .29 5 HP-Intrex 4 55 0.8 28 5.60 0 22 9.87 Q=2 9 .61 1 HP-Intrex 3 51 7.8 29 2.3 0 0 22 9.8 7 Spraying 2 51 7.8 29 2.30 0 22 9.87 60 0.0 Q=- 1 6 3.7 9 8 27 8.50 0 22 9.87 Superheater 2 46 0.0 46 2.30 0 22 9.87 Spraying 1 46 0.0 46 2.3 0 0 Reheating TURBINE 22 9.8 7 60 1 .0 57 .000 19 2 .00 Q=63 .93 6 H Superheater 1 35 3.2 58 .500 19 2.00 4 3 8.6 3 0 1.70 0 2 2 9.87 Q=-6 9.76 0 90 .0 0.7 00 60 0.0 17 0.76 Cross over duct and Convection cage 27 8.50 0 25 .0 22 9.87 Fuel feed 1.0 12 30 .10 HP-turbine IP-turbine LP-turbine Total electric power -92 .52 7 -28 1.1 75 25 .0 LIM E 1.0 0 0 37 .5 2 41 5.7 W Lime feed 31 0.40 0 23 .5 22 9.87 90 .0 0.0 29 0.7 00 23 .5 Condensation tank 85 .38 6.2 4 0.0 29 72 .88 35 3.4 35 3.2 10 .000 58 .5 00 Hierarc h y 5.0 0 Furnace 38 .0 0 18 0.3 O2 2.2 00 9.0 0 42 7.1 17 .100 20 .0 1.0 0 1.0 00 0.0 0 H 1 .0 00 7 .4 2 20 4 .6 33 7 .7 17 .100 31 2 .40 0 S21 39 .00 22 .000 34 2 .0 53 - 22 9 .87 15 8.13 62 .8 63 .9 1.0 1 2 10 .0 00 25 2.67 1.0 5 6 0.0 0 99 .8 0 63 .9 17 9.7 70 .1 1.0 5 6 Q=- 8 1.30 7 10 .00 0 0.3 1 3 15 2.86 22 9.8 7 12 .5 0 1.5 20 Eco 11 3.8 70 .00 26 9.1 18 6.1 16 .000 31 2.9 0 0 31 2.90 0 71 .37 22 9.8 7 22 9.87 Hierarc h y Hie rchy r a Q=0. 196 1 7 9.9 HP-Preheating 1 0 .00 0 LP-Preheating W=9.8 11 2 2 9.8 7 Feedwater tank Feedwater pump
7 02/10/2014 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 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.
8 02/10/2014 Combination of Apros and Aspen models APROS CFB boiler SIMULINK Turbine and water circulation ASPEN PLUS DYNAMICS Oxygen production plant CO2 pressurizing and separation
9 2.10.2014 Simulation examples (Apros) Load change: oxygen 100% - 40% - 100% Mode change: air – oxygen - air Flue gas CO2 Flue gas H2O 80 22 20 70 18 60 16 50 14 mol% mol% 12 40 10 30 8 20 6 10 4 0 500 1000 1500 2000 2500 3000 0 500 1000 1500 2000 2500 3000 Time, s Time, s Flue gas O2 Flue gas N2 6 80 70 5 60 50 4 mol% mol% 40 3 30 20 2 10 1 0 0 500 1000 1500 2000 2500 3000 0 500 1000 1500 2000 2500 3000 Time, s Time, s
10 02/10/2014 Conclusion � VTT has powerful modelling tools for researching, analysing, design, testing and education. � Apros is capable to dynamic evaluation of large process areas. � Aspen Plus is capable to steady state studies and is powerful tool for chemical process evaluations. � At VTT there are made several years process modelling in different kind of projects � Modelling projects on-going at VTT: - Apros furnace model development - Boiler and CCS-process heat integrations - Combined use of the solar field power and boiler - Controlling of the whole concept including process and control development
VTT 2014
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