The Vision 21 Planner: The Vision 21 Planner: A New Modeling Tool for PreliminaryA New Modeling Tool for PreliminaryCost and Performance Assessments ofCost and Performance Assessments of

Vision 21 PlantsVision 21 Plants

Edward S. RubinDepartment of Engineering and Public Policy

Carnegie Mellon UniversityPittsburgh, Pennsylvania

28th International Conference on Coal Utilization & Fuel SystemsClearwater, Florida

March 12, 2003

Vision 21 Modeling NeedsVision 21 Modeling Needs

• A hierarchy of models tailored to the needs of different users and applications, ranging from:

Preliminary design and screening analysis, toDetailed design of a “virtual” plant

• A range of capabilities for predicting the performance, reliability and cost of:

Individual plant componentsIntegrated Vision 21 plant designs

The Vision 21 Planner Would The Vision 21 Planner Would ……

• Bring together performance and cost models for a variety of enabling technologies and Vision 21 system designs

• Run quickly and easily on a desktop or laptop computer for preliminary design and analysis

• Allow new process concepts and components to be easily incorporated into new Vision 21 designs

• Allow uncertainties to be characterized explicitly• Facilitate rapid analysis of “what if” questions and the

selection of promising designs for further study

Attributes of Different ModelsAttributes of Different ModelsTurnaround

Time

Scope

Complexity

Micro-Scale

PlantComponent

Mult-Component

IntegratedPlant

Sec

Min

Days

Hrs

Weeks

Algebraic

Mechanistic

CFD

ASPEN

IECM / V21PIECM / V21P

Modeling ApproachModeling Approach

• Systems Analysis Framework• Process Technology Models• Engineering Economic Models• Advanced Software Capabilities

Probabilistic analysis capabilityUser-friendly graphical interfaceEasy to add or update models

Framework for the V21 Planner:Framework for the V21 Planner:The Integrated Environmental Control Model (IECM)The Integrated Environmental Control Model (IECM)

Current IECM TechnologiesCurrent IECM TechnologiesSO2 Removal• Wet limestone

- Conventional- Forced oxidation- Additives

• Wet lime• Lime spray dryer

Combined SO2/NOx Removal• Copper oxide• NOXSO

Solids Management• Ash pond• Landfill• Stacking• Co-mixing• Byproducts

- Ash - Gypsum- Sulfuric Acid

Furnace Types• Tangential• Wall• Cyclone

Furnace NOx Controls• LNB• SNCR• SNCR + LNB• Gas reburn

NOx Removal• Hot-side SCR

Mercury Removal• Carbon injection• Carbon + water

Particulate Removal• Cold-side ESP• Fabric filter

- Reverse Air- Pulse Jet

Model Software PackageModel Software Package

PowerPowerPlantPlant

ModelsModels

GraphicalGraphicalUserUser

InterfaceInterface

Plant andPlant andFuelFuel

DatabasesDatabases

Fuel PropertiesFuel PropertiesHeating ValueHeating ValueCompositionCompositionDelivered CostDelivered Cost

Plant DesignPlant DesignConversion ProcessConversion ProcessEmission ControlsEmission ControlsSolid Waste MgmtSolid Waste MgmtChemical InputsChemical Inputs

Cost DataCost DataO&M CostsO&M CostsCapital CostsCapital CostsFinancial FactorsFinancial Factors

Plant & ProcessPlant & ProcessPerformancePerformance

-- EfficiencyEfficiency-- Resource useResource use

EnvironmentalEnvironmentalEmissionsEmissions

-- Air, water, landAir, water, land

Plant & ProcessPlant & ProcessCosts Costs -- CapitalCapital

-- O&MO&M-- COECOE

IECM User GroupIECM User GroupABBAEP-SCR EngineeringAirborne TechnologiesAkzo Nobel Functional ChemAlberta Economic DevelopmentAlberta EnvironmentALCOA Power Generating, Inc.Allegheny Energy SupplyAlliant EnergyAlstom Power Inc.American Electric PowerApogee Scientific, Inc.Applied Technology ServicesArgonne National LaboratoryATCO PowerBabcock Borsig Power, Inc.Babcock & Wilcox Co.Bechtel Power Corp.Black & Veatch Corp.BOC GasesBoiler Systems EngineeringCanada EnvironmentCanada Natural ResourcesCarnegie Mellon UniversityCinergy Power Generation Clean Energy Int.Cogentrix Energy, Inc.CONSOL Energy, Inc.Consumers EnergyCP&LCPG, Inc.CQ, Inc.

Croll-ReynoldsDepartment of Environmental ProtDetroit Edison Co.Diamond Power Specialty Co Doyen & Associates, Inc.Duke Engineering & Services.Duke Fluor DanielDynegy Midwest GenerationElectric Energy, Inc. (EEI)Electricte de FranceEmera Inc.Emery Recycling CorporationEnel ProduzioneEnerenUEEnergy & Environ Research Corp.Energy & Environ StrategiesEnergy Systems AssociatesEnergy Technology Enterprises ENSR, Inc.Environmental DefenseEnvirol & Renewable Energy SystEPRI, Palo AltoExportech Company, Inc.FirstEnergy Corp.Florida Power & Light Co.FLS Miljo A/SFortum Power and Heat OyFossil Energy Research Corp.Foster Wheeler DevelopmentFoster Wheeler USA Corp.Fuel Tech, Inc.General Electric Company

Goodwin Environmental Great River EnergyGyeongsang National UniversityH&W Management Science Hamon Research Cottrell, Inc.Harza EngineeringHolland Board of Public WorksIEA Coal ResearchIllinois Clean Coal InstituteIllinois Dept. of Natural ResourcesIllinois EPAIllinois Institute of TechnologyIndiana Dept. of Env. Mgt.Intermountain Power Service Corp.Jack R. McDonald, Inc.Kansas City Power & Light Co.KEMA Nederland B.V.KinectricsKorea Electric Power CorporationKorea Institute of Energy ResearchKorea Western Power Co.Krupp Polysius Corp.LAB SALehigh UniversityLower Colorado River AuthorityMail Station PAß358McDermott Technology, Inc.MidAmerican Energy Co.Minnkota Power Cooperative, Inc.Mitsubishi Heavy Industries, Ltd.Mitsui Babcock Energy Ltd.National Park Service

National Power Plc.NESCAUMNew Hampshire Dept. of Env. SvcNew Jersey DEPNicholson Environmental, Inc.Niksa Energy AssociatesNIPSCONiro A/SNorth Carolina DENRNorth Carolina State UnivOntario Power GenerationPacific Corp.Parsons TechnologyPavillon Technologies, Inc.Pennsylvania Electric AssocPEPCOPG&E National Energy GroupPinnacle West EnergyPotomac Electric Power Co.PowerGenPPL Generation, LLCPPL Montana, LLCPredict Maintenance TechPrinceton UniversityProgress Materials, Inc.PSEG Power LLCPublic Power InstituteReaction Engineering IntlResearch Triangle InstituteRheinbraun Brennstoff GmbHSargent & Lundy, LLC

SaskPowerSavvy Engineering, LLCScientechSierra Pacific Power Co.Southern Company Services, Inc.State of New JerseyStone & Webster Engineering Corp.Superior Adsorbents, Inc.SyncrudeTampa Electric Co.Tennessee Valley Authority Texas Natural Resource Conv CommTNO Envit, Energy & Process InnovTransAltaTXU ElectricU.S. DOEU.S. EPAUniversity of CaliforniaUniversity of New OrleansUniversity of PittsburghURS CorporationUtah Dept. of Env. QualityW.L. Gore & Associates, Inc.Washington PowerWestern Kentucky Energy Corp.Wheelabrator Air PollControlWisconsin Dept. of Nat ResourcesWisconsin Electric Power Co.Wisconsin Energy Corp.Wisconsin Public Service Corp.Wisvest-Connecticut, LLC

Expanding the FrameworkExpanding the Frameworkto Vision 21 Plantsto Vision 21 Plants

Major Components of V21 PlantsMajor Components of V21 Plants

• Gasifiers• Combustors• Fuel Cells• Gas Turbines• Steam Turbines• Air Separation Units• Byproduct Recovery

Systems

• Gas Purification Systems for:

Solids (ash)Sulfur compoundsNitrogen oxidesMercuryOther trace elementsCarbon dioxide

Current Modeling Activities Current Modeling Activities

• Enhanced Software Capabilities• Plant Component Models (perf & cost)

Air separation unitsOxygen-blown gasifiersAdvanced gas turbinesSolid oxide fuel cellsCO2 capture systems

• Integrated Plant ModelsCurrent IGCC with cold gas cleanupAdvanced IGCC with CO2 capture and storageCombustion-based systems w/ CO2 capture Hybrid plants with SOFC/gas turbines

WaterWater--Gas Shift Reactor ModelGas Shift Reactor Model

High Temp

ReactorSyngas

SteamLow Temp

Reactor

H2OHeater

H2OHeater

Fuel Gas

HeaterShiftedSyngas

Absorber

TurbSump

Comp

Turb

Flash 1 Flash 2 Flash 3

CompComp

ShiftedSyngas

Lean Selexol

PumpRefrigeration

COCO22 Capture System Model Capture System Model (Selexol Process)(Selexol Process)

H2 Fuel Gas

CO2 to Storage

Gasifier ModelsGasifier Models

CoalCoal%C, H, S, O, N, %C, H, S, O, N, ClCl%Ash%Ash

HydrogenHydrogenHH22OO

OxygenOxygenAir or OAir or O22

SyngasSyngas% CO% CO% H% H22

% CH% CH44

% CO% CO22

% H% H22SS% COS% COS% NH% NH33

SlagSlag

Gasifier Model ParametersGasifier Model Parameters

• Independent variables for V21 Planner include:Gasifier type (Texaco, E-Gas, Shell, KRW)Coal type (6 coal choices)Water-to-coal input ratioOxygen-to-coal input ratioGasifier temperature Carbon loss in gasifier

• Performance models derived from ASPEN-based IGCC flowsheets developed by DOE/NETL

Gasifier Response Surface Model Gasifier Response Surface Model (Carbon partitioning to CO, E(Carbon partitioning to CO, E--Gas gasifier, PRB coal)Gas gasifier, PRB coal)

0.67

0.68

0.69

0.70

0.71

0.72

0.67 0.68 0.69 0.70 0.71 0.72

Fraction of Carbon converted to CO (ASPEN simulation)

Frac

tion

of c

arbo

n co

nver

ted

to C

O (R

SM

sim

ulat

ion)

Linking Performance and CostLinking Performance and Cost

PerformanceModel

CostModel

Fuel and Plant InputData

Performance

Emissions

Cost

BEAVON-STRETFORD UNITmass flow rate sulfur produced

BOILER FEEDWATER SYSTEMraw water flow to demineralizerpolished water flow to polisher

PROCESS CONDENSATE TREATMENTscrubber blowdown flow rate

GAS TURBINEnet gas turbine shaft work

HEAT RECOVERY STEAM GENERATORhigh pressure flow to steam turbine

STEAM TURBINEnet steam turbine shaft work

AUXILIARY EQUIPMENTmiscellaneous power consumptionsteam cycle auxiliary power consumption

AIR SEPARATION UNIT oxygen feed rate to gasifier

COAL HANDLING AND SLURRY PREPARATIONcoal feed rate to gasifier

GASIFICATIONas-received coal flow rate percent moisture in coal percent ash in coal feed solids mass flow leaving gasifier

LOW TEMPERATURE GAS COOLINGsyngas mass flow rate

SELEXOL UNITsyngas mass flow rate

CLAUS PLANTrecovered sulfur mass flow rate

Example IGCC Capital Cost Process Areas and their Dependent Variables

Prototype Prototype GraphicalGraphicalInterfaceInterface

Open a New SessionOpen a New Session

Case Study Results forCase Study Results forCost of COCost of CO22 AvoidedAvoided

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

10 15 20 25 30 35 40

Cost of CO2 Avoided ($/tonne CO2)

Cum

ulat

ive

prob

abili

ty

Deterministic

Performance + cost modelsCO2 compres, transp & storage

All uncertainties combined

Coming Soon . . .Coming Soon . . .

Fuel Composition

Oxidant

Pressure

Temperature

Ideal Nerst Voltage

Actual Cell Voltage

Ohmic Polarization

Fuel Utilization

Activation Polarization

Concentration Polarization

No. of Cells

Power Power OutputOutput

Current Density

Cell Area

Resistivity Thickness Area

Exchange Current

Limiting Current

Solid Oxide Fuel Cell ModelSolid Oxide Fuel Cell Model

StandStand--Alone Fuel Cell PlantAlone Fuel Cell Plant

InternalReformer SOFC

Fuel Desulfurizer

After Burner

Fuel Input(Gas) Air

Heat Exchanger

Exhaust

Fuel Cell Fuel Cell –– Gas Turbine HybridGas Turbine Hybrid

Air

InternalReformer SOFC After

Burner

Fuel Input (Gas)

Heat Exchanger

Exhaust

Gas Turbine

Fuel Desulfurizer

CompressorCompressor

Gasification + Fuel Cell PlantGasification + Fuel Cell Plant

Air Separator

Air

O2

Coal + H2O

HGCU SOFC HRSGWater Gas

Shift Reactor

CO2 Capture

Gas Turbine

Steam Turbine

Exhaust

Coming Later . . .Coming Later . . .

Other Vision 21 FlowsheetsOther Vision 21 Flowsheets

Water

Air

Air

GT

GT

ST

GC

HRSG

GA

ASU

FC

FC

Configure a New SystemConfigure a New System

Air

H2

CO2

H2O

Looking AheadLooking Ahead

• Finish implementing and testing prototype V21P model (including SOFC); distribute for beta testing and user feedback

• Continue to develop and improve modeling of:Individual plant components (Performance/Cost)Interactions and integration across components

• Develop “seamless” linkages with higher-level modelsCFD models of key components (e.g., gasifiers)Virtual Engineering simulation of an entire plant