During start-up and shutdown procedures, the dynamic simulation models can reproduce the qualitative behavior of the real power plant but larger discrepancies between simulations and measurements were observed. AMPL (2021). Appl. GateCycle (2021). De Greef, J., Villani, K., Goethals, J., Van Belle, H., Van Caneghem, J., and Vandecasteele, C. (2013). After model validation with the reference start-up, faster start-ups, less fuel consumption, and less emission were identified, maintaining the thermal and mechanical stress, caused by higher ramp rates, within reasonably range. In the case of two-phase flow components (e.g., evaporator and condenser), the three variables are complemented by the void fraction. doi:10.1016/j.energy.2015.02.059. Energ. Energy 50, 194204. Volumes 44 (1), 70437048. doi:10.1016/j.fuel.2014.01.032. GTPRO: A Flexible, Interactive Computer Program for the Design and Optimization of Gas Turbine Power Systems. The developed model and its implemented controls are evaluated during a load change scenario from 100 to 22.7% (see Figure 10: Operational data and simulated results of the high-pressure and reheater circuits during load change scenario (source Starkloff et al., 2015)). The equation-oriented approach consists of solving the system of the equation as a whole using specifically developed numerical algorithms, like the well-known Newton Raphson algorithm or the Powell dogleg algorithm (Biegler et al., 1997). strm, K. J., and Bell, R. D. (2000). Dynamic Simulations of Fresnel Solar Power Plants. Bui, M., Gunawan, I., Verheyen, V., Feron, P., Meuleman, E., and Adeloju, S. (2014). Energy 149, 230249. Solar Energy 86 (5), 12081221. Available at: https://www.gams.com/ (Accessed May 5, 2021). Usually, the design and optimization of a process start with steady-state process modeling, where the system operates continuously at its design base-load. doi:10.1016/j.apenergy.2015.10.001, Bogale, W., and Vigan, F. (2014). 144, 250260. Determination of Start-Up Curves for a Boiler with Natural Circulation Based on the Analysis of Stress Distribution in Critical Pressure Components. 7, 695706. Richter, M., Mllenbruck, F., Starinsk, A., Oeljeklaus, G., and Grner, K. (2015). J. Eng. doi:10.1016/j.egypro.2014.01.137, Bongartz, D., Najman, J., and Mitsos, A. According to the same reference, the first steam cycle had an efficiency of only 1.6% while those built about 10years later reached an efficiency of about 15% thanks also to the adoption of regenerative feedwater preheaters. Int. Transient Simulation for Developing a Combined Solar thermal Power Plant. Res., 168186. Since most of todays commercial plant simulation software have this capability, the black-box approach has become very popular. Besides, the differences arise primarily from the different gas enthalpy calculations. doi:10.1016/b978-0-444-64235-6.50068-1, Elsido, C., Martelli, E., and Grossmann, I. E. (2020a). Despite the dynamic nature of the operation, the solid waste incinerator is almost not considered in the dynamic studies apart from a few exceptions such as the work of Alobaid et al. doi:10.1016/0098-1354(83)85024-8. Transient Simulation and Fatigue Evaluation of Fast Gas Turbine Startups and Shutdowns in a Combined Cycle Plant with an Innovative thermal Buffer Storage. Fuel 116, 672691. Thermodynamic Analysis on the Transient Cycling of Coal-Fired Power Plants: Simulation Study of a 660 MW Supercritical Unit. Analysis of the Dynamic Characteristics of a Combined-Cycle Power Plant. Investigation on the Dynamic Behaviour of a Parabolic Trough Power Plant during Strongly Cloudy Days. doi:10.1002/aic.690320114, Durn, M. D., Valds, M., Rovira, A., and Rincn, E. (2013). Management 90, 347363. The HRSG produces superheated steam, generating additional power in the steam turbine. Results of the dynamic simulations during start-up and ramps may be used to assess thermo-mechanical stresses on the most critical equipment units. Chem. doi:10.1016/j.apenergy.2011.01.015, Rakopoulos, D., Avagianos, I., Almpanidis, D., Nikolopoulos, N., and Grammelis, P. (2017). 9781108241625. TABLE 3. doi:10.1016/j.energy.2011.03.073. The ASPEN project led to the foundation of the well-known Aspen Tech company. doi:10.1016/j.apenergy.2016.10.058. Management 87, 12691280. Energ. Available at: https://it.mathworks.com/products/matlab.html (Accessed May 5, 2021). When transplanting the gas-solid fluidized bed technology to the offshore floating platform, the gas-solid flow characteristics in the bed will be affected by the rolling of the platform. 1990 ASME Cogen-Turbo (New Orleans: Louisiana). Nadir, M., Ghenaiet, A., and Carcasci, C. (2016). (2012) (in 2012, a state-of-the-art review on modeling and simulation of the thermal power plant), Alobaid et al. 162, 880891. Most of the software provides specialized component libraries for the time-dependent simulation, including the combined-cycle power plant, the coal-fired power plant, and the concentrated solar power plant. Prod. Despite the large number of hot/cold streams and technical design/operational constraints, the methodology provided very good solutions featuring cost-effective designs. Harvey, A., Larson, A., and Patel, S. (2020). Eng. (2016), proposed an improved multiperiod version of the sequential synthesis methodology employing a derivative-free algorithm to improve the HEN solution by optimizing the penalty levels of the HX matches (Gundersen et al., 1996), the heat recovery approach temperatures, and the utility sizes. doi:10.1016/s0005-1098(99)00171-5, Avagianos, I., Rakopoulos, D., Karellas, S., and Kakaras, E. (2020). Therm. Equation 3 indicates the objective function to be minimized (e.g., cost of electricity, heat rate, etc), Eq. Examples of conventional steam cycle-based power plants include coal-fired power plants (Speight, 2013), gas-steam turbine combined-cycles (Kehlhofer et al., 2009), and nuclear power plants (Rinzic, 2017) (either boiling water reactor or pressurized water reactor); examples of novel plant concepts include concentrated solar power plants (Peinado Gonzalo et al., 2019), integrated solar combined-cycles (Dersch et al., 2004), waste to energy plants (Bogale and Vigan, 2014), integrated gasification combined-cycles (Martelli et al., 2011), electricity/hydrogen/synfuels polygeneration plants (Larson et al., 2009), power plants with CO2 capture and storage (Spinelli et al., 2015) and all the cycles that are specifically designed for industrial processes (typically for combined heat and power applications or for heat recovery). (Spliethoff, 2010). Energ. Management 207, 112547. doi:10.1016/j.enconman.2020.112547, Barigozzi, G., Perdichizzi, A., and Ravelli, S. (2011). The usual practice for the design of steam cycles of conventional power plants (e.g., coal-fired power plants, combined cycles) consists of the following sequential procedure: 1) The structure of the cycle is defined (i.e., number of evaporation pressure levels, number of regenerators for feedwater preheating, number of reheating stages, etc.) 31 (4), 405417. Proced. Accurately compute thermodynamic performance; automatically create detailed, physical preliminary designs for all significant components and piping; automatically create cost and labor preliminary estimates with detailed breakdowns for your entire project; compute economic results, such as ROI and NPV, based on your energy prices and annual operating profile; provide over a hundred pages of detailed outputs comprising detailed heat balance diagrams, environmental impact, equipment specs, cost breakdowns, and economic performance. During the design phase of a power plant, off-design simulation codes are used to assess the performance of the cycle when operating at part-loads and/or site conditions (e.g, cooling water temperature, ambient temperature, fuel type) different from those considered in the design phase. For power and heat generation, two types of coals are generally used, namely lignite (brown coal) and bituminous (hard coal). doi:10.1016/j.apenergy.2015.01.065. Prog. Thermal Design and Optimization. Fuel 167, 135148. (2018b). 2) The thermodynamic steady-state simulation of the cycle at design conditions (full-load, nominal ambient/site conditions) is performed using an ad hoc software (either internally developed by the company/university, like GS (Consonni, 1983), or commercially available like Thermoflex/GT PRO/Steam Pro (Thermoflow, 2021), Aspen Tech (2021), Cycle Tempo (2021), Gate Cycle (2021) and Ebsilon Professional (2021) and setting the key design variables (steam pressures, steam temperatures, pinch temperature differences in the heat exchangers, etc.) Review papers that systematically analyze scientific publications on certain topics are very valuable. Although someone can consider steam cycles as an obsolete technology, the analysis of the literature has shown that steam cycles are still the object of research and development efforts to improve their efficiency, operational flexibility, and range of applicability (i.e., tailoring their design for novel concepts of power plants such as concentrated solar power plants, integrated solar combined-cycle, waste to energy plants, electricity/hydrogen/synfuels polygeneration plants). Combined Cycle Power Plants as Ideal Solution to Balance Grid FluctuationsFast Start-Up Capabilities, in Proc. The minimum load is mainly determined by the gas turbine, where stable combustion, as well as CO and NOx levels in compliance with emission regulations (country-specific regulation), should be conserved. Modelling and Dynamic Simulation of a Supercritical, Oxy Combustion Circulating Fluidized Bed Power Plant ConceptFiring Mode Switching Case. Renew. Numerical and Experimental Study of a Heat Recovery Steam Generator during Start-Up Procedure. Start-up Improvement of a Supplementary-Fired Large Combined-Cycle Power Plant. FIGURE 2. This section focuses on steam cycles which are widely adopted in the electric power industry, namely highly regenerative steam cycles for coal-fired power plants, and heat recovery steam cycles (also called bottoming cycles) for combined cycles. Program Features: Automated Design and Off-Design/Simulation. Aiche J. For these plants, computer-aided optimization approaches are essential to assess the performance and costs of the possible steam cycle configurations. The specific design is influenced by different factors, including coal composition and handling (effect on e.g., mills, burners, furnaces, and heat exchangers), local emission regulation (effect on e.g., flue gas cleaning devices), water/steam cycle (sup-critical, supercritical or ultra-supercritical steam parameters), plant configuration (natural, forced circulation or once-through), reheater temperature control (e.g., attemperators, tilting burners, flue gas dampers). Le Grange, W., Lee, H.-H., Lee, J.-C., Joo, Y.-J., Oh, M., and Lee, C.-H. (2018). 4. Given challenges for the electricity market with the continuing expansion of intermittent renewables, the operational flexibility including load changes, start-up procedures and minimal load limit is recent of interest to utilities operators. Convers. Energy 76, 891898. doi:10.1016/j.egypro.2014.03.159, Rossi, I., Sorce, A., and Traverso, A. Solar Energy 110, 830842. Therm. Eng. 41, 6775. AMPL Software Webpage. Energy 149, 230249. Dynamic Process Simulation for Polish lignite Combustion in a 1 MWth Circulating Fluidized Bed during Load Changes. Thermoflow (2021). Experimentally validated axisymmetric simulation for thermo-fluid performance of an active flat-plate solar water heater at low flow rates. Appl. doi:10.1016/j.apenergy.2010.09.023, Beiron, J., Montas, R. M., Normann, F., and Johnsson, F. (2019). Recent software alleviates the users effort in initializing the solution by adopting ad hoc routines (e.g., doing some iterations with the sequential modular approach). Appl. Energ. (2007). ), literature cost correlations (see e.g., (Turton et al., 2008; Carcasci et al., 2015; Elsido et al., 2019)), dedicated commercial software packages (e.g., PEACE (Thermoflow, 2021), Aspen economics (Aspen Tech, 2021)), or quotations from manufacturers are used. Wang, L., Lampe, M., Voll, P., Yang, Y., and Bardow, A. doi:10.1016/j.ces.2005.03.015, Shin, J., Jeon, Y., Maeng, D., Kim, J., and Ro, S. (2002). Introduction to Derivative-free Optimization. Dynamic Modelling, Validation and Analysis of Coal-Fired Subcritical Power Plant. doi:10.1016/j.apenergy.2018.01.017, Keywords: steam cycle, dynamic simulation, heat integration, process simulation, power plant, combined cycle, plant optimization, plant flexibility, Citation: Martelli E, Alobaid F and Elsido C (2021) Design Optimization and Dynamic Simulation of Steam Cycle Power Plants: A Review. (2016). EM and CE wrote the sections on steam cycle optimization approaches while FA the sections on dynamic simulations. An Extended Vertical MILP Model for Heat Exchanger Network Synthesis. Comput. PGS-COM: A Hybrid Method for Constrained Non-smooth Black-Box Optimization Problems. The main solution approaches adopted in the energy and process industry are called single-shooting, multiple-shooting, and collocation. Proc. 213 (1), 722. Han, X.-g., Qu, W.-h., Dong, Y., and Nie, H.-g. (2010). However, such an optimization problem would be extremely challenging owing to a large number of variables (mixed binary, discrete, and continuous) and nonlinear nonconvex constraints. Sciacovelli, A., Li, Y., Chen, H., Wu, Y., Wang, J., Garvey, S., et al. POWERGEN Int., 1113. Dynamic Characteristics of a Direct-Heated Supercritical Carbon-Dioxide Brayton Cycle in a Solar thermal Power Plant. Spliethoff, H. (2010). (2015). Solar Energy 98, 2333. 12 (5), 130. Pyomo (2021). Sci. (2017). Approximately 50min after an overnight shutdown (hot start-up) is required to complete the start-up procedure of a modern CCPP. Dynamic Modeling for Assessment of Steam Cycle Operation in Waste-Fired Combined Heat and Power Plants. Garca, I. L., lvarez, J. L., and Blanco, D. (2011). doi:10.1016/j.fuel.2015.02.011, Alobaid, F. (2018b). The methodology has been applied to two industrial energy system case studies taken from literature, to demonstrate the capability of the method to find improved solutions compared to schemes without steam cycle/ORC integration. Nowadays, a 1 + 1 arrangement of gas turbine and steam turbine in combination with a triple-pressure reheat HRSG is state of the art (see Figure 3). (2000) studied the effect of CCPP cold start-up with a flue gas bypass on thermal stress in the drum of a single-pressure HRSG. The model has been applied to highly integrated plants: biomass to FischerTropsch liquids plants, IGCCs with and without carbon capture and storage (CCS), integrated reforming combined cycles (Martelli et al., 2012), and coal-to-synthetic natural gas facilities (Martelli et al., 2013). Hbel et al. Online, September 2125, 2020. Study of Supercritical Coal Fired Power Plant Dynamic Responses and Control for Grid Code ComplianceMathematical Modelling and Simulation of Power Plants and CO2 Capture WORKSHOP. Constructal Design and Optimization of a Dual Pressure Heat Recovery Steam Generator. Improving Operational Flexibility by Regulating Extraction Steam of High-Pressure Heaters on a 660 MW Supercritical Coal-Fired Power Plant: A Dynamic Simulation. Energy 92, 153159. Udono, K., and Sitte, R. (2008). Proced. Molten Carbonate Fuel Cells as Means for Post-Combustion CO2 Capture: Retrofitting Coal-Fired Steam Plants and Natural Gas-Fired Combined Cycles, in ASME 2015 13th International Conference on Fuel Cell Science. Ponce, C. V., Sez, D., Bordons, C., and Nez, A. Thermoeconomic Optimization of Combined Cycle Gas Turbine Power Plants Using Genetic Algorithms. The dynamic simulation problem of a power plant can be formulated as in Eq. Appl. Process Des. Thus, a limited number of interesting cycle configurations is possible and design optimization is mainly focusing on the cycle variables (pressures, temperatures) and arrangement of the steam tube banks within the steam generator. Global Thermoflow Team: Karsten Huschka - Director, Thermoflow Europe GmbH +49 640 790 6991: huschka@thermoflow.com: Ignacio Martin - Regional Manager, Iberia & Latin America +34 659 95 39 59: martin@thermoflow.com: Aldo de'Bonis, Dr. Ing. State-of-the-art coal-fired power plants have single reheat and several low-pressure and high-pressure feedwater preheaters, reaching a net thermal process efficiency of about 46%. Comput. 69, 14511460. VGB Powertech 92 (1-2), 6268. (2017). Front. doi:10.1016/j.energy.2013.11.007, Alobaid, F., Mertens, N., Starkloff, R., Lanz, T., Heinze, C., and Epple, B. Combined-Cycle Gas-Steam Turbine Power Plants. doi:10.1016/j.enconman.2014.11.014. Schuhbauer, C., Angerer, M., Spliethoff, H., Kluger, F., and Tschaffon, H. (2014). and some are differential (including time derivatives), the system of equations is called DAE (Differential Algebraic Equation). Lu, S. (1999). doi:10.1016/s0360-5442(03)00199-3, Duran, M. A., and Grossmann, I. E. (1986). Current developments aim at increasing the electrical conversion efficiency by using higher process temperatures, which in turn results in a decrease in the levelized cost of electricity (LCOE). Systematic Optimization of the Design of Steam Cycles Using MINLP and Differential Evolution. Energ. doi:10.1016/j.compchemeng.2019.05.041, Elsido, C., Martelli, E., and Grossmann, I. E. (2018). (2014). Due to the high temperature at the gas turbine outlet (in the order of 650C), the supplementary firing is omitted. Modelling and Dynamic Simulation of the 2nd Generation Oxy Fired Power PlantOxidant Fan Failure Case. Appl. Advanced Methods of HRSG Design for Life Cycle Optimization under Fast Startups. Convers. doi:10.1016/j.simpat.2011.12.009, Hentschel, J., Zindler, H., and Spliethoff, H. (2017). This section gives an overview of the published studies on dynamic simulation applied to combined-cycle power plants. for the design optimization of non-conventional steam cycles and steam networks (source Elsido et al., 2019). Energ. Energy 93, 20692078. doi:10.1016/j.apenergy.2008.09.013. 6 Articles, Paper presented at the Proceedings of the 45th IEEE Conference on Decision and Control, The 25th International Conference on Efficiency, Cost, Optimization, Simulation and Environmental Impact of Energy Systems, Paper presented at the Modelica Conference, Paper presented at the ASME 2011 International Mechanical Engineering Congress and Exposition, Princeton university MAE Dept, Ph.D Thesis n. 1983-T, Turbine Technical Conference and Exposition, Paper presented at the Energy Incorporated PEPSE Users Group Meeting, Proceedings of the sixth international symposium on micro machine and human science, Proceedings of the 8th International Modelica Conference, Paper presented at the Turbo Expo: Power for Land, Sea, and Air, Paper presented at the International Heat Transfer Conference Digital Library, Paper presented at the ASME 2015 9th International Conference on Energy Sustainability collocated with the ASME 2015 Power Conference, the ASME 2015 13th International Conference on Fuel Cell Science, Engineering and Technology, and the ASME 2015 Nuclear Forum, Proceedings of Solar Forum 2001: Solar Energy: The Power to Choose, Proceedings of the 2001 IEEE International Conference on Control Applications (CCA'01) (Cat. Energy 74, 202214. Springer. 87, 4457. A Thermodynamic Approach to Steam-Power System Design. The numerical results were compared towards the operational data, showing very good agreement. Meinke, S., Gottelt, F., Mller, M., and Hassel, E. (2011). The modern layout of the combined-cycle power plant (CCPP) is the result of evolutionary development in the second half of the last century, driven by the increasing performance of the gas turbine. Modeling of Coal-Fired Power Units with Thermopower Focussing on Start-Up Process, in Paper presented at the Proceedings of the 8th International Modelica Conference, Dresden; Germany, March 20th-22nd, 2011 (Technical Univeristy). Shang, Z., and Kokossis, A. Compared to equation-oriented software, the convergence issues of sequential modular ones increases rapidly with the number of recycle loops of the flowsheet because more tear variables need to be assumed and converged. Also, multi-period optimization approaches have been proposed for steam cycles and steam networks to find designs able to work in the expected operating modes/loads with high efficiency. Thermoeconomic Analysis of a One-Pressure Level Heat Recovery Steam Generator Considering Real Steam Turbine Cost. As a result, the MINLP is particularly challenging due to its nonconvexity and a large number of variables and constraints. Modelling, Optimization and Dynamic Simulation of a Parabolic Trough Power Plant. J. These were attributed to incomplete information on real operation and control circuits. Zhang, J., Liu, P., Zhou, Z., Ma, L., Li, Z., and Ni, W. (2014). (2017). Thermoflows Application-Specific and Fully-Flexible programs are designed to be used on their own, independently of each other. IFAC Proc. 32 (1), 123138. The first works are the sequential synthesis approaches proposed in (Duran and Grossmann, 1986; Marchal and Kalitventzeff, 1998; Mar chal and Kalitventzeff, 1999; Papoulias and Grossmann, 1983; Papoulias and Grossmann, 1983c): In the first step a targeting method is used to determine the optimal cycle configuration and steam flow rates (without dealing with the combinatorial problem associated with the design of the HEN) and, in a second step, the HEN is optimized (for fixed steam and utility mass flow rates). 2) Several possible arrangements/order/interconnections of the steam tube banks (i.e., the heat exchanger network, HEN) are possible and the optimal solution is not obvious. The thermodynamic optimization of steam cycle variables was first investigated in the 1980s. Dynamic Modelling and Analysis of post-combustion CO2 Chemical Absorption Process for Coal-Fired Power Plants. Thermoflow was founded by Dr. THERMOFLEX is a modular program of Thermoflow Company with a graphical interface that allows Engineers to assemble a model from icons representing over 175 different . Multi-objective Optimization of Multi-Period Interplant Heat Integration Using Steam System. Available at: http://www.pfrengineering.com/products/frnc-5pc/ (Accessed May 5, 2021). Comput. 47 (1), 99131. Appl. At each discrete location, an algebraic system of equations is obtained. Res. Privacy Policy, 4601 Touchton Road East, Building 300, Suite 3280, Jacksonville FL 32246, USA. Cellier, F. E., and Kofman, E. (2006). For conceptual and preliminary studies, this design step is typically sufficient. Ma et al. Operational data and simulated results of the high-pressure and reheater circuits during load change scenario (source Starkloff et al., 2015). Eng., 108139. (2020). Sci. Mertens et al. doi:10.1016/j.wasman.2013.05.026, PubMed Abstract | CrossRef Full Text | Google Scholar, de Klerk, G., Rousseau, P., and Jestin, L. (2020). Convers. Available at: https://computing.llnl.gov/projects/sundials/ida (Accessed May 5, 2021). doi:10.1016/s1474-6670(17)50423-1, Manassaldi, J. I., Arias, A. M., Scenna, N. J., Mussati, M. C., and Mussati, S. F. (2016). Energ. The comparison between three dynamic simulations using three different process software for the same power plant give more confidence in dynamic simulation for the design and optimization of CCPPs. On one hand, gradient-based optimization algorithms with guaranteed quadratic/superlinear convergence rates can be adopted; on the other hand, depending on the type of solver, the number of variables, and problem nonlinearity, achieving convergence to the global optimum may be difficult (local minima, infeasible solutions, etc.). doi:10.1016/j.apenergy.2013.09.057, Zhao, Y., Wang, C., Liu, M., Chong, D., and Yan, J. Fuel 89 (10), 27912801. The dynamic simulation is also a cost-efficient approach to support unit commissioning and regular operation by estimating component lifetime and directing maintenance. Energ. doi:10.1016/j.apenergy.2016.12.141, Roth, K., Scherer, V., and Behnke, K. (2005). The inherent complexity of the governing differential conservation equations and the numerical solution methods leads to highly complex models with long development periods. Solar Energy 86 (1), 531540. The superstructure of the HRSG has a fixed number of tube banks (i.e., sections of economizers, superheaters) and one evaporator for each pressure level. This paper provides an introduction to the main types of simulation and optimization problems (design, off-design operation and dynamic), an overview of the mathematical background (possible solution approaches, numerical methods and available software), and a review of the main scientific contributions. Springer Science & Business Media.
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