ESI Zitney

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Advanced Process and Dynamic Systems R&D

for Energy and the EnvironmentStephen E. Zitney, Ph.D.Director, Collaboratory for Process & Dynamic Systems Research

Energy SystemsInitiative (ESI)

Computer-AidedProcessDecision-making(CAPD)

Carnegie MellonUniversity

Pittsburgh, PA

March 6, 2011


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NETL Regional University AllianceProcess & Dynamic Systems Research

Combines NETLs fossil energyexpertise with the broad

capabilities of five nationally

recognized, regional universities:

CMU, PSU, Pitt, VT, and WVU

Promotes applied R&D on thedesign, optimization, operation,

and control of advanced energy

systems with carbon capture

Accelerates deployment ofinnovative process simulation-

based solutions for energy

and the environment


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Process & Dynamic Systems Research

Advanced ProcessEngineering

Co-Simulator (APECS)

Advanced Virtual EnergySimulation Training And

Research (AVESTARTM)Center

Carbon Capture SimulationInitiative (CCSI)

APECS


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Process/CFD co-simulation CAPE-OPEN software standardANSYS Engineering Knowledge

ManagerTM (EKMTM)

ANSYSDesignXplorerTM Reduced order models (ROMs) Hybrid solution strategies Equipment design optimization Remote/parallel CFD execution CFD viewer for 2-3D analysis Optimization of plant performance

wrt complex thermal and fluid flow

Advanced Process Engineering Co-Simulator (APECS)High-Fidelity Design and Optimization of Energy Plants

2-3D

ANSYS Engineering Knowledge Manager (EKM)

Process Simulator

CO

APECS Integration Controller(CAPE-OPEN Interface )

Configuration

Wizard

Reduced

Order Model

CO

FLUENT CFD

CO

Configuration

Wizard

Custom

Device Model

CO

Configuration

Wizard

CFD Viewer

R&D100 and FLC Awards2004 R&D100 Award (APECS)2007, 2006 FLC Tech Transfer Awards (APECS)2008 R&D100 Award (APECS with EKM)2009 R&D100 Award (VE-PSI)2010, 2009 FLC Tech Transfer Awards (VE-PSI)

Recent PublicationZitney, S.E., Process/Equipment Co-Simulation forDesign and Analysis of Advanced Energy Systems,

Computers & Chemical Engineering, 34(9), 1532-1542(2010).


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APECS v2.0

Support for FLUENT

v13.0 and EKMTM

v13.0 Enhanced support for multiphase flow and combustion

PDF-based chemical reaction models for combustionAdditional DPM injections for entrained-flow gasification Dense DPM for transport gasifiers and chemical looping reactors Time-averaged ROMs from transient E-E CFD models

ROM Builder with ANSYS DesignXplorerTM v13.0Additional data sampling (DoE) approaches

Central Composite Design Optimal Space-Filling Design

Additional responsesurface methods Full 2nd-Order Polynomials Kriging Non-Parametric Regression Neural Network

TransportGasifier


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APECS Reduced Order ModelingMultizonal Gasification ROMs

Analyze 3-D CFD results todetermine equivalent reactor

networks (ERNs) for gasifiers

Account for multiphase floweffects

Identify dominant flowcharacteristics

Add detailed reaction kineticsand solve using CHEMKIN-PRO

Deliver gasifier ERNs as CAPE-OPEN compliant ROMs for use

in APECS Multizonal Gasifier ROMs for APECS


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APECS Application Projects at ALSTOM Power

Oxy-Combustion 18 MWth Boiler Simulation Facility (BSF) BSF island (gas side only) with flue gas recycle (FGR) FLUENT 3D CFD boiler with pollutant species (NOx, SOx)

exposed to Aspen Plus via CAPE-OPEN parameters

Characterize impact of various FGR and cleanup scenarioson pollutant emissions for candidate BSF configurations

IGCC with CO2 Capture 556 MWe IGCC simulated in Aspen Plus FLUENT CFD models

Single-stage, downward-fired, coal-fed,entrained-flow gasifier

Radiant syngas cooler (RSC) Transfer multi-dimensional boundary conditions Analyze integration of gasifier and RSC Optimize heat integration with overall plant

Chemical Looping Combustion APECS co-simulation of 65 kWth pilot-scale facility FLUENT 3DCFD/ROMs for solid fuel and air reactors Dense, multiphase flow using E-E solution

NOx

and

SOx

ALSTOM: Oxy-Combustion

ALSTOM: IGCC with CO2 Capture

RSC

RSCGasifier

ALSTOM: Chemical Looping Combustion


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Coal

Slurry

& O2

Coal

Slurry

& O2

Coal

Slurry &

Syngas

Recycle

APECS Application Polygeneration PlantPower and Hydrogen Production with CO2Capture

Process SimulationAspen Plus steady-stateAll major plant sections Over 250 unit ops

APECS Co-Simulation of Polygeneration Plant

GasTurbine

Combustor

Gasifier

- Gas Turbine Combustor FLUENT 3D/ROM Accurate calculation of GT inlet T Embedded in design spec loop to

determine power/H2 production

Optimizedcooling tominimize NOx

CFD Simulations-Entrained-flow Gasifier

FLUENT 3D/ROM Accurate calculation of

syngas composition

Embedded in syngasrecycle loop

Optimized flow ofcoal slurry andsyngas recycleto 2nd stage

Fuel*

Air

Premixin

(B

(C

(A

Cooling bottom

Cooling top

Cooling dump


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Virtual Power Plant Co-SimulationAPECS/VE-Suite Integration with VE-PSI

Using VE-PSI to overlay CFD results on 3D CAD forHRSG from APECS co-simulation of IGCC plant

VE-Suite 3D immersive, virtual plant

software environment

Display of process simulation,CFD, and CAD data

Desktop to multi-wall caves VE-PSI v1.0

Steady-state simulationAspen Plus, APECS process/

equipment co-simulations

VE-PSI v2.0 Dynamic simulationAspen Plus Dynamics, DYNSIM Immersive training systems

NETL CollaboratorsAmes Lab, Iowa State University

R&D100 and FLC Awards2009 R&D100 Award (VE-PSI v1.0)2010 FLC Tech Transfer Awards (VE-PSI v1.0)Recent ReferenceS.E. Zitney, Virtual Engineering for the Designand Operation of Advanced Energy Plants,

Presented at Virtual Engineering 2009, October27-28, Ames, IA (2009).


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AVESTARTMCenter atAdvanced Virtual Energy

Simulation Training And Research

R&D, training, and education for the operationand control of advanced energy systems with

CO2 capture and storage (CCS)

Real-time dynamic simulators with OperatorTraining System (OTS) capabilities

3D virtual Immersive Training Systems (ITS) IGCC plant with CO2 capture

Deployment: OTS:3/2011; ITS:7/2011 Major Project Partners

Industry Collaborators

Benefits

OTS for normal and faulted operations aswell as plant start-up, shutdown, and load

following

ITS for added dimension of plant realism OTS/ITS for training both control room and

plant field operators, promoting teamwork

Work force development in IGCC plantand CO2 capture operations

Advanced R&Din high-fidelity

dynamics,

model predictive

control, sensors,3D virtual

simulation, and

more


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IGCC Dynamic Simulator/OTS

Capabilities and Features

IGCC simulator scope First-of-a-kind, combined

Gasification with CO2 capture

and Combined cycle simulators

20 major plant areas plus electrical Fuels: Coal, Biomass, Petcoke

Model fidelity High fidelity models for key plant

areas (e.g., gasifier, AGR)

Capture major transients Model performance

Slow (0.5X), real-time, fast (3X) Multiple dynamic engines running

in parallel

Full-scope OTS Operator training HMI Normal operations Start-ups (cold, warm, hot),

shutdown (ESD), load changes Faulted operations

200 process malfunctions 30 major malfunctions or

accident investigations (ITS)

Instructor capabilities Scenarios, trending, snapshots

200 remote functions (ITS) Controls

DCS control emulation


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IGCC Dynamic Simulator/OTSSoftware Invensys Operations Management

DynsimTM Gasification and CO2 capture

through gas turbine

Process controls and ESD logic Dynsim PowerTM

Steam cycle InTouchTM

Human machine interface (HMI) Look and feel of plant DCS

operator interface

EYESim Virtual engines for ITS

Sim4Me Executive for integration of

dynamic engines

Distribution of engines acrossCPUs for real-time performance

InTouchTM

HMI

Sim4Me

DynSimTM

Process

Models

DynSimTM

Based

Controls

EYESim

Virtual

Engines


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IGCC Immersive Training System/ITSCombined Control Room and Plant Training

Real-time, 3D, immersive, interactivevirtual environment for training plant

engineers and outside field operators

Executive software provides seamlessintegration, synchronization, and

interoperability of ITS and OTS

ITS software components Plant-wide IGCC 3D photorealistic

visualization model

Virtual reality (VR) dynamic engines 3D real-time interactions and content

Realistic response to field operatoractions via hand valves, switches, etc.

Collision geometry, popup trends, andtransparent equipment objects

Benefits Enables full plant crew training and

enhances communication

Offers more realistic training environment (Courtesy of Invensys Operations Management)


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IGCC Immersive Training System/ITSCapabilities and Features

3D Virtual Plant Model 3D computer-aided design

(CAD)

3D stereoscopic visualizationmodel

Plant photographs forphotorealism

(Courtesy of Invensys Operations Management)

3D Immersive InteractionAvatar represents field operator Navigation using game pad Single operator

3D visor with head tracking Multiple operators

Projector with 3D glasses



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IGCC Immersive Training System/ITSCapabilities and Features


3D Real-time Content/Interactions Realistic response to operator actions Remote field functions

e.g., hand valves, pump switches Collision geometry and sound Popup trends (variables vs. time) Transparent equipment objects

e.g., tank levels Highlighted virtual content/scenarios

Gasifiero

Hot spots, plugging CO2 captureo Distillation column operation

for CO2 absorber

Power generationo Gas turbine combustion modes


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OTS/ITS Solution and InfrastructureSoftware and Hardware Integration

Software integration Real-time executive Dynamic simulator/OTS HMI displays Virtual reality (VR)/ITS

Hardware integration Local area network OTS/HMI

8 operator computers 20 dynamic engines

ITS 2 computers 2 virtual engines

Instructor station 2 computers

Engineering station 2 computers Operator Training System (OTS)

Control Room at NETLImmersive Training System (ITS)3D Virtual Plant Room at NETL


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AVESTARTM CenterIGCC Training Program

Training Courses IGCC Operations; Gasification, Combined

Cycle, and CO2 Capture Operations

Target Audience Electric power providers

Research/process engineers, plant engineers,control room and field operators, shift supervisors

Engineering & construction firms Equipment vendors

Gasifier, CO2 capture, and turbine suppliers Research, consulting, and training entities U.S. DOE national laboratories Universities

Students, professors, chemical engineers, control engineers Others interested in learning more about IGCC plant operations and control


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CCSI: Plant Operations and ControlGoals and Objectives

Develop and apply dynamic simulation to pulverized coal (PC)plants withpost- and oxy-combustion CO2capture systems

Improve operational flexibility, controllability, and efficiency Optimize transient operations including disturbances, startup,

shutdown, fuel switching, and load following

Enhance malfunction, safety, andenvironmentalanalysis

Provide dynamicsimulator-based trainingfor design, process, and control engineers,

as well as plant operators

Learn-by-operating to accelerateCO2 capture technology scale-up,

risk reduction, and deployment


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UQ/RiskAnalysis

Learn-by-Operating to Accelerate CO2 Capture

Scale-up, Risk Reduction, and Deployment

Learn-by-Operating

CO2 Capture &Compression

(100 MW)

CO2 Capture &Compression(Full-Scale)

Learn-by-Operating

Learn-by-Operating

Training andTechnology

Transfer

CO2 Capture &Compression

(1 MW)

Full-Scale PC PlantDynamic Simulation

Energy

Industry

Dynamic Simulator/OTSVirtual Plant/ITS

Scale-Up &Risk Reduction

Scale-Up &Risk Reduction

AcceleratedDeployment

Process

Design

DeviceScale

BasicData

UQ/RiskAnalysis



Operability,Controllability,and Safety

Design,Economic, andEnvironmental

Process

Design

DeviceScale

BasicData


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CCSI: Plant Operations and ControlIndustrial Challenge Problems

BaselinePulverized Coal

(PC) Plant

Air QualityControls

(AQC)

SCR(NOx Control)

FGD - Flue GasDesulfurization

Baghouse(Particulates)

CO2Capture

CO2Compression

Solid Sorbent

1/100/Full MW

Liquid Solvent1/100/Full MW

H2O/CO2 Sep.1/Full MW

Multizonal

Air SeparationUnit (ASU)

Air-FiredPC Boiler

O2-FiredPC Boiler

CFD D-ROMs

1D PDE

O2 TransportMembrane

CyrogenicDistillation

Rate-based

CFD D-ROMs

1D PDE

Solid SorbentICP A

Liquid SolventICP B

Oxy-Combustion

ICP C

Industrial Challenge Problems

Multizonal

CFD D-ROMs

1D PDE


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CCSI Dynamic Simulator Facilities and Infrastructure

Leverage Center

OTS/ITS Facilities NETL in Morgantown, WV West Virginia University (WVU)

National Research Center for

Coal & Energy (NRCCE)

Hardware Infrastructure Local Area Network Dynamic Simulator/OTS

8 operator computers Instructor Station

2 computers

Simulation Servers 2 computers

Engineering Stations 2 computers

Virtual Plant/ITS 2 computers/2 virtual engines Operator Training System (OTS)Control Room at NETL Immersive Training System (ITS)3D Virtual Plant Room at NETL


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Process & Dynamic Systems Research Team

Dr. Stephen E. Zitney (NETL)

Eric Liese: Dynamics, Combined Cycle, Turbines Terry Jordan: VE-Suite, VE-PSI, Virtual Plant Simulation

Prof. Richard Turton (WVU) Job Kasule (PhD): Gasification modeling and dynamics Dustin Jones (PhD): IGCC, ASU/GT Integration, Dynamics, Control

Prof. Debangsu Bhattacharyya (WVU) Prokash Paul (PhD): IGCC Dynamics, Sensor Placement TBD (Post-Doc): CO

2

Capture Dynamics and Control Prof. Larry Biegler (CMU)

Dr. Yidong Lang (Researcher): APECS ROMs, Optimization Prof. Mao (Pitt)

Iheanyi Umez-Eronini (PhD): Optimal Design of PSA Systems URS Corp.

Dr. Priyam Mahapatra: IGCC/ASU Dynamics, Model Predictive Control Dr. Jinliang Ma: APECS Energy Applications

Fossil Consulting Services Graham Provost: IGCC, Operating Training Systems (OTS) Mike McClintock: Combined Cycles, PC Plants, OTS Mark Collins: IGCC, PC Plants, OTS

Ames Laboratory Dr. Doug McCorkle: VE-Suite, VE-PSI, Virtual Plant Simulation

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