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DYNAMIC MODELLING AND SIMULATION OF SUPERCRITICAL COAL-FIRED POWER PLANT
(SCPP) WITH CO2 CAPTURE
• Dynamic Modelling of System Components• Dynamic Modelling of Whole SCPP
•Steady State Validation
Akeem OlaleyeProcess\Energy Systems Engineering GroupDepartment of Chemical EngineeringSchool of EngineeringUniversity of Hull
Supervisors:
Dr. Meihong Wang (University of Hull)
Dr. Muhammad Abubakar (BF2RA)
BF2RA-CRF SEMINAR
1
Critical point of water-steam: 22.115 MPa, 374.150C
Water Phase Diagram
PROJECT BACKGROUND
What is Supercritical?
4
PROJECT BACKGROUND
Typical Primary and Secondary frequency responseTypical Primary and Secondary frequency response
UK Grid Code Requirement
5
• Project Background• Literature Review• 1ST Technical Report• Steady State Model• 2nd Technical Report
• Dynamic Component model
• 3rd Technical Report• Whole plant dynamic model
• Steady state validation
2012 2013 2014 2015
• Dynamic validation• Analysis of validated
model for grid code compliance studies
• Dynamic model of CO2 capture
• Integration of the dynamic model of SCPP and CO2capture
• Analysis of integrated model for grid compliance
PROJECT BACKGROUND 6
Review of Past WPs : WP1, WP2, WP3
WP1: Literature Review
WP2: Simplified flow Diagram WP3: Steady State Simulation
PROJECT BACKGROUND 7
• Deaerator• Feedwater heaters• Economiser• Boiler Feed Pump (BFP)
• HP, IP, LP Turbines• BFP Turbine• Condenser• Condenser Hotwell
• Steam Generation (Waterwalls)• Superheaters (Pry & Sec)• Reheaters
• Pulverised coal Flow
• Air Pre-Heaters• FD and ID Fans• Furnace• Superheaters
DEVELOPMENT OF DYNAMIC MODELS OF SCPP
CURRENT PROGRESS 8
CURRENT PROGRESS
SCPP COMPONENT S MODEL in gPROMS: General Model Equation
Global mass balance,
)..(
..............
..),(,
),(,
dtdPn
dtdTnVmm
nP
nT
dtdP
PdtdT
TdtTPd
HenceTPf
ButdtdVmm
iiiout in
iii
out in
)(
,
)()()(,
)(),(,,
dtdP
dtdh
dtdhVQhmhm
HencedtdP
dtdh
dtdhV
dtdPV
dthdV
dtPhdV
dtdUHence
PhVUPvhMUVMPVHU
dtdUQhmhm
ooii
ooii
Global energy balance, (Fluid)
Momentum balance, msgmm
pm QQdt
dTCM
Energy balance,(Metal)
2
. mfPP outin
Steam Property Relations Steam properties are estimated using Multiflash, a commercial property package.
Obtained by regression analysis on the steam table from IAPWS IFP-97 formulation
9
CURRENT PROGRESS
Heat Transfer Equations
Convection
)( coldhotcc TTAhQ
Radiation
g
gfR
TVKQ
4...
Heat transfer coefficient at supercritical condition
• The outside and inside tube heat transfer coefficients are simplified to be proportional to m0.6 and m0.8
)(6.0
6.0
mggkggm
gkc
TTmUQ
mUAhU
(Ordys et al, 1994)
(Masada, 1979)
SCPP COMPONENTS MODEL in gPROMS: General Model Equation
6.0
6.0
gk
g
mUU
mU
8.0
8.0
sk
s
mUU
mU
)(8.0
6.0
smsksms
gkc
TTmUQ
mUAhU
Outside tube (gas side) Inside tube (steam/water side)
10
CURRENT PROGRESS
Coal Mill Model
mcoal
ma
Var,f
mpf
Var,f out
mcoal = As received coal flowma = Air flowVar,f= Inlet T & P of air, coal
mpf = Pulverised coal flowma = Air flowVar,f out = outlet T & P of air, coal
SCPP COMPONENT MODELS in gPROMS : Coal Mill Model
11
CURRENT PROGRESS
Furnace Model
mpf
ma
Var,f
mg
Tgas, Tad
QR
mpf = Pulverised coal flowma = Air flowVar,f = Inlet T & P of air,
pulverised coal
mg = flue gas mass flowVar,f out = outlet P of air, coal
Tgas = Temperature of flue gasTad = Adiabatic flame TemperatureQR = Radiation heat transfer
SCPP COMPONENT MODEL in gPROMS : Furnace Model
12
CURRENT PROGRESS
Tg
Tm
Ts
P, Ps
Var,b
mgHEX
mw
QoQch
mw = Feedwater flowmg = flue gas flowVar,b = Inlet T & P of gas & feedwaterQch = heat flow in
P, Ps = gas and steam Pressure out , Ts = steam TemperatureTm = metal TemperatureQo = heat flow outms = steam flow
ms
SCPP COMPONENT MODEL in gPROMS : Heat Exchangers Model
(Waterwall, Economiser, Superheaters, Reheaters)
13
CURRENT PROGRESS
FeedwaterHeating
Train
mfwin
mstmin
Var,f
mstmout
mfwout
Var,f out
mfwinl = feedwater flow inmstmin = extracted steam flowmatt = attemperator mass flowVar,f= Inlet T & P of water, steam
mfwout = feedwater flow outmstmout = steam flow outVar,f out = outlet T & P of water, steam
SCPP COMPONENT MODEL in gPROMS : Feedwater Heaters Model
(HP and LP Feedwater heaters)
14
CURRENT PROGRESS
WHOLE PLANT MODEL in gPROMS
Data Value Unit
Net Power Output 491 MWe
Fuel flow 42.03 kg/s
Excess air 20 %
Steam flow at superheater outlet 372.03 kg/s
Superheater exit temperature 565.56 oC
Superheater exit pressure 279.07 bar
Steam flow at reheater inlet 313.69 kg/s
Reheater inlet temperature 377.89 oC
Reheater exit temperature 565.26 oC
Reheater exit pressure 66.09 bar
Mass flow of condensing steam 229.46 kg/s
• Reference Plant:500MWe supercritical coal-fired power plant using a once-through
boiler to power a double-reheat steam turbine.
(Halsbeck, J.L., 2002)
15
CURRENT PROGRESS
Primary Superheater
Secondary Superheater
ConvectionPass
Furnace Waterwalls
(multiple loop)
Economizer
HP Feedwater Heater Feed PumpStorage Tank
Deaerator
LP Feedwater Heater
CondensatePump
Hotwell
Condenser
LP TurbineIP Turbine
HP Turbine
Reheaters
Attemperator
Attemperator
Generator
Interceptvalve
WHOLE PLANT MODEL
Structure of the Dynamic Model of the Water-steam circuit of the SCPP in gPROMS®
16
CURRENT PROGRESS
WHOLE PLANT MODEL
Structure of the Dynamic Model of the Air-flue gas flow path of the SCPP in gPROMS®
PERFORMANCE DATA
Unit REFERENCE PLANT
gPROMS®MODEL
RELATIVE ERROR (%)
Net Power output MWe 491 489.44 -0.32
Fuel Flow kg/s 42.03 42.03 -
Excess air % 20.0 19.61 -1.95
Steam flow at superheater outlet kg/s 372.03 381.3 2.50
Superheater exit temperature oC 565.56 575.13 1.69
Superheater exit pressure bar 279.07 282.64 1.28
Reheater inlet temperature oC 377.89 383.42 1.46
Reheater exit temperature oC 565.26 561.72 -0.61
Reheater exit pressure bar 66.09 64.08 -3.04
Mass flow of condensing steam kg/s 229.46 226.65 -1.22
STEADY STATE VALIDATION
17
CURRENT PROGRESS
Dynamic Model of CO2 Capture in gPROMS ® (reduced Model 3)
Biliyok et al., 2012 Detailed Capture Model: Validated with good prediction Physical property calculations obtained from Aspen Plus® and Multiflash®
18
• Lumped Parameter Approximation (sections)
• Distributed Parameter Model
• Linking the individual components model
• Steady state Validation of the whole plant
• Dynamic validation of the whole plant model
• Analysis of the model for UK Grid Compliance studies
• Linking the Dynamic Model with CO2 Capture model
• Analysis of the Integrated Model for grid studies
FUTURE WORK 19
• Haslbeck, John L. Evaluation of Fossil Fuel Power Plants with CO2 Recovery. NETL Report 40465, 2002.
• Berry JE, Holland MR, Watkiss PR, Boyd R, Stephenson W. Power Generation and the Environment – a UK Perspective. Report number AEAT3776, ExternE Project, AEA Technology Environment, Abingdon, Oxfordshire; 1998.
• Paranjape, R. D., Modelling and control of a supercritical coal-fired boiler, PhD thesis, Texas Technical University, Lubbock, USA. 1996
• Masada, Y., Wormley, D.N. (1982),”Dynamic model of a 1400MW supercritical pressure steam plant”, ASME Papers.
• Zindler, H., Walter, H., Hauschke, A., and Leithner, R (2008), "Dynamic simulation of a 800MWe hard coal once-through supercritical power plant to fulfill the Great Britain grid code", 6th IASME/WSEAS International Conference on Heat Transfer, Thermal Engineering and Environment, 20-22 August, 2008, Rhodes, Greece, pp. 184-192
• Wagner, W., Kretzschmar, H.J. (2008), “International Steam Table – Properties of Water and Steam – Based on the Industrial Formulation IAPWS-IFP97”, 2nd Edition, Springer-Verlag, Berlin.
REFERENCES 21