Resilient decision making in steam network investments

Steam is a key energy vector for industrial sites, used for process heating, direct injection and stripping, tracing and cogeneration of mechanical power. Steam networks transport steam from producers to consumers and across different pressure levels. The steam production equipments (boilers, cogeneration units and heat exchangers) should be dimensioned to always supply key consumers as well as to deal with extreme demand caused by exceptional events such as unit startups or extreme weather. An important issue to be dealt with is that of unexpected boiler shutdowns, which can take significant amounts of time to bring back online. In cases where demand surpasses the available production of steam, load shedding is necessary in order to keep the network operable. A penalty cost can be associated to load shedding. A well dimensioned steam network is one which is resilient to such events, being able to overcome extreme demand and unexpected boiler shutdowns at minimum cost. This paper proposes a methodology for evaluating the operability of a steam network when facing unexpected boiler shutdowns. A Monte-Carlo simulation is carried out on a multi-period steam network problem, randomly shutting down boilers according to their failure properties (probability of failure and duration of failure). The aim of this method is to evaluate how resilient a steam network is to boiler shutdowns. The Monte-Carlo simulation is applied to a steam network model built using a Mixed Integer Linear Programming (MILP) formulation, whose objective function is to minimise the operational costs of the steam network and therefore also to minimise the penalty costs associated to load shedding. A case study based on anonymised industrial data is used to demonstrate the method. Two investment propositions are evaluated and compared using the proposed method

Numerical Simulation of the Accidental Transient of an Industrial Steam Boiler

Numerical simulation allows a better understanding of thermal-hydraulic phenomena that can take place in thermal installations. It is a capital contribution, especially in accident situations. The code RELAP5/Mod3.2 makes it possible to predict the thermal-hydraulic behavior of these installations during the normal and accidental operations. The present chapter focuses on accidental transient modeling and simulation of an industrial steam boiler by the code RELAP5/Mod3.2. This steam boiler is radiant type, high power, natural circulation, and a single drum. The model of the boiler developed for the RELAP5/Mod3.2 code encompasses the entire installation. The control loop of the water level in the steam drum and the superheated steam temperature are also included in the model. The qualification process of the steam boiler model is based on the steam boiler operation data under steady-state operating conditions. The comparative study shows that the theoretical results of the code RELAP5 are in good agreement with the operating data of the installation. To evaluate the behavior and response of the boiler in accident situations, the loss of feedwater following pump power loss, with and without protective operations, was simulated

INVESTIGATING THE EFFECT OF COIL PLATES ON THE PERFORMANCE OF FIRE TUBE STEAM PACKAGED BOILER USING SIMULATION SOFTWARE

In recent years, the study of increasing the heat transfer rate in a boiler had been conducted widely. Boiler is a type of heat exchangers which can be categorized as; Fire-tube boiler and Water-tube boiler. The project was entitled as "Investigating the effect of coil plates on the performance of Fire-tube steam packaged boiler using the simulation software

Perancangan Boiler dengan Memanfaatkan Sampah Kering untuk Bahan Bakar Pltu Mini 3 Kw Stt-pln

Boiler is a heat exchanger that serves to evaporate boiler feed water to produce dry steam to drive the turbines in order to produce electricity. The fuels used in this study are dry wastes such as paper, plastic, and wood. The process of designing this boiler is carried out so that the use of diesel to generate steam on energy conversion practicum/experiment in STT-PLN is no longer needed. Instead, they can use dry waste as fuel to produce steam which later will drive the turbines. The residue of burning waste process in the form of ashes is approximately 0.053% of the weight or volume of dry waste before burnt. The calculation conducted on this works is to determine the design of evaporator and economizer pipe. The calculation is also adjusted to the generated steam needed in order to spin the turbines. The pressure produced from this boiler design should be 2.9 bar and for the amount of steam was 21 kg / hour. As a result, the calculation of evaporator surface area is 8,83 m2, result simulation HTRI 8.95m2 with 88 pipes and 1500 mm for each pipe, while the heated surface area for economizer is 0,46 m2 result simulation HTRI 0,45 m2 with 18 pipes and 400 mm long for each pipe

Simulation of Combustion and Thermal Flow inside an Industrial Boiler

Industrial boilers that produce steam or electric power represent a large capital investment as well as a crucial facility for overall plant operations. In real applications, the operation of the superheater for producing high-pressure, high-temperature steam may result in problems frequently caused by ruptured superheater tubes. To make the boiler more efficient, less emission and less prone to tube rupture problems, it is important to understand the combustion and thermal flow behaviors inside the boiler. This study performs a detailed simulation of combustion and thermal flow behaviors inside an industrial boiler. The simulations are conducted using the commercial CFD package FLUENT. The 3-D Navier-Stokes equations and five species transport equations are solved with the eddy-breakup combustion model. Calculation of NOx is performed after obtaining a converged flow, thermal and combustion solution. The results provide insight into the detailed thermal-flow and combustion in the boiler and showing possible reasons for superheater ruptur

Steam storage systems for flexible biomass CHP plants - Evaluation and initial model based calculation

The file attached to this record is the author's final peer reviewed version. The Publisher's final version can be found by following the DOI link.Within the present study a novel concept for the demand-oriented power generation of a solid-biomass fueled combined heat and power (CHP) plant is investigated. The integration of a steam storage system into the plants process enables a decoupling of the steam (boiler) and the power generation (steam turbine). By buffering the steam, the power output of the turbine can be adjusted without changing the rated thermal capacity of the plant. Various available storage systems are selected and comparatively evaluated applying the adapted analytic hierarchy process (AHP). The technology assessment revealed that the combination of a steam accumulator and solid concrete storage represents the best suiting option. An initial model based simulation study is performed to identify the fundamental behaviour of this system, integrated in a biomass CHP plant. The operation principle is has proved their technical feasibility and seems to be applicable at a commercial scale. According to the modelling results flexible short term power generation in a time range of up to fifteen minutes is applicable. A load-range of almost the plants rated capacity can be achieved

Optimal operations and resilient investments in steam networks

Steam is a key energy vector for industrial sites, most commonly used for process heating and cooling, cogeneration of heat and mechanical power as a motive fluid or for stripping. Steam networks are used to carry steam from producers to consumers and between pressure levels through letdowns and steam turbines. The steam producers (boilers, heat and power cogeneration units, heat exchangers, chemical reactors) should be sized to supply the consumers at nominal operating conditions as well as peak demand. First, this paper proposes an Mixed Integer Linear Programing formulation to optimize the operations of steam networks in normal operating conditions and exceptional demand (when operating reserves fall to zero), through the introduction of load shedding. Optimization of investments based on operational and investment costs are included in the formulation. Though rare, boiler failures can have a heavy impact on steam network operations and costs, leading to undercapacity and unit shutdowns. A method is therefore proposed to simulate steam network operations when facing boiler failures. Key performance indicators are introduced to quantify the network’s resilience. The proposed methods are applied and demonstrated in an industrial case study using industrial data. The results indicate the importance of oversizing key steam producing equipments and the value of industrial symbiosis to increase industrial site resilience

Modeling and supervisory control design for a combined cycle power plant

The traditional control strategy based on PID controllers may be unsatisfactory when dealing with processes with large time delay and constraints. This paper presents a supervisory model based constrained predictive controller (MPC) for a combined cycle power plant (CCPP). First, a non-linear dynamic model of CCPP using the laws of physics was proposed. Then, the supervisory control using the linear constrained MPC method was designed to tune the performance of the PID controllers by including output constraints and manipulating the set points. This scheme showed excellent tracking and disturbance rejection results and improved performance compared with a stand-alone PID controller’s scheme

Dynamic modelling, validation and analysis of coal-fired subcritical power plant

Coal-fired power plants are the main source of global electricity. As environmental regulations tighten, there is need to improve the design, operation and control of existing or new built coal-fired power plants. Modelling and simulation is identified as an economic, safe and reliable approach to reach this objective. In this study, a detailed dynamic model of a 500 MWe coal-fired subcritical power plant was developed using gPROMS based on first principles. Model validations were performed against actual plant measurements and the relative error was less than 5%. The model is able to predict plant performance reasonably from 70% load level to full load. Our analysis showed that implementing load changes through ramping introduces less process disturbances than step change. The model can be useful for providing operator training and for process troubleshooting among others

Steady state simulation and exergy analysis of supercritical coal-fired power plant with CO₂ capture

Integrating a power plant with CO₂ capture incurs serious efficiency and energy penalty due to use of energy for solvent regeneration in the capture process. Reducing the exergy destruction and losses associated with the power plant systems can improve the rational efficiency of the system and thereby reducing energy penalties. This paper presents steady state simulation and exergy analysis of supercritical coal-fired power plant (SCPP) integrated with post-combustion CO₂ capture (PCC). The simulation was validated by comparing the results with a greenfield design case study based on a 550 MWe SCPP unit. The analyses show that the once-through boiler exhibits the highest exergy destruction but also has a limited influence on fuel-saving potentials of the system. The turbine subsystems show lower exergy destruction compared to the boiler subsystem but more significance in fuel-saving potentials of the system. Four cases of the integrated SCPP-CO2 capture configuration was considered for reducing thermodynamic irreversibilities in the system by reducing the driving forces responsible for the CO₂ capture process: conventional process, absorber intercooling (AIC), split-flow (SF), and a combination of absorber intercooling and split-flow (AIC + SF). The AIC + SF configuration shows the most significant reduction in exergy destruction when compared to the SCPP system with conventional CO₂ capture. This study shows that improvement in turbine performance design and the driving forces responsible for CO₂ capture (without compromising cost) can help improve the rational efficiency of the integrated system