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I NTRODUCTION         M ETHOD AND T OOLS             I NTEGRATION C ASE S TUDY   S UMMARY




        E NERGY I NTEGRATION...
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S EQUENTIAL F RAMEWORK FOR HENS
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Energy Integration of IGCC

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Energy Integration of IGCC

  1. 1. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY E NERGY I NTEGRATION OF AN IGCC PLANT FOR COMBINED HYDROGEN & ELECTRICITY PRODUCTION FROM COAL Rahul Anantharaman1 , Charles Eickhoff2 & Olav Bolland1 1 Department of Energy & Process Engineering Norwegian University of Science and Technology 2 Progressive Energy Limited Trondheim CCS Conference Trondheim, 16.06.2009
  2. 2. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY O UTLINE 1 I NTRODUCTION Motivation The Process 2 M ETHOD AND T OOLS Heat Exchaner Network Synthesis Tools 3 I NTEGRATION C ASE S TUDY Utilities and cost information Results 4 S UMMARY
  3. 3. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY O UTLINE 1 I NTRODUCTION Motivation The Process 2 M ETHOD AND T OOLS Heat Exchaner Network Synthesis Tools 3 I NTEGRATION C ASE S TUDY Utilities and cost information Results 4 S UMMARY
  4. 4. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY M OTIVATION T HE PLANT 400 MW power plant with 50 MW (LHV) of H2 with 90% CO2 capture using coal as the fuel. Most capture plants are associated with large energy penalty (~10%) - decreasing their economic viability. Efficiency is the one of the most important factors when selecting and designing plants with CO2 capture. A IM Explore opportunities for energy integration in an IGCC plant for improving the efficiency using Heat Exchanger Network Synthesis and an integration of tools.
  5. 5. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY O UTLINE 1 I NTRODUCTION Motivation The Process 2 M ETHOD AND T OOLS Heat Exchaner Network Synthesis Tools 3 I NTEGRATION C ASE S TUDY Utilities and cost information Results 4 S UMMARY
  6. 6. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY P ROCESS PARAMETERS G ASIFICATION S ECTION Gasifier Type: Siemens - water quench Shift: 2 stage sour shift ASU: 95% O2 CO2 C APTURE S ECTION Type: Selexol CO2 capture rate: 90 % CO2 pressure: 110 bar P OWER I SLAND Turbine: GE 9FA Steam system: 3 pressure levels
  7. 7. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY P ROCESS F LOW D IAGRAM
  8. 8. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY O UTLINE 1 I NTRODUCTION Motivation The Process 2 M ETHOD AND T OOLS Heat Exchaner Network Synthesis Tools 3 I NTEGRATION C ASE S TUDY Utilities and cost information Results 4 S UMMARY
  9. 9. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY W HAT IS H EAT E XCHANGER N ETWORK S YNTHESIS ? For a given set of hot and cold process streams as well as external utilities, design a heat exchanger network that minimizes Total Annualized Cost (TAC). TAC = Capital Cost + Energy Cost
  10. 10. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY S EQUENTIAL F RAMEWORK FOR HENS M OTIVATION Pinch based methods for Network Design Improper trade-off handling Cannot handle constrained matches Time consuming Several topological traps MINLP Methods for Network Design Severe numerical problems Difficult user interaction Fail to solve large scale problems Stochastic Optimization Methods for Network Design Non-rigorous algorithms Quality of solution depends on time spent on search
  11. 11. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY S EQUENTIAL F RAMEWORK FOR HENS M OTIVATION HENS TECHNIQUES DECOMPOSE THE MAIN PROBLEM Pinch Design Method is sequential and evolutionary Simultaneous MINLP methods let math considerations define the decomposition The Sequential Framework decomposes the problem into subproblems based on knowledge of the HENS problem Engineer acts as optimizer at the top level Quantitative and qualitative considerations included
  12. 12. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY S EQUENTIAL F RAMEWORK FOR HENS U LTIMATE G OAL Solve Industrial Size Problems Defined to involve 30 or more streams Include Industrial Realism Multiple and ``Complex´´Utilities Constraints in Heat Utilization (Forbidden matches) Heat exchanger models beyond pure countercurrent Avoid Heuristics and Simplifications No global or fixed ∆ Tmin No Pinch Decomposition Develop a Semi-Automatic Design Tool EXCEL/VBA (preprocessing and front end) MATLAB (mathematical processing) GAMS (core optimization engine) Allow significant user interaction and control Identify near optimal and practical networks
  13. 13. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY S EQUENTIAL F RAMEWORK FOR HENS T HE E NGINE C OMPROMISE BETWEEN P INCH D ESIGN AND MINLP METHODS
  14. 14. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY O UTLINE 1 I NTRODUCTION Motivation The Process 2 M ETHOD AND T OOLS Heat Exchaner Network Synthesis Tools 3 I NTEGRATION C ASE S TUDY Utilities and cost information Results 4 S UMMARY
  15. 15. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY M ODELING T OOLS GTP RO GTPro from Thermoflow Inc. is used to model the power island. GTPro is particularly effective for creating new designs and finding their optimal configurations. To this end, it has a library of gas turbine models that replicates real performance. Initial HRSG design and marginal costs for HP, IP & LP steam are derived from GTPro. GAMS General Algebraic Modeling System (GAMS) is used for modeling and optimization of the Heat Exchanger Network.
  16. 16. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY T OOLS I NTEGRATION S EQ HENS GAMS E XCEL A DD - IN
  17. 17. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY O UTLINE 1 I NTRODUCTION Motivation The Process 2 M ETHOD AND T OOLS Heat Exchaner Network Synthesis Tools 3 I NTEGRATION C ASE S TUDY Utilities and cost information Results 4 S UMMARY
  18. 18. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY U TILITIES S TEAM L EVELS HP/IP/LP steam: 118/41/3 bar U TILITIES COST Electricty: 63 ¤/MWh HP steam: 0.79 MW for 1 kg/s of sat steam raised IP Steam: 0.68 MW for 1 kg/s of sat steam raised LP Steam: 0.42 MW for 1 kg/s of sat steam raised
  19. 19. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY H EAT E XCHANGER Cost law - B + D(Area)c B = 10,000 ¤ D = 800 ¤ c = 0.6 PL (1+ ROR ) 100 Annualization factor = PL ROR - Rate of Return - 8% PL - Plant life - 25 years
  20. 20. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY O UTLINE 1 I NTRODUCTION Motivation The Process 2 M ETHOD AND T OOLS Heat Exchaner Network Synthesis Tools 3 I NTEGRATION C ASE S TUDY Utilities and cost information Results 4 S UMMARY
  21. 21. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY H EAT E XCHANGER N ETWORK S YNTHESIS I NTEGRATION O PTIONS 1 Reboilers in process directly integrated with process streams. Saturated HP and LP steam raised in the process sent to HRSG for superheating. Steam extracted from ST for gasifier. 2 Similar to 1, except saturated HP BFW to the cooling screen of the gasifier extracted from HRSG. 3 Reboilers are not directly integrated with process streams. Steam extracted from ST for this. HP, IP and LP steam raised in the process sent to HRSG for superheating. 4 Similar to 3, except saturated HP BFW to the cooling screen of the gasifier extracted from HRSG. All above cases have an additional case (denoted by a) - where BFW is preheated in process in addition to HRSG. This raises the stack temperature to 115 °C.
  22. 22. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY C OMPOSITE C URVES
  23. 23. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY C OMPOSITE C URVES
  24. 24. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY C OMPOSITE C URVES
  25. 25. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY C OMPOSITE C URVES
  26. 26. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY H EAT E XCHANGER N ETWORK C ASE 1 - G ASIFICATION ISLAND
  27. 27. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY C ASE COMPARISONS BASIC DETAILS Process Steam(kg/s) HRSG Steam(kg/s) ST Extraction(kg/s) HP IP LP HP IP LP IP 41bar IP 6.5 bar ST Power No HX Case 1 36.85 12.50 80.70 14.55 16.87 6.28 172.15 20.00 Case 1a 36.85 12.50 80.70 14.55 17.30 6.28 172.35 24.00 Case 2 38.85 12.50 79.92 13.78 15.88 6.28 172.49 20.00 Case 2a 38.85 12.50 81.66 14.97 16.62 6.28 172.85 24.00 Case 3 41.15 6.60 12.50 79.32 16.26 16.39 11.50 172.29 21.00 Case 3a 41.15 6.60 12.50 79.32 16.26 16.39 11.50 172.29 26.00 Case 4 41.15 7.95 13.50 79.26 15.21 15.36 11.50 172.50 21.00 Case 4a 41.15 7.95 13.50 79.26 15.21 15.60 11.50 172.61 26.00
  28. 28. I NTRODUCTION M ETHOD AND T OOLS I NTEGRATION C ASE S TUDY S UMMARY S UMMARY An integration of methodologies and tools for the energy integration of a combined hydrogen and electricity is presented. The HENS methodology presented lead to designs with improved efficiency. The methodology provides multiple designs with same efficiency and similar costs but with varying degrees of complexity to enable the engineer to select an integration scheme based on qualitative parameters such as operability etc. This work carried out by NTNU in the Dynamis IP project under the Sixth Framework Programme. Dynamis project aims at developing technologies for hydrogen and electricity co-production based on fossil fuels with 90% carbon capture rate.

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