Guofu_Chen_Presentation_in_AspenTech_HYSYS_Conference
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Guofu_Chen_Presentation_in_AspenTech_HYSYS_Conference
- 1. www.tas.com
- 2. www.tas.com
- 3. www.tas.com
- 4. Optimize Design and Operation of Renewable Energy Cycle through HYSYS Integrated with EDR By Guofu Chen P. E. of Mechanical and Chemical Economic Clean Energy www.tas.com gchen@tas.com
- 5. Agenda • Introduction – Who is TAS Energy? – What’s a renewable energy power plant? • Setting up HYSYS process model • HYSYS optimizer to maximize power output • Rigorous exchangers modelling – Optimize the number of Air-Cooled Condenser bays – Optimize the size of the evaporator • What-if? • Conclusions – Technical improvement diagram – Business benefits summary www.tas.com
- 7. Who is TAS Energy • Founded in 1999 and grew to $150m of revenues with minimal financing • Headquartered in Houston, TX – Offices in Dubai and Doha • TAS is an Innovator and Leader in Modular Thermal Energy Equipment – Invented the concept of “Turbine Inlet Cooling” – Introduced “Packaging” to the Cooling Industry – Pioneer of Renewable Energy business – Developed Innovative “Mission Critical” offerings www.tas.com
- 8. What’s a Renewable Energy Power Plant? • Based on Rankine cycle principle, use an organic working fluid to turn geothermal fluid energy or waste heat into electricity. www.tas.com
- 9. Setting up HYSYS Model www.tas.com
- 10. Setting up HYSYS • Step 1: Set up HYSYS based on "Best Engineering Practice", subject to exchangers pinch. www.tas.com
- 11. HYSYS Optimizer to Maximize Output www.tas.com
- 12. Optimizer Variables Setting up • Step 2.1: Use HYSYS optimizer to get the most output of the process while respecting the pinch. The graph shows how variables are set up. www.tas.com
- 13. Optimizer Goal and Constraints Setting up • Step 2.2: The graph below shows how the goal and constraints are set up. www.tas.com
- 14. Optimizer Result • After HYSYS finishes the optimization, the optimum pressure is 50.33 bara (730 psia) and the optimum temperature is 122.67 °C (252.8 °F). At such conditions, the net power output is maximized at 8635 kW (1.158×104 HP). The net output is improved by 3.3% www.tas.com
- 15. Rigorous Exchangers Modelling www.tas.com
- 16. Rigorous Rating Model with Geometries www.tas.com
- 17. Integrate ACHE EDR into HYSYS • Step 3.1: Start from 30 Air-Cooled condenser bays and integrate Air-Cooled exchanger into HYSYS www.tas.com
- 18. Optimize Condensing Pressure • Step 3.2: Higher condensing pressure leads to lower expander output, and less ACC fan power as well. The net power output goes through an maximum and an optimum condensing pressure exists. www.tas.com
- 19. Select Optimum Number of Bays • Step 3.3: Compare and select the number of No of Bays 24 27 30 33 36 39 3,600,0 ACC cost $ 00 4,050,0 00 4,500,00 0 4,950,0 00 5,400,00 0 5,850,00 0 Condensing Temperature °C 25.53 24.68 23.65 22.81 21.91 20.95 Condensing Pressure bara 6.964 6.757 6.567 6.378 6.188 5.998 Air Flow kg/h 17,463, 485 18,127, 638 18,847,4 10 20,048, 988 21,296,2 51 23,188,7 87 Net Output kW 7,835 8,039 8,209 8,346 8,464 8,572 Incremental $/kW - 2,207 2,651 3,289 3,790 4,166 cost bays www.tas.com Geothermal industry criterion
- 20. Optimize Evaporator Size • Step 3.4: Use “Utility” to size the evaporator with variant UA. www.tas.com
- 21. Choose Optimum Evaporator Size • Step 3.5: Evaluate and choose Heater size www.tas.com Geothermal industry criterion UA Percentage 90% 100% 110% 130% 150% Evaporator UA kJ/°C-h 20,172,31 4 22,413,68 2 24,655,05 0 29,137,78 6 33,620,52 3 No. of Tubes 1,017 1,162 1,312 1,742 2,203 Shell Diameter mm 889 940 991 1,118 1,245 EDR Cost * $ 613,400 691,600 784,200 1,010,580 1,263,488 Net Output kW 8,083 8,210 8,307 8,437 8,535 Incremental cost $/kW - 864 1,337 2,438 3,612 *A cost multiplier was used to modify this cost.
- 23. What-if? • Step 4: Rate the overall cycle with actual equipment geometries and do what-if studies www.tas.com
- 24. Rigorous Rating Model with Geometries www.tas.com
- 26. Technical Improvement Diagram Setup HYSYS, based on “Best Engineering Practice” Optimize HYSYS Generate the “Best Engineering Practice” Optimize Heater Optimize ACC bays www.tas.com
- 27. Business Benefit Summary • Faster: deliver projects several weeks faster by shortening the discussion time with vendors • Better: more confident with the plant performance and exchangers design • Cheaper: optimize the cost and performance to have overall lowest price • Results: as a new comer in the Renewable Energy Industry, TAS has won several projects against the previous market leader with 40 years experience www.tas.com
- 28. Refer to HTFS research paper RS1230 for more information. www.tas.com
Editor's Notes
- Is there anyone who knows what this is? Fly Geyser is a small geothermal geyser that is located approximately 20 miles (32 km) north of Gerlach, in Washoe County, Nevada. The Geyser is about 1/3 miles from the County Road 34 and is large enough to be seen from the road.
- Here is another very beautiful picture of the geyser in the evening. What comes out of your mind when you first see the pretty geyser? How can we take advantage of these kind of hot water springs? Tourism, bathing or heating?
- One way to use the geyser is to generate electricity through an Organic Rankine Cycle (ORC) An easy to understand picture to show how a geothermal power plant works. The hot water from the underground is extracted, giving out heat and then injected back to the ground. A binary working fluid is vaporized in the exchanger and forms high pressure vapor to drive the expander to generate electricity through a Generator.
- This PPT is for AspenTech 2011 Global User Conference Here comes the topic I’m going to cover today. Optimize Design and Operation of Renewable Energy Cycle through HYSYS Integrated with EDR My name is Guofu Chen. I’m a professional mechanical engineer and a professional chemical engineer as well.
- Here is the agenda I’m going through First part is the introduction of who is TAS Energy and what’s a renewable energy power plant. Next I’m going to explain how to use HSYSY to setup the models and how to utilize the HYSYS optimizer to maximize the power output. Next a rigorous exchanger modeling approach is utilized to optimize the economics to size the Air condensers and evaporator cost effectively. Once you build your models with real geometries, you can mimic the real plant operations and answer what-if questions. Finally, we conclude by using HYSYS with EDR, TAS has improved the best engineering practice and gains valuable business benefits.
- This section is the introduction section.
- Who is TAS? TAS invented the “Turbine Inlet Cooling” industry and it’s the solid foundation of the company. Thanks to Obama’s administration, with all the finance and tax support to the renewable energy, TAS became the pioneer of Renewable Energy business. During the past two years, TAS has awarded 200 million dollars projects.
- We are using a cycle called Organic Rankine Cycle. The working principle of the organic Rankine cycle is the same as that of the Rankine cycle: the working fluid is pumped to a boiler where it is evaporated, passes through a turbine to generate power and is finally condensed before returning to the pump. The difference between Rankine Cycle and Organic Rankine Cycle is: Rankine Cycle uses water as the working fluid and in general the heat source temperature should be above 1000 F. While using Organic Rankine Cycle, it’s possible to turn the boiled water at your home at about 200 F into electricity. Imagine, at your home, on your stove, the boiled water turns into electricity to supply your AC and lighting system
- Next I’m going to explain how to use HYSYS to make this idea into reality. First we need to set up a HYSYS model.
- Calculation starts from the outlet of ACC, as we know it’s saturated liquid at a temperature higher than ambient condition. Then pump discharge pressure of 650 psia is assumed and thus temperature and pressure of EvaporatorIn are known. Assuming HeaterOut temperature is 240 F, then the refrigerant flow can be calculated from the duty of the Evaporator. ExpanderOut pressure is slightly higher than ACCOut pressure by the pressure drop across the pipes and ACC. Then the expander is able to solve. The diagram here shows what it looks like after it’s converged.
- Next step is to use HYSYS optimizer to maximize the power output.
- Once HYSYS is set up, the HYSYS optimizer can be used to maximize the net electricity output by 1, changing the key variables within the given range 2, targeting the goal 3, and impose the constraints. The diagram shows ExpanderOut temperature is limited between 93.33 C and 135 C. The PumpOut pressure is limited between 41.37 and 50.33 bara.
- This diagram shows we are going to maximize the net output and constrain the evaporator temperature pinch should be higher than 5.556 C, which is 10 F.
- The optimization is finished here, from a thermodynamic point of view. However, we have not figured out the optimum number of ACC and optimize sizing of the heater yet.
- In this section, I’m going to examine how we utilize EDR program to size the Air condensers and evaporator cost effectively.
- The diagram is modified to adapt to this kind of optimization. A dummy exchanger is added to make sure the pump will not cavitate in case ACC does not fully condense the working fluid. Now HYSYS is configured with real geometries of air cooled condensers.
- To make Air-Cooled Condensers (ACC) cost effective and reliable, TAS Energy has made a standard bay size. For smaller project, only one or two bays are used, while for larger projects 30 bays or more can be deployed. We start to try different number of ACC bays and see the impact both on performance and cost.
- Even with fixed number of ACC bays, an optimum condensing pressure exists. The net output is maximized at a condensing pressure of 6.567 bara. This can be done either through case studies or HYSYS optimizer.
- Following the same principle, we tried different number of ACC bays. And the result is summarized here. From the chart and table, we see the incremental cost of ACC is increasing. In geothermal industry, the performance is evaluated based on the power cost about 3000 $/kW. In other words, if it costs less than 3000, say 2500 dollars to generate one more kW, this is a done deal. Otherwise, if the cost is higher than 3000, say 3500 dollars to produce one more kW, it’s a no deal. Thus we eventually selected 30 bays in this project. If you choose 27 bays, you lose the opportunity to earn 3000 $/kW by spending 2651 dollars. Or if you choose 33 bays, you are paying 3289 $, but you only gain 3000 $ benefit.
- After 30 bays of ACC is selected, the geometry is embed in HSYSY and the real time calculation will be based on the real ACC geometry. Originally I tried to follow the same philosophy which I used to optimize the number of ACC bays. I could have tried to have different size of exchangers and see the cost and the benefit. But then I will need to free the hot water exit temperature, which will not give a fair comparison between different options. So eventually I fix the UA of the exchanger by freeing the heater outlet temperature. And keep the same hot water exit temperature for fair comparison. And through Shell and Tube exchanger utility, the heater is sized for given UA and process conditions. The graph shows a shell and tube exchanger with 1118 mm diameter is chosen for given UA.
- Then by manipulating UA, HYSYS is able to calculate the electricity output. While Shell and Tube Exchanger utility is used to size the heater. We tried different UA of the exchangers and the result is summarized here. By the way, the comparison is still fare, because the cool water outlet temperature is always the same. Based on the incremental or marginal cost analysis, 1118 mm shell diameter exchanger should be selected, which gives a minimum temperature approach about 7 F. The optimum minimum temperature approach deviates from the traditional 10 F, probably because we use 3000 $/kW to evaluate performance while the traditional industry is using 2000 $/kW only.
- Now we concluded we optimized the equipment size cost effectively and then we are able to answer “What-if” questions.
- What if one day you’ve got a fortune? And What if you lose it soon after? With the real life, we just have so many what-if situations and sometimes it’s so hard for us to answer. However, with HYSYS and EDR, answering what-if questions is just one click away.
- Now HYSYS is configured with 30 bays of air cooled condensers and 1118 mm diameter evaporator. Simply change the input parameter, such as hot water inlet temperature, flow or dry bulb temperature, the program will be able to start to calculate and give you an answer. What’s more, you can use the HYSYS optimizer again to maximize the net output with real geometries. Besides, you can use the model to do trouble shooting or guide the plant operation.
- Through utilizing HYSYS integrated with EDR, we have the following conclusions:
- We have improved our technical best engineering practice. We start from the best engineering practice with 10 F as the exchanger pinch, through the optimization, we might want to use 7 F minimum approach as the new best engineering practice in geothermal power plant industry.
- In addition, faster, better and cheaper products and service are provided by utilizing AspenTech products. And TAS has a better market position to continue to succeed.
- I would like to thank you for listening this presentation. Along with this presentation, you can refer to HTFS research paper RS 1230 for more detailed information. I would like to thank Vishwas and Tom as well for their help to make this presentation better. Last, but not least, TAS would like to thank the Giant of AspenTech, by standing on the Giant’s shoulder, TAS is growing stronger and stronger. Any questions?