Design and dynamic simulation of a 200 kWth laboratory sCO ...

Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig

2nd European sCO2 ConferenceAugust, 30th-31st 2018 - Essen - Germany

Gregor Klemencic, Markus Haider, Andreas Werner,Helmut Leibinger, Thomas Fellner, Norbert Steinschaden,

Thomas Bergthaller, Tim Nowack

Project Partners

2

FFG

Klima und Energie Fonds

Rohrdorfer Zement

Maschinenfabrik Liezen

Salzburg AG

Firma Scheuch

Firma Zauner GesmbHDesign and dynamic simulation of a 200 kWth laboratory sCO2‐test rig,

2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Overview

Design of the sCO2 test rig

Phase 1 and Phase 2

Dynamic simulation

Simulation results and first experiments

Outlook

3Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Objectives of the sCO2 project

Planning, constructing and taking into operation a sCO2 test rig at the laboratory of TU Wien

Performance of the different components of the sCO2 cycle process (heat exchangers, control valves, etc.) at different operating conditions (stationary, transient,...) should be investigated

this includes: developing control strategies for the cycle processes, validation of heat exchanger designs, influence of thermal property variations on performance, etc.

Final result: reliable overall concept for sCO2 heat recovery systems for industrial purposes (also including solutions for heat transformation and heat storage)

4Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Design of the test rig: Basic Concept

5Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Phase 1

Phase 2

Pump

high pressure level (tRC) 220 bar

low pressure level (tRC) 60 bar

min. mass flow (100 kWth) 0.2 kg/s

max. mass flow (200 kWth) 0.4 kg/s

max. CO2 temperature (hot air) 380 °C

max. CO2 temperature (thermal oil) 360 °C

Phase 1 and Phase 2 in T, s‐Diagramm

Selection of CO2 process data:

Calculation of the tRC in IPSEPro (Thermal Oil, 200 kWth)

Photo of the test rig

6Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

R&I Scheme – Phase 1:

7Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

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R&I Scheme – Phase 2:

8Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

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turbine orexpansionvalve used

air or water

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Dynamic Simulation I:

9Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Reason for:

• To test the process control system and the general dynamic behavior of the complete test rig,

applied to:• both operating modes of the test rig: transcritical and supercritical

Dynamic Simulation II:

10Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Simulation tool: APROS (Advanced Process Simulator, VTT)

Dynamic Simulation III: Results TC

11Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Temperature rise: Pressure increase:

Level in buffer tank:

Dynamic Simulation IV: Results SC

12Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Temperature rise: Pressure increase:

Level in buffer tank:

Filling the test rig

The temperature of the rig and the gas bottle limits the amount of CO2 that can be fed into theplant.• A heater can be used to heat the

gas bottle.• Natural circulation can be used to

cool the plant.

First Experiment

Pressure Oscillations at Pump

Lessons learned

HAZOP study revealed the need for additional safety mechanisms• Hard wired over-temperature shut-down (SIL2)• Protection of heat exchangers against rupture of CO2 tubes

Burst disks are used to protect the HEX shell, but…• Burst pressure limits pressure in thermal oil circuit.• Thermal oil pressure, in turn, limits the temperature (370 °C).• Pressure surges in may cause a rupture of the disks when

operating valves too quickly.

Acknowledgements

Recent and Current Research Projects on sCO2 at TU Wien:

SuCritDioCyc „(s)-CO2-Prozesse zur Abwärmenutzung“ (FFG, Project Number: 848889, duration: 01.04.2015‐31.03.2016)

sCO2-Phase 1 „CO2 als Arbeitsmedium in der Energierückgewinnung“ (FFG, Project Number: 853568, duration: 01.03.2016‐28.02.2019)

17Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen

Thank you very much for your

attention !

18Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen