5 th Oxyfuel Combustion Research Network Meeting, Wuhan, China October 29, 2015 Dynamic Simulation and Controls for Oxy- Fired Boiler and Steam Power Plant with CO2 Capture System Alstom Power Xinsheng Lou, Armand Levasseur, Francois Granier, Olaf Stallmann, Carl Neuschaefer, Robert Schrecengost
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5th Oxyfuel Combustion Research Network Meeting, Wuhan, China
October 29, 2015
Dynamic Simulation and Controls for Oxy-Fired Boiler and Steam Power Plant with
CO2 Capture System
Alstom Power
Xinsheng Lou, Armand Levasseur, Francois Granier, Olaf Stallmann, Carl Neuschaefer, Robert Schrecengost
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 4
Oxy Plant Dynamic ModelingWhy Oxy Combustion
• Near Zero Emissions• High CO2 Capture Rates (>90%)• Cost Competitive (v.s. other CCS, Wind, Solar, etc.)• Fuel and Operating Flexibility • Ready for Scale Up - Fit for New and Retrofit Applications
Proven
Reliable
Flexible
Alstom offers all major Oxy-Fuel Power Plant components [Boiler, AQCS, GPU] and integrated turnkey power plants and power blocks
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 9
Oxy Process ModelingGPU Scope
• EOR Based Gas Processing Unit— Rigorous Thermo-physical properties prediction methods— Modeling of the Direct Contact Cooler (DCC)— Improved purity of CO2 product (~1.0x10-5 O2/mole of CO2)— CO2 Recirculation Added for Anti-Surge Control— Control loops well tuned
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 13
Simulations of Dynamic OperationsGrid Code Compliance Analysis
• Power Responses- The primary response simulation results show that the power (gross MWe load)
produced by the generator can increase by 44MWe or 10%MCR in 10 seconds and that this level of power production (gross MWe load) can be maintained for 30 minutes to satisfy the secondary response.
- The full response capability of the plant is restored in about 20 minutes, ready to undergo another power (gross MWe load) jump as the condenser level returns back to normal set point conditions.
- The furnace pressure deviation is within a small range, indicating that the boiler is not negatively impacted by the event.
• GPU Responses- The GPU compressor powers increases as the boiler catches up and as more flue
gases have to be processed. - The GPU response shows that the CO2 purity remains steady and the product
quality is not affected by the grid code event.- The CO2 recovery is reduced initially, dropping to about 75% within the first 5
minutes but returning to about 90% in less than 20 minutes.
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 14
Simulations of Dynamic OperationsGPU Flexibility and Trip Analysis
• Flexibility Analysis −Both Models Used: full GPU Stand-Alone Model vs. Boiler+Simplified GPU −The simulation shows that a minimum of 90% CO2 product recovery is achieved. −Off-gas, CO2 product recirculation and the process control system assure that
product purity is within the acceptable limits (O2 contaminant of less than 10ppm).−The GPU is capable of supporting 5%BMCR/min load ramping operations
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 15
Simulations of Dynamic OperationsGPU Flexibility and Trip Analysis
• Trip Analysis −Both Models Used: Full GPU Stand-Alone Model vs. Boiler+Simplified GPU −The hot flue gas flow from boiler and the primary air flow recycled from the DCC
to the boiler are not affected by the compressor trip.−The full GPU model can be used to analyze FG compressor trip when a minimum
feed into the cold-box is used to sustain the trip simulation transients.
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 17
Simulations of Dynamic OperationsLoad Change and MI Analysis
• Oxy Boiler Load Cycling and MI Analysis −Transient simulation analysis were conducted using the Alstom Dynamics model−Pressures vs. time incorporated into the model−Heat transfer coefficients. Vs. temperatures incorporated into the model for both
header and tubes in MI analysis−Material property ( modulus of elasticity, density, coefficients of thermal
expansion, conductivity, etc..) vs. temp is incorporated into the model) −Fatigue life was estimated, which generally decreases as ramping rate increases
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 18
Simulations of Dynamic OperationsAdvanced Controls and Optimization
• What Is Advanced Controls−Computer based algorithm, strategy and
system that deviates from conventional PID based controls
• Model Predictive Controls (MPC)• Model Reference Adaptive Controls (MRAC)• Fuzzy Controls (FC)• Real-Time Optimization (RTO)
• Potential Benefits from Advanced Controls−Steam temperature variations suppression−Heat rate Improvement−NOx Emission reduction− Improve CO2 capture rate−Maintain CO2,O2 concentrations in CO2 product−MW Flexibility vs ASU operations −Optimization of Startup, Shutdown, Mode
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 22
Conclusions
1. Technical approach to modeling and controls of industrial scale oxy fired boiler and CCS proved feasible and effective
2. Process dynamic model developed and validated with reference design data for 350+MWe oxy boiler and CCS plant
3. The regulatory controls designs were implemented and evaluated with the oxy boiler and CCS plant dynamic simulator
4. Transient analysis was conducted using the oxy boiler dynamic model, GPU model, and the integrated plant model in FEED
5. Integrated advanced controls were developed and evaluated for the industrial scale reference design unit with oxy firing and carbon capture and sequestration. Potential incremental operating performance and economic benefits are to be achieved with advanced process controls (APC)
5th IEAGHG International Oxyfuel Combustion Research Network, Wuhan, China, X. Lou Oct. 29, 2015 – P 23
Acknowledgements and Disclaimer
Acknowledgement
Some of work presented was supported by the US Department of Energy through the National Energy Technology Laboratories under Agreement DE NT-0005290. The guidance and direction of NETL Project Managers Steve Mascaro and Tim Fout is acknowledged and appreciated.
Disclaimer
Parts of this presentation were prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.
Information disclosed herein is furnished to the recipient solely for the use thereof as has been agreed upon with ALSTOM and all rights to such information are reserved by ALSTOM. The recipient of the information disclosed herein agrees, as a condition of its receipt of such information, that ALSTOM shall have no liability for any direct or indirect damages including special, punitive, incidental, or consequential damages caused by, or arising from, the recipient’s use or non-use of the information.