Two Line Subject Title One Line Title

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AVESTARTM Center for the Operation

and Control of Clean Energy Plants

Stephen E. Zitney, PhD.

Director, AVESTARTM Center

National Energy Technology Laboratory

Morgantown, WV

www.netl.doe.gov/avestar

Energy Systems Initiative (ESI)

Carnegie Mellon University

Pittsburgh, PA

March 11, 2012

2

Presentation Outline

• U.S. Energy Challenges

– Electricity Generation, Modern Grid Era, and

Clean Energy Plants

• Advanced Virtual Energy Simulation

Training And Research (AVESTARTM)

– Mission and Goals

– Meet Our People, Partners, and Trainers

– Integrated Gasification Combined Cycle (IGCC)

with CO2 Capture

• Dynamic Simulator/Operator Training System (OTS)

• 3D Virtual Immersive Training System (ITS)

– Simulator Facilities

– Training, Education, and R&D Programs

– Future Directions

• Concluding Remarks

3

U.S. Energy Challenges Electricity Generation

• Maintain generation and optimize efficiency of coal-fired plants,

while taking full advantage of carbon capture, utilization, and

storage (CCUS)

– Exploit CO2 capture advantages and

fuel/product flexibility of gasification-

based systems (e.g., IGCC)

• Grow gas-fired generation driven

by increase in shale gas

– Accelerate deployment of post-

combustion CO2 capture

• Maintain generation from nuclear

• Grow share of generation from

renewables (e.g., wind, solar)

Source: DOE/EIA-0383, Annual Energy Outlook 2011

Bil

lio

n k

Wh

U.S. Electricity Generation by

Fuel Type

Meet increasing demand for clean, affordable, and secure energy

by developing a diversified portfolio of power generation plants

4

U.S. Energy Challenges

Modern Grid Era

• Variable demand from active

participation of consumers

• Variable and non-storable supply

from renewable energy resources,

such as wind and solar

• Combine renewable energy forms

with clean fossil fuel power plants

and energy storage

• Produce reliable, near-constant

baseload power

Renewables

Clean Energy Plant

with Energy Storage

Fast-Ramping CAES

5

U.S. Energy Challenges Clean Energy Plants

• Clean energy plants (e.g., IGCC) require effective operation

of large, highly-integrated, multipurpose power and process

systems

• CCUS adds CO2 capture and utilization processes,

as well as CO2 transport and sequestration platforms

• Modern grid requirements increase need for cycling, load-

following, and faster startups/ramp rates

• Optimize dynamic plant performance using advanced

automation and control technologies to achieve operational

excellence

• Minimize plant derates, emissions, equipment damage,

downtime, and safety hazards

6

www.netl.doe.gov/avestar

7

AVESTARTM Center

Advanced Virtual Energy

Simulation Training And Research

• Mission

– Accelerate progress toward achieving Operational Excellence for

Clean Energy Plants

• 1) Asset, 2) Control, 3) Environment & Safety, and 4) People

• Goals

– Develop portfolio of high-fidelity real-time dynamic simulators with

full-scope operator training systems (OTSs) and 3D virtual

immersive training systems (ITSs)

– Bring together advanced simulation-based technologies, state-of-

the-art facilities, and leading energy experts

– Conduct collaborative, innovative, internationally-recognized R&D

on dynamics, control, and virtual plant simulation technologies

– Train workforce and educate students using experiential learning

www.netl.doe.gov/avestar

8

AVESTARTM Center – Meet Our People

Dr. Stephen E. Zitney, NETL

Director, AVESTAR Center

Prof. Richard Turton

ChE Dept., WVU

Manager, AVESTAR Center

at National Research

Center for Coal & Energy

(0.5 PhDs)

George Darakos, NETL

Business Manager,

AVESTAR Center

Prof. Debangsu Bhattacharya

ChE Dept., WVU

R&D Manager,

AVESTAR Center

(2.5 PhDs, 1 Post-doc)

Terry E. Jordan Jr., NETL

Sr. Computer Engineer,

AVESTAR Center

Eric Liese, NETL

Sr. Research Engineer,

AVESTAR Center

Dr. Priyadarshi Mahapatra

URS/NETL

Sr. Research Engineer,

AVESTAR Center

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AVESTARTM Center

Meet Our Partners Meet Our Trainers

Industrial Collaborators

Graham Provost

Fossil Consulting

Services

Michael McClintock

Fossil Consulting

Services

Victor Madison

Fossil Consulting

Services

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Presentation Outline

• U.S. Energy Challenges

– Electricity Generation, Modern Grid Era, and

Clean Energy Plants

• Advanced Virtual Energy Simulation

Training And Research (AVESTARTM)

– Mission and Goals

– Meet Our People, Partners, and Trainers

– Integrated Gasification Combined Cycle (IGCC)

with CO2 Capture

• Dynamic Simulator/Operator Training System (OTS)

• 3D Virtual Immersive Training System (ITS)

– Simulator Facilities

– Training, Education, and R&D Programs

– Future Directions

• Concluding Remarks

11

IGCC Power Plant with CO2 Capture

Coal

O2

Gasifier Water Gas

Shift

Cryogenic

ASU

Syngas Cooler

Steam

Acid Gas

Removal

Claus Plant

Sulfur

CO2 Comp

CO 2 2200 psig

CO 2

Steam

Reheat / Humid.

Fuel Gas

Syngas

Cooler /

Quench

Particulate Removal

Gas

Turbine

HRSG Steam

Steam

Turbine Power

Power

H2S

Syngas

CO

H2

Syngas

CO2

H2 (High P,T)

N2

Dilution

N2 for

Dilution

IGCC Case #2, Cost and Performance Baseline for Fossil Energy Power Plants Study, Volume 1: Bituminous Coal

and Natural Gas to Electricity, www.netl.doe.gov, DOE/NETL-2010/1397, November 2010.

Plant Section Description

Gasification Entrained-flow Gasifier

Air Separation Elevated-P Cryogenic ASU (95% vol O2)

H2S Separation Physical Solvent AGR 1st Stage

Sulfur Recovery Claus Plant

CO2 Separation Physical Solvent AGR 2nd Stage

CO2 Compression Four stage (2200 psia)

Gas Turbines Adv. F Class (232 MW output each)

Steam Cycle Subcritical (1,800 psig/1,000ºF/1,000ºF)

Power Output 746 MW gross (556 MW net)

• IGCC operates at high pressure with

oxygen instead of air

• Volume of gas to be treated is nearly

two order of magnitude lower

• CO2 is removed before combustion

• CO2 is easier to capture and is

produced at higher pressures

• Increased power plant efficiency

• Lower cost of electricity

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IGCC Dynamic Simulator/OTS

Capabilities and Features

• Full-Scope, High-Fidelity, Real-Time

Dynamic Simulator (DYNSIM)

• Modular: IGCC with CO2 Capture,

Process (Gasification), Power (CC)

• Fuels: Coal, Petcoke, Biomass

• OTS: HMI (InTouch), Trends, Alarms

• Instructor: ICs, RFs, Malfunctions

• Controls: Regulatory (PID),

Coordinated (Gasifier/Turbine Lead)

• Operations: Normal Baseload, Startup,

Shutdown, Load Shedding, Abnormal

Situation Handling

Deployed at AVESTAR Center in March 2011

DYNSIM Gasifier Model

InTouch Gasifier HMI

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IGCC Immersive Training System/ITS Capabilities and Features

• 3D Virtual Plant Model

– 3D computer-aided design (CAD)

– Plant photos for photorealism

• 3D Immersive Interaction/Content

– Avatar represents field operator

– Navigation using game pad

– Remote field functions

– Collision geometry and sound

– Popup trends (variables vs. time)

– Transparent equipment objects

– Highlighted virtual content/scenarios

• Benefits

– Added dimension of plant realism

– Plant familiarization and walkthrough

– OTS/ITS for control room and plant

field operators, promoting teamwork

Scheduled for deployment at AVESTAR Center in June 2012; Invensys EYESIM software

Distillation

Column

Gasifier

Gas

Leak

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Presentation Outline

• U.S. Energy Challenges

– Electricity Generation, Modern Grid Era, and

Clean Energy Plants

• Advanced Virtual Energy Simulation

Training And Research (AVESTARTM)

– Overview

– Meet Our People, Partners, and Trainers

– Integrated Gasification Combined Cycle (IGCC)

with CO2 Capture

• Dynamic Simulator/Operator Training System (OTS)

• 3D Virtual Immersive Training System (ITS)

– Simulator Facilities

– Training, Education, and R&D Programs

– Future Directions

• Concluding Remarks

15

AVESTAR Center Facilities

AVESTAR Center at AVESTAR Center at

• Locations

– NETL: R&D

– WVU: Education, Training

– Both in Morgantown, WV

• Facilities

– OTS Room: Control Room

Divider for 2 Simulators

– ITS Room: Plant/Field

– Local area network

• Training Systems

– IGCC OTS

8 Operator Stations

2 Instructor Stations

2 Engineering Stations

– IGCC ITS

2 Field Stations

1 Instructor Station

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AVESTAR Training Program

For more information on AVESTAR training, please visit: www.netl.doe.gov/avestar/training.html

• Comprehensive, hands-on, dynamic

simulator-based training

• Experienced power plant trainers

• IGCC with CO2 capture courses

– Orientation to advanced operations

– Registration inquiries and fees online

– ITS integrated into training in June 2012

• Customized courses/programs

available for industry

• CEUs through West Virginia Univ.

• Collaborating with regional technical

colleges on Power Plant Technology

certificate/degree programs

– Partnering with electric utilities to assure

availability of well-qualified workforce

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AVESTAR Education Program

• Leverage real-time OTS/ITS technology

• Enhance engineering education in process

simulation, dynamics, control, and safety

• Example courses at WVU include:

– Process Control for Chemical Engineers

• Seniors in Chemical Engineering

• 4-6 hours on IGCC dynamic simulator

• Learn how plant responds dynamically to changes in

manipulated inputs, as well as how control system

impacts plant performance, stability, and robustness

– Process and Dynamic Simulation

• New course for ChE juniors and seniors

• Theory of steady-state/dynamic process simulation

• Development of operator training simulators

• 3-4 weeks on IGCC dynamic simulator

• Learn key OTS features and capabilities

• Practice start-up and malfunction scenarios

• Extend to other NETL-RUA universities

Prof. Bhattacharyya

(WVU, ChE)

Prof. Turton

(WVU, ChE)

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AVESTAR R&D Program

• Dynamic Modeling/Simulation

– High-fidelity dynamic models

• Gasification/ROMs (Turton/Bhattacharyya/

Kasule, WVU)

• CO2 capture (Bhattacharyya/Modekurti, WVU)

– Load following and ramp rate

• (Bhattacharyya, WVU); (Mahapatra, URS)

• Advanced Process Control/Sensors

– Advanced regulatory/coordinated control

• (Mahapatra, URS)

– Model predictive control (MPC)

• (Bhattacharyya/Jones, WVU); (Mahapatra, URS)

– Optimal sensor placement

• (Bhattacharyya/Paul, WVU)

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19

AVESTAR Center Future Directions for Virtual Energy Simulation

• Clean Energy Plants

– Derivative versions of IGCC with CO2 Capture

• Air Separation, Gasification, CO2 Capture

• Generic OTS/ITS for Acid Gas Removal (AGR – H2S/CO2) and

Sulfur Recovery Unit (SRU – Claus)*

– Natural Gas Combined Cycle (NGCC) with CO2 Capture**

– Supercritical Pulverized Coal (SCPC) with CO2 Capture*

• U.S. DOE Carbon Capture Simulation Initiative

– Solid sorbent post-combustion capture

– Virtual Carbon Capture Center

• Carbon Capture, Utilization, and Storage (CCUS)

– CO2 Pipeline/Transport, CO2 Utilization, CO2 Injection

• Shale Gas Processing Facilities

• Modern Power Grid

– Energy Plants, Variable Generators, Energy Storage

* - Project is planned; ** - Project is underway

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AVESTARTM Center

Concluding Remarks

• Increasing demand for clean, affordable, and secure energy

requires diversified portfolio of power generation plants

• Clean energy plants with CCUS require operation and

control of large, highly-integrated, power + process systems

• Modern grid requirements increase need for load-following

and faster startups/ramp rates

• Changing demographics and rapidly evolving technologies

necessitate training the next generation of engineering and

operations professionals

• High-fidelity dynamic simulators with OTSs and 3D virtual

ITSs are well suited for training, education, and R&D

• AVESTAR Center brings together simulation technology,

energy experts, and innovation to address challenges to

achieving the operational excellence of clean energy plants

21

Thank You / Questions?

For more information on AVESTAR’s simulators, facilities, training,

education, and R&D, please visit us at www.netl.doe.gov/avestar

or contact us at [email protected].

Disclaimer

"This report was prepared as an account of work sponsored by an agency of the United States

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employees, makes any warranty, express or implied, or assumes any legal liability or

responsibility for the accuracy, completeness, or usefulness of any information, apparatus,

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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."