Towards the Integration of APECS and VE-Suite for Virtual

Towards the Integration of APECS and VE-Suite for Virtual Power Plant Co-Simulation

Stephen E. Zitney1, Doug McCorkle2, Chongguan Yang3, Terry Jordan1,

Dave Swensen3, Mark Bryden2

1Collaboratory for Process & Dynamic Systems Research,

National Energy Technology Laboratory, Morgantown, WV 26507-0880 2Iowa State University, Ames, Iowa 50011-2161

3Reaction Engineering International, Salt Lake City, UT 84101

Process modeling and simulation tools are widely used for the design and operation of advanced power generation systems. These tools enable engineers to solve the critical process systems engineering problems that arise throughout the lifecycle of a power plant, such as designing a new process, troubleshooting a process unit or optimizing operations of the full process. To analyze the impact of complex thermal and fluid flow phenomena on overall power plant performance, the Department of Energy’s (DOE) National Energy Technology Laboratory (NETL) has developed the Advanced Process Engineering Co-Simulator (APECS). The APECS system is an integrated software suite that combines process simulation (e.g., Aspen Plus) and high-fidelity equipment simulations such as those based on computational fluid dynamics (CFD), together with advanced analysis capabilities including case studies, sensitivity analysis, stochastic simulation for risk/uncertainty analysis, and multi-objective optimization. In this paper we discuss the initial phases of the integration of the APECS system with the immersive and interactive virtual engineering software, VE-Suite, developed at Iowa State University and Ames Laboratory. VE-Suite uses the ActiveX (OLE Automation) controls in the Aspen Plus process simulator wrapped by the CASI library developed by Reaction Engineering International to run process/CFD co-simulations and query for results. This integration represents a necessary step in the development of virtual power plant co-simulations that will ultimately reduce the time, cost, and technical risk of developing advanced power generation systems.

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DOE/NETL-IR-2007-139

Towards the Integration of APECS and VE-Suite for Virtual Power Plant Co-Simulation

Stephen E. Zitney1, Doug McCorkle2,

Chongguan Yang3, Terry Jordan1,Dave Swensen3, Mark Bryden2

presented at

VE2007Iowa State University

Ames, IA May 1-2, 2007

1Collaboratory for Process & Dynamic Systems Research, National Energy Technology Laboratory, Morgantown, WV 26507-0880

2Iowa State University, Ames, Iowa 50011-21613Reaction Engineering International, Salt Lake City, UT 84101

cwright

Text Box

DOE/NETL-IR-2007-139

Zitney/NETL/VE2007, May 1-2, 2007

Outline of Presentation

• Introduction− NETL/Office of R&D/Process

& Dynamic Systems Research• Advanced Process Engineering

Co-Simulator (APECS) − Brief Overview and History− Process/CFD Software

Components and Features• APECS Energy Applications

− Fuel Cell Auxiliary Power Unit− FutureGen Power Plant

• Virtual Power Plant Co-Simulation− Goals/Objectives

• Concluding Remarks FutureGen Plant

NETL Onsite R&D

APECS Co-Simulation


National Energy Technology Laboratory• Only DOE national lab dedicated to fossil energy

−Fossil fuels provide 85% of U.S. energy supply• One lab, five locations, one management structure• 1,200 Federal and support-contractor employees• NETL’s Fossil Energy Mission

− Implement an R&D and demonstration program to resolve the environmental, supply, and reliability constraints of producing and using fossil energy

Morgantown, WV Pittsburgh, PA Tulsa, Oklahoma Fairbanks, AlaskaAlbany, Oregon


Accomplishing Our Mission

• Support energy policy development− Clean Coal Power (IGCC), Hydrogen− Clear Skies, Climate Change− FutureGen

• Implement and manage extramural RD&D− Over 1,800 research activities in U.S.

and more than 40 foreign countries− Total award value over $9 billion− Private sector cost-sharing over $5 billion

• Conduct onsite research− Approximately 550 engineers and scientists− Over 150 PhDs− Office of Research and Development


Focus Areas• Energy System

Dynamics• Geological &

Environmental Science• Materials Science• Computational & Basic

Science− Computational Chemistry− Multiphase Flow− Model Validation− Device-Scale Simulation− Process & Dynamic Systems

Office of Research and DevelopmentCreates and Transfers Innovative

Fossil Energy Technologies


Process & Dynamic Systems ResearchGoals and Objectives

• Research and develop innovative computational models, methods, and tools

• Apply to advanced fossil energy (FE) systems− IGCC, FutureGen− Polygeneration

• Establish strong R&D collaborations

• Transfer technology to process and energy industries NETL Collaboratory for

Process & Dynamic Systems Research


Process & Dynamic Systems ResearchFocus Areas

• High-Fidelity Systems− Advanced process engineering

co-simulation (APECS)− Virtual power plant simulation

• Dynamic Systems− Dynamic simulation− Process control− Real-time applications

• Systems Optimization− Plant-wide optimization− Stochastic simulation for

uncertainty/risk analysis− Cost estimation

Process Optimization

P1

Time Hours

STR

EAM

S("W

ET-C

OAL

").F

mcR

("C

OAL

") lb

/hr

STR

EAM

S("N

ETW

OR

K").W

hp

STR

EAM

S("W

-GR

OSS

").W

hp

0.0 2.0 4.0 6.0 8.0

5050

00.0

5250

00.0

5450

00.0

-450

000.

0-440

000.

0-430

000.

0-420

000.

0-410

000.

0-400

000.

0

-638

000.

0-6

3600

0.0

-634

000.

0-6

3200

0.0

-630

000.

0

IGCC Dynamic Simulation

APECS FutureGen

TrGTrG


Advanced Process Engineering Co-Simulator (APECS)

• Combines process simulationwith computational fluid dynamics (CFD)

• Provides engineers with a better understanding of the fluid dynamics impacting overall plant performance

• Provides high-fidelity process co-simulation essential for advanced power plant design and optimization

APECS-based FutureGen Plant Simulation

Gas TurbineCombustor

Gasifier

HRSG

Gas TurbineCombustor

Gasifier

HRSG

Transport Gasifier


Advanced Process Engineering Co-SimulatorBrief History

• Phase-1 APECS R&D Project Start (2000)• Steady-State Co-Simulation Prototype (2001)• Commercial Release by Ansys/Fluent (2003)• First Commercial Success (2004) • R&D 100 Award (2004)• APECS FutureGen Demo at Supercomputing (2004)• 2nd Annual CAPE-OPEN Meeting at NETL (2005)• Phase-2 APECS R&D Project Start (2005)• US/APECS – UK/VPDM Collaboration (2005)• APECS/VE-Suite Integration Prototype (2006)• US Federal Technology Transfer Awards (2006/7)


Advanced Process Engineering Co-Simulator (APECS) for Virtual Engineering (VE)

Transport Gasifier

Gas TurbineCombustorHRSG

EntrainedFlow

Gasifier

Transport Gasifier

Gas TurbineCombustorHRSG

EntrainedFlow

Gasifier

• Process Simulators− CAPE-OPEN compliant− Aspen Plus®, HYSYS®, gPROMS®

• Equipment Models and Database− CAPE-OPEN compliant− CFD: FLUENT®

− Custom Models: e.g., INDVU− ROMs: LR, NN, PCA

• Integration Controller− CAPE-OPEN v1.0 Interfaces− Unit Ops, Phys Props, Reactions

• Configuration Wizards− FLUENT®, Custom Model, and ROM

• Solution/Analysis Tools− Hybrid: Speed (ROM), Accuracy (CFD)− Stochastic, Optimization

• Distributed Execution− CAPE-OPEN COM/Corba Bridge− Windows/Linux, Serial/Parallel

• Virtual Engineering− CFD Viewer (2D), Paraview (3D)− VE-Suite

Advanced Process Engineering Co-Simulator (APECS)

APECS/VE-Suite

2-3D

Equipment Model Database

Aspen Plus Process Model CFD Viewer

CO

Integration Controller(CAPE-OPEN Interface )

Configuration Wizard

Reduced Order Model

CO

Nu ≅ a RebPrc

FLUENT CFD

CO


Custom Device Model

CO


2-3D

Equipment Model DatabaseEquipment Model Database

Aspen Plus Process ModelAspen Plus Process Model CFD ViewerCFD Viewer

CO


CO



Reduced Order Model

CO

Nu ≅ a RebPrc


Reduced Order Model

CO

Nu ≅ a RebPrc

Reduced Order Model

CO

Reduced Order Model

CO

Nu ≅ a RebPrc

FLUENT CFD

CO


FLUENT CFD

CO

FLUENT CFD

CO


Custom Device Model

CO


Custom Device Model

CO


Custom Device Model

CO

Custom Device Model

CO










• Concluding Remarks FutureGen Plant

NETL Onsite R&D

APECS Co-Simulation


APECS Power Generation Applications

• ALSTOM Conventional Steam Plant (250MWe) with 3D CFD Boiler

ThrottleSH Outlet Steam Turbine Extractions

CondenserDeaerator

Feedwater HeatersAir Preheater

Boiler

Volatile Feed StreamCoal Moisture Feed StreamVenturi Air Feed Stream

Tertiary Air Feed

Secondary Air Feed

Primary Air Feed

CFD Block


CondenserDeaerator


Boiler


Tertiary Air Feed

Secondary Air Feed

Primary Air Feed

CFD Block


CondenserDeaerator


Boiler


Tertiary Air Feed

Secondary Air Feed

Primary Air Feed

CFD Block

• Fuel Cell Auxiliary Power Unit (APU) with 3D CFD SOFC

• FutureGen Plant (250MWe) with 3D CFD Gasifier and 2D CFD Turbine Combustor

FC-AIR-A C-DEPLET

E-O2

AN-ANHTR

CAT-OUTA

DCOUT

Q

AN-OUT

CAT-OUT

QATR-CMB

PRODUCTS

PAIR

COLDPROD

R-FUEL

SULFUR

AN-IN

FC-AIR

ATR-AIR

WATER

H2ODUMP

H2ORECYCP-WATER

CP1

STEAM

AIRIN

WAPW

FUELIN

P-FUELIN

WFP

W

WWPW

CP3

CHILLOUT

Q

AN-IN-A ANODEIN2

AN1-AN2

AN-OUT-A

CAT-IN-F

AN-IN-F

CAT-I-F2

AN-IN-F2

FSPLIT

O2-SEP C-HTR COMBUSTAIR-HX

DESULF

FS PLIT

AIRSPLIT

FS PLIT

H2OSPLIT

H2OHX

AIRPUMP

FUELPUMP

H2OPUMP

CHILLER

ATR

INTREF

ANODE

DUPL

CAT-DUPL

DUPL

AN-DUPL

MULT

CAT-REDU

MULT

AN-REDU

AN-SEL

CAT-SEL

MULT

CAT-MULT

MULT

AN-MULTFC-HOLD

AN-SPLIT

AN-RECYC

0

0.2

0.4

0.6

0.8

1

1.2

0 5 10 15 20Current (A)

Voltage (V) Fuel Utilization

Power Density (W/cm2) System Efficiency (LHV)

• ALSTOM NGCC (250MWe ) with 3D CFD HRSG

Gas Turbine

LP Turbine

FWEconomizers

Air

Natural Gas

Once-Through Separator

IP Turbines

SH OutletSteam

LPEvaporator

LP Pump

LP Drum

HP PumpHP Turbine

Condenser

HPEvaporator

GT Exhaust Gas to HRSG

SH

RH

HPEconomizer

GTEconomizer

GT Cooler

Gas Turbine

LP Turbine

FWEconomizers

Air

Natural Gas


IP Turbines

SH OutletSteam

LPEvaporator

LP Pump

LP Drum

HP PumpHP Turbine

Condenser

HPEvaporator


SH

RH

HPEconomizer

GTEconomizer

GT Cooler

Gas Turbine

LP Turbine

FWEconomizers

Air

Natural Gas


IP Turbines

SH OutletSteam

LPEvaporator

LP Pump

LP Drum

HP PumpHP Turbine

Condenser

HPEvaporator


SH

RH

HPEconomizer

GTEconomizer

GT Cooler


APECS Application - Fuel Cell APU Systems

• Fuel cell systems are emerging as versatile energy solutions

• DOE-sponsored Solid state Energy Conversion Alliance

• Solid oxide fuel cells (SOFC)• Auxiliary power units (APU) for

transportation can reduce:− Diesel fuel

consumption

− Cost

− Pollutant emissions

SOFC Objectives• Power: 3-10 kW• Cost: $400/kW• Efficiency: 30-50%

(APU)

Stationary

Transportation Military

• Need to analyze fuel cell APU systems for low cost, high efficiency, and maximum integration


APECS Application - Fuel Cell APU System• Aspen Plus process model of

Auxiliary Power Unit (APU) • FLUENT 3D CFD model of

SECA solid oxide fuel cell• Optimize process efficiency

by varying CFD parameter (fuel cell current)

• Maximum system efficiency (LHV) of 45% at 18 amps

• Max. system power of 4.3 kW

FC-AIR-A C-DEPLET

E-O2

AN-ANHTR

CAT-OUTA

DCOUT

Q

AN-OUT

CAT-OUT

QATR-CMB

PRODUCTS

PAIR

COLDPROD

R-FUEL

SULFUR

AN-IN

FC-AIR

ATR-AIR

WATER

H2ODUMP

H2ORECYCP-WATER

CP1

STEAM

AIRIN

WAPW

FUELIN

P-FUELIN

WFP

W

WWPW

CP3

CHILLOUT

Q

AN-IN-A ANODEIN2

AN1-AN2

AN-OUT-A

CAT-IN-F

AN-IN-F

CAT-I-F2

AN-IN-F2

FSPLIT

O2-SEP C-HTR COMBUSTAIR-HX

DESULF

FSPLIT

AIRSPLIT

FSPLIT

H2OSPLIT

H2OHX

AIRPUMP

FUELPUMP

H2OPUMP

CHILLER

ATR

INTREF

ANODE

DUPL

CAT-DUPL

DUPL

AN-DUPL

MULT

CAT-REDU

MULT

AN-REDU

AN-SEL

CAT-SEL

MULT

CAT-MULT

MULT

AN-MULTFC-HOLD

AN-SPLIT

AN-RECYC

0

0.2

0.4

0.6

0.8

1

1.2

0 5 10 15 20Current (Amps)

Voltage (volts) Fuel UtilizationCurrent Density (A/m2) Power Density (W/cm2)System Efficiency (LHV)

Zitney, S.E., Prinkey, M.T., Shahnam, M., and Rogers, W.A. (2004), “Coupled CFD and Process Simulation of a Fuel Cell Auxiliary Power Unit,” In Proc. of the ASME Second International Conference on Fuel Cell Science, Engineering, and Technology, Eds. R. Shah and S.G. Kandlikar, Rochester NY, June 13-16, 2004, Paper 2490, pp. 339-345.

Current density for cathode

Temperature for anode


U.S. DOE FutureGen InitiativePathway to Zero Emissions

• 10-year, $1B DOE project • Commercial-scale, coal-fired,

gasification-based plant• Co-production of H2 and

electricity (275 MWe) • Sequester >90% CO2 with

potential for ~100% • Minimum 1-million tons/year

CO2 captured and sequestered• “Living R&D laboratory” for

cutting-edge technologies• FutureGen Alliance• On-line 2012

Coal-Fired IGCC

Refinery

CO2 Pipeline

Oil

Pip

elin

e Electricity

Hydrogen Pipeline

Enhanced Oil Recovery Geologic Sequestration

and / or

Coal-Fired IGCC

Refinery

CO2 Pipeline

Oil

Pip

elin

e Electricity

Hydrogen Pipeline


and / or

Geological Sequestration

CO2

Coal-fired IGCCCoal-Fired IGCC

Refinery

CO2 Pipeline

Oil

Pip

elin

e Electricity

Hydrogen Pipeline


and / or

Coal-Fired IGCC

Refinery

CO2 Pipeline

Oil

Pip

elin

e Electricity

Hydrogen Pipeline


and / or

Geological Sequestration

CO2

Coal-fired IGCC

Geological SequestrationGeological Sequestration

CO2

Coal-fired IGCC


FutureGen Power/Hydrogen Production Plant

• IGCC with CO2 capture and H2 generation− Air separation unit (ASU)

integrated with gas turbine− Entrained-flow, coal-slurry,

oxygen-blown gasifier− Water gas shift− Gas cleanup for

particulates, Cl2, and S2

− Selexol for CO2 capture with compression to liquid

− Pressure-swing adsorption (PSA) for generating H2

− GE 7FB gas turbine− Steam cycle with three

pressure levels and HRSGFutureGen Process Diagram

• IGCC plant with advanced technology modules and aggressive integration, performance, and environment goals


APECS Application - FutureGen Plant

• Process Simulation − Aspen Plus®

steady-state− All major plant

sections− Over 250 unit ops APECS Co-Simulation of FutureGen Power Plant

Gas Turbine Combustor

Gasifier

−Gas Turbine Combustor• FLUENT® 2D/3D/ROM • Accurate calculation of GT

inlet temperature• Embedded in design spec

loop to determine power/H2 production

• CFD Simulations−Entrained-Flow Gasifier

• FLUENT® 3D/ROM• Accurate calculation

of synthesis gas composition

• Embedded in syngasrecycle loop


FutureGen Process/CFD Co-Simulation Results• Gas turbine inlet temperature specification

of 1619.3 K is met when:− 43% of syngas is sent to GT combustor and

remainder goes to PSA unit for H2 production − Net equivalent power output from plant is

243.8 MW, corresponding to HHV thermal efficiency of 53%

Zitney, S.E., M.O. Osawe, L. Collins, E. Ferguson, D.G. Sloan, W.A. Fiveland, and J.M. Madsen, “Advanced Process Co-Simulation of the FutureGen Power Plant,” Proc. of the 31st International Technical Conference on Coal Utilization & Fuel Systems, May 21-25, Clearwater, FL (2006).

0.2390.290H2O

0.0200.020N2

0.0080.007Ar

0.0060.006H2S

0.0170.021CH4

0.1220.105CO2

0.2290.212H2

0.3590.339CO

FLUENTAspen Plus

Mole FractionsChemicalSpecies

Synthesis Gas Composition

Velocity vectors

Char Conversion• 1st Stage

100%• 2nd Stage

86%

O2 CO H2

Species mole fraction contoursat the center plane









• Concluding RemarksFutureGen Plant

NETL Onsite R&D

APECS Co-Simulation


Virtual Power Plant Co-SimulationIntegration of APECS and VE-Suite

• Goals− Reduce the time, cost, and technical risk to develop

high-efficiency, near zero-emission power generation systems, such as FutureGen

− Promote collaborative engineering and design, as well as communication of advanced power plant concepts to other key stakeholders

• Objectives− Deploy process/equipment co-simulations in a 3D,

immersive and interactive, virtual plant walkthrough environment

− Automate complex virtual engineering workflow across the plant lifecycle, from design to operations


Concluding Remarks

• APECS facilitates the effective integration, solution, and analysis of process/CFD co-simulations

• NETL is using APECS to optimize a wide variety of advanced power generation systems

• Virtual power plant simulation with APECS/VE-Suite offers opportunities for accelerating the development of future zero-emission power plants


Thank You

Questions?

• For additional information on the application of APECS to power generation applications, please contact:− Stephen E. Zitney, NETL

• EML: [email protected]• TEL: 304-285-1379

Documents

Towards the Integration of APECS and VE-Suite for Virtual