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DEVELOPMENT OF TECHNOLOGIES AND ANALYTICAL CAPABILITIES FOR VISION 21 ENERGY PLANTS

Description: A software design review meeting was conducted (Task 2.0). A CFD Viewer was developed, to allow the process analyst to view CFD results from the process simulator (Task 2.14). Work on developing a CO wrapper for the INDVU code was continued (Task 2.15). The model-edit GUI was modified to allow the user to specify a solution strategy. Enhancements were made to the solution strategy implementation (Task 2.16). Testing of the integrated software was continued and several bug fixes and enhancements were made: ability to expose CFD parameters to the process analyst and support for velocity and pressure inlet boundary conditions (Task 2.21). Work on preparing the release version progressed: Version 0.3 of V21 Controller was released, a global configuration dialog was implemented, and a code review process was initiated (Task 2.24). The calibration of the tube bank CFD model for the RP&L case was completed. While integrating the tube bank CFD model into the flow sheet model, several development requirements were identified and communicated to the developers. The requirements of porting V21 Controller and Configuration Wizard to FLUENT 6.1, turning off the transfer of temperature dependent properties, exposing CFD parameters in Aspen Plus and supporting velocity boundary conditions have been implemented (Task 4.1). An initial grid for the HRSG component has been prepared (Task 4.2). A web-based advisory board meeting was conducted on December 18, 2003 (Task 5.0). Project personnel attended and gave presentations at the Aspen World Conference, October 28-30, 2002; AIChE Annual Meeting, November 8, 2002; and the Vision 21 Simulation meeting at Iowa State University, November 19-20, 2002 (Task 7.0).
Date: December 31, 2002
Creator: Madhava Syamlal, Ph.D.
Partner: UNT Libraries Government Documents Department

DEVELOPMENT OF TECHNOLOGIES AND ANALYTICAL CAPABILITIES FOR VISION 21 ENERGY PLANTS

Description: DOE Vision 21 project requirements for the support of Global CAPE-OPEN Reaction Kinetics interfaces in Aspen Plus 12 was written (Task 2.4). The software design document was written and posted on the project web site. Intergraph started work on a proof of concept demo of the physical domain software (Task 2.6). The COM-side (Aspen Plus) and CORBA-side (Fluent) pieces of the Vision 21 controller code were written and independently verified. The two pieces of the code were then combined. Debugging of the combined code is underway (Task 2.7). Papers on fuel cell processes were read in preparation for developing an example based on a fuel cell process (Task 2.8). The INDVU code has been used to replace the boiler component in the Aspen Plus flowsheet of the RP&L power plant. The INDVU code receives information from Aspen Plus and iterates on the split backpass LTSH bypass and excess air quantities until the stipulated superheat outlet temperature is satisfied. The combined INDVU-Aspen Plus model has been run for several load conditions (Task 2.14). Work on identifying a second demonstration case involving an advanced power cycle has been started (Task 3.2). Plans for the second Advisory Board meeting in November were made (Task 5.0). Intergraph subcontract was signed and work on a physical domain software demo was started. A second teleconference with Norsk Hydro was conducted to discuss Global CAPE-OPEN standards and issues related to COM-CORBA Bridge (Task 7.0).
Date: October 20, 2001
Creator: Madhava Syamlal, Ph.D.
Partner: UNT Libraries Government Documents Department

FINAL SIMULATION RESULTS FOR DEMONSTRATION CASE 1 AND 2

Description: The goal of this DOE Vision-21 project work scope was to develop an integrated suite of software tools that could be used to simulate and visualize advanced plant concepts. Existing process simulation software did not meet the DOE's objective of ''virtual simulation'' which was needed to evaluate complex cycles. The overall intent of the DOE was to improve predictive tools for cycle analysis, and to improve the component models that are used in turn to simulate equipment in the cycle. Advanced component models are available; however, a generic coupling capability that would link the advanced component models to the cycle simulation software remained to be developed. In the current project, the coupling of the cycle analysis and cycle component simulation software was based on an existing suite of programs. The challenge was to develop a general-purpose software and communications link between the cycle analysis software Aspen Plus{reg_sign} (marketed by Aspen Technology, Inc.), and specialized component modeling packages, as exemplified by industrial proprietary codes (utilized by ALSTOM Power Inc.) and the FLUENT{reg_sign} computational fluid dynamics (CFD) code (provided by Fluent Inc). A software interface and controller, based on an open CAPE-OPEN standard, has been developed and extensively tested. Various test runs and demonstration cases have been utilized to confirm the viability and reliability of the software. ALSTOM Power was tasked with the responsibility to select and run two demonstration cases to test the software--(1) a conventional steam cycle (designated as Demonstration Case 1), and (2) a combined cycle test case (designated as Demonstration Case 2). Demonstration Case 1 is a 30 MWe coal-fired power plant for municipal electricity generation, while Demonstration Case 2 is a 270 MWe, natural gas-fired, combined cycle power plant. Sufficient data was available from the operation of both power plants to complete the cycle configurations. Three runs ...
Date: October 15, 2003
Creator: Sloan, David & Fiveland, Woodrow
Partner: UNT Libraries Government Documents Department

HIGH PRESSURE COAL COMBUSTION KINETICS PROJECT

Description: The modifications to the SRT-RCFR facility described in the June report were completed. As a result of these changes, the furnace hot zone was increased in length from 7 cm to 15.5 cm. The injector region of the furnace, providing entrainment and sheath flows, was unchanged, while the flow path from the exit of the furnace to the sample collection section was shortened by approximately 10 cm. The modified facility was used to resume testing of Pittsburgh No. 8 coal at 10 atm. The first goal was to confirm that the facility now provides true secondary pyrolysis test conditions. That is, the tar product should be completely converted to soot even in the absence of oxygen in the gas stream. We have now performed four tests with pure argon carrier gas, and have consistently observed voluminous soot product with little or no evidence of tar. Thus, this objective was met. The clogging problems for Pittsburgh No. 8 coal under secondary pyrolysis test conditions may preclude achieving this data point. In that case, we will make measurements under oxidizing conditions, which are expected to eliminate the clogging, and to gradually reduce the oxygen content to the point where product yields can reliably be extrapolated to the zero oxygen case.
Date: October 28, 2002
Creator: Guenther, Chris
Partner: UNT Libraries Government Documents Department

HIGH PRESSURE COAL COMBUSTON KINETICS PROJECT

Description: As part of the U.S. Department of Energy (DoE) initiative to improve the efficiency of coal-fired power plants and reduce the pollution generated by these facilities, DOE has funded the High-Pressure Coal Combustion Kinetics (HPCCK) Projects. A series of laboratory experiments were conducted on selected pulverized coals at elevated pressures with the specific goals to provide new data for pressurized coal combustion that will help extend to high pressure and validate models for burnout, pollutant formation, and generate samples of solid combustion products for analyses to fill crucial gaps in knowledge of char morphology and fly ash formation. Two series of high-pressure coal combustion experiments were performed using SRI's pressurized radiant coal flow reactor. The first series of tests characterized the near burner flame zone (NBFZ). Three coals were tested, two high volatile bituminous (Pittsburgh No.8 and Illinois No.6), and one sub-bituminous (Powder River Basin), at pressures of 1, 2, and 3 MPa (10, 20, and 30 atm). The second series of experiments, which covered high-pressure burnout (HPBO) conditions, utilized a range of substantially longer combustion residence times to produce char burnout levels from 50% to 100%. The same three coals were tested at 1, 2, and 3 MPa, as well as at 0.2 MPa. Tests were also conducted on Pittsburgh No.8 coal in CO2 entrainment gas at 0.2, 1, and 2 MPa to begin establishing a database of experiments relevant to carbon sequestration techniques. The HPBO test series included use of an impactor-type particle sampler to measure the particle size distribution of fly ash produced under complete burnout conditions. The collected data have been interpreted with the help of CFD and detailed kinetics simulation to extend and validate devolatilization, char combustion and pollutant model at elevated pressure. A global NOX production sub-model has been proposed. The submodel reproduces the ...
Date: March 30, 2005
Creator: Orsino, Stefano
Partner: UNT Libraries Government Documents Department

DEVELOPMENT OF TECHNOLOGIES AND ANALYTICAL CAPABILITIES FOR VISION 21 ENERGY PLANTS

Description: To accelerate the development of advanced power plants, DOE's Vision 21 program identified the need for an integrated suite of software tools that could be used to simulate and visualize new plant concepts. Existing process simulation software did not meet this objective of virtual-plant simulation. Sophisticated models of many individual equipment items are available; however, a seamless coupling capability that would integrate the advanced equipment (component) models to the process (system) simulation software remained to be developed. The inability to use models in an integrated manner causes knowledge loss (e.g., knowledge captured in detailed equipment models is usually not available in process simulation) and modeling inconsistencies (e.g., physical properties and reaction kinetics data in different models are not the same). A team consisting of Fluent Inc., ALSTOM Power Inc., Aspen Technology Inc., Intergraph Corporation, and West Virginia University, in collaboration with the National Energy Technology Laboratory (NETL), addressed this challenge in a project performed over the period from October 2000 through December 2004. In this project the integration of the cycle analysis software was based on widely used commercial software: Aspen Plus{reg_sign} for process simulation and FLUENT{reg_sign} for computational fluid dynamics (CFD) modeling of equipment items. The integration software was designed to also include custom (in-house, proprietary, legacy) equipment models that often encapsulate the experience from the many years of designing and operating the equipment. The team adopted CAPE-OPEN (CO) interfaces, the de facto international standard for communication among process models, for exchanging information between software. The software developed in this project is the first demonstration of the use of CO interfaces to link CFD and custom equipment models with process simulators. New interface requirements identified during this project were communicated to the CO standard developers. The new software capability was designed to make the construction of integrated models fast ...
Date: April 1, 2005
Creator: Syamlal, Madhava; Osawe, Maxwell; Zitney, Stephen; Collins, Lewis; Sloan, David; Fiveland, Woodrow et al.
Partner: UNT Libraries Government Documents Department

HIGH PRESSURE COAL COMBUSTION KINETICS PROJECT

Description: The HPCCK project was initiated with a kickoff meeting held on June 12, 2001 in Morgantown, WV, which was attended by all project participants. SRI's existing g-RCFR reactor was reconfigured to a SRT-RCFR geometry (Task 1.1). This new design is suitable for performing the NBFZ experiments of Task 1.2. It was decided that the SRT-RCFR apparatus could be modified and used for the HPBO experiments. The purchase, assembly, and testing of required instrumentation and hardware is nearly complete (Task 1.1 and 1.2). Initial samples of PBR coal have been shipped from FWC to SRI (Task 1.1). The ECT device for coal flow measurements used at FWC will not be used in the SRI apparatus and a screw type feeder has been suggested instead (Task 5.1). NEA has completed a upgrade of an existing Fluent simulator for SRI's RCFR to a version that is suitable for interpreting results from tests in the NBFZ configuration (Task 1.3) this upgrade includes finite-rate submodels for devolatilization, secondary volatiles pyrolysis, volatiles combustion, and char oxidation. Plans for an enhanced version of CBK have been discussed and development of this enhanced version has begun (Task 2.5). A developmental framework for implementing pressure and oxygen effects on ash formation in an ash formation model (Task 3.3) has begun.
Date: September 15, 2001
Creator: Guenther, Chris & Rogers, Bill
Partner: UNT Libraries Government Documents Department

DEVELOPMENT OF TECHNOLOGIES AND ANALYTICAL CAPABILITES FOR VISION 21 ENERGY PLANTS

Description: This is the twelfth Quarterly Technical Report for DOE Cooperative Agreement No: DE-FC26-00NT40954. The goal of the project is to develop and demonstrate a software framework to enable virtual simulation of Vision 21 plants. During the last quarter the software development was completed and the testing of the integrated software was completed. A user manual was written to complete software documentation. An installation CD-ROM including the following items was written: software installer, controller source code, proprietary CORBA wrapper templates for building local and remote servers, publicly available source code of the ACE/TAO CORBA library that needs to be built before compiling the controller source code, pre-built binaries of the publicly available XERCES XML library, and a PDF version of the software user's manual. The software was delivered to DOE. During the last quarter software demonstration tasks were completed. A few additional load points of Demo Case 1 were solved. Integrated simulations of Demo Case 2 with the proprietary HRSGSIM code and FLUENT CFD model were completed. The final task report describing Demo Case1 and Demo Case 2 simulation results was written and delivered to DOE.
Date: October 30, 2003
Creator: Osawe, Maxwell; Syamlal, Madhava; Thotapalli, Krishna & Zitney, and Stephen
Partner: UNT Libraries Government Documents Department

HIGH PRESSURE COAL COMBUSTION KINETICS PROJECT

Description: NEA completed the CFD simulations for all NBFZ tests. SRI resumed work on HPBO experiments and conducted preliminary tests using the UCONN impactor. UCONN prepared several samples of char for cross-sectional analysis by SEM and characterization is underway. BU completed the NBFZ char characterization program. CBK model had been implemented into Fluent.
Date: July 25, 2003
Creator: Orsino, Stefano
Partner: UNT Libraries Government Documents Department

DEVELOPMENT OF TECHNOLOGIES AND ANALYTICAL CAPABILITIES FOR VISION 21 ENERGY PLANTS

Description: This is the tenth Quarterly Technical Report for DOE Cooperative Agreement No: DE-FC26-00NT40954. The goal of the project is to develop and demonstrate a software framework to enable virtual simulation of Vision 21 plants. During the last quarter much progress was made in software development. The CO wrapper template was developed for the integration of Alstom Power proprietary code INDVU. The session management tasks were completed. The multithreading capability was made functional so that user of the integrated simulation may directly interact with the CFD software. The V21-Controller and the Fluent CO wrapper were upgraded to CO v.1.0. The testing and debugging of the upgraded software is ongoing. Testing of the integrated software was continued. A list of suggested GUI enhancements was made. Remote simulation capability was successfully tested using two networked Windows machines. Work on preparing the release version progressed: CFD database was enhanced, a convergence detection capability was implemented, a Configuration Wizard for low-order models was developed, and the Configuration Wizard for Fluent was enhanced. During the last quarter good progress was made in software demonstration. Various simplified versions of Demo Case 1 were used to debug Configuration Wizard and V21-Controller. The heat exchanger model in FLUENT was calibrated and the energy balance was verified. The INDVU code was integrated into the V21-Controller, and the integrated model is being debugged. A sensitivity loop was inserted into Demo Case 2 to check whether the simulation converges over the desired load range. Work on converting HRSGSIM code to run in batch mode was started. Work on calibrating Demo Case 2 was started.
Date: April 30, 2003
Creator: Osawe, Maxwell; Symlal, Madhave; Thotapalli, Krishna & Zitney, and Stephen
Partner: UNT Libraries Government Documents Department

DEVELOPMENT OF TECHNOLOGIES AND ANALYTICAL CAPABILITIES FOR VISION 21 ENERGY PLANTS

Description: To complete project planning, various project groups conducted several meetings and teleconferences. As a result a draft project management plan was written and circulated. The plan will be finalized in a project kick off meeting to be held on January 16, 2001 in Lebanon, NH, which will be attended by all project participants (Task 1.0). Various project personnel have been trained in the use of Fluent and Aspen Plus, which completes all the training tasks except for Aspen Plus and IDL training for Alstom Power (Task 2.1). A preliminary version of User Requirements Document (preURD) was written. This document will be sent to key users of Aspen Plus and FLUENT and their responses will be collected in January (Task 2.3). A prototype of Fluent integration with Aspen Plus was constructed for understanding the required software design. The development of a general architecture for the integrated software suite has been started (Task 2.6). Invitation letters for participation in an Advisory Board were sent out to several Vision 21 contractors. Their responses will be used to form an Advisory Board in January (Task 5.0). Fluent has awarded subcontracts to Alstom Power, CERC, and Aspen Tech and negotiations with Intergraph are underway. Aspen Plus and FLUENT were installed on a computer at CERC. The design of a project web site was completed, and the site setup was started (Task 7.0).
Date: January 23, 2001
Creator: Madhava Syamlal, Ph.D.
Partner: UNT Libraries Government Documents Department

DEVELOPMENT OF TECHNOLOGIES AND ANALYTICAL CAPABILITIES FOR VISION 21 ENERGY PLANTS

Description: A software design review meeting was held May 2-3 in Lebanon, NH. The work on integrating a reformer model based on CFD with a fuel cell flow sheet was completed (Task 2.0). The CFD database design was completed and the database API's finalized. A file -based CFD database was implemented and tested (Task 2.8). The task COM-CORBA Bridge-I was completed. The bridge now has CO interfaces for transferring reaction kinetics information from Aspen Plus to Fluent (Task 2.11). The capability for transferring temperature-dependent physical properties from Aspen Plus to Fluent was implemented (Task 2.12). Work on ''Model Selection'' GUI was completed. This GUI allows the process analyst to select models from the CFD database. Work on ''Model Edit'' GUI was started (Task 2.13). A version of Aspen Plus with the capability for using CO parameters in ''design spec'' analysis has become available. With this version being available, work on adding CO wrapper to INDVU code has been started (Task 2.15). A preliminary design for the Solution Strategy class was developed (Task 2.16). The requirements for transferring pressure data between Aspen Plus and Fluent were defined. The ability to include two CFD models in a flow sheet was successfully tested. The capability to handle multiple inlets and outlets in a CO block was tested (Task 2.17). A preliminary version of the Configuration Wizard, which helps a user to make any Fluent model readable from a process simulator, was developed and tested (Task 2.18). Work on constructing a flow sheet model for Demo Case 2 was started. The work on documenting Demo Case 2 is nearing completion (Task 3.2). A Fluent heat exchanger model was installed and tested. Work on calibrating the heat exchanger model was started (Task 4.1). An advisory board meeting was held in conjunction with the Fluent Users Group ...
Date: July 1, 2002
Creator: Madhava Syamlal, Ph.D.
Partner: UNT Libraries Government Documents Department

HIGH PRESSURE COAL COMBUSTION KINETICS PROJECT

Description: SRI has completed the NBFZ test program, made modification to the experimental furnace for the HPBO test. The NBFZ datasets provide the information NEA needs to simulate the combustion and fuel-N conversion with detailed chemical reaction mechanisms. BU has determined a linear swell of 1.55 corresponding to a volumetric increase of a factor of 3.7 and a decrease in char density by the same factor. These results are highly significant, and indicate significantly faster burnout at elevated pressure due to the low char density and large diameter.
Date: January 28, 2003
Creator: Chris Guenther, Ph.D.
Partner: UNT Libraries Government Documents Department

Circulating Fluid-Bed Technology for Advanced Power Systems

Description: Circulating fluid bed technology offers the advantages of a plug flow, yet well-mixed, and high throughput reactor for power plant applications. The ability to effectively scale these systems in size, geometry, and operating conditions is limited because of the extensive deviation from ideal dilute gas-solids flow behavior (Monazam et al., 2001; Li, 1994). Two fluid computations show promise of accurately simulating the hydrodynamics in the riser circulating fluid bed; however, validation tests for large vessels with materials of interest to the power industry are lacking (Guenther et al., 2002). There is little available data in reactors large enough so that geometry (i.e. entrance, exit, and wall) effects do not dominate the hydrodynamics, yet with sufficiently large particle sizes to allow sufficiently large grid sizes to allow accurate and timely hydrodynamic simulations. To meet this need experimental tests were undertaken with relatively large particles of narrow size distribution in a large enough unit to reduce the contributions of wall effects and light enough to avoid geometry effects. While computational fluid dynamic calculations are capable of generating detailed velocity and density profiles, it is believed that the validation and model development begins with the ability to simulate the global flow regime transitions. The purpose of this research is to generate well-defined test data for model validation and to identify and measure critical parameters needed for these simulations.
Date: November 6, 2001
Creator: Shadle, Lawrence J.; Ludlow, J. Christopher; Mei, Joseph S. & Guenther, Christopher
Partner: UNT Libraries Government Documents Department

COMPUTATIONAL FLUID DYNAMICS MODELING ANALYSIS OF COMBUSTORS

Description: In the current fiscal year FY01, several CFD simulations were conducted to investigate the effects of moisture in biomass/coal, particle injection locations, and flow parameters on carbon burnout and NO{sub x} inside a 150 MW GEEZER industrial boiler. Various simulations were designed to predict the suitability of biomass cofiring in coal combustors, and to explore the possibility of using biomass as a reburning fuel to reduce NO{sub x}. Some additional CFD simulations were also conducted on CERF combustor to examine the combustion characteristics of pulverized coal in enriched O{sub 2}/CO{sub 2} environments. Most of the CFD models available in the literature treat particles to be point masses with uniform temperature inside the particles. This isothermal condition may not be suitable for larger biomass particles. To this end, a stand alone program was developed from the first principles to account for heat conduction from the surface of the particle to its center. It is envisaged that the recently developed non-isothermal stand alone module will be integrated with the Fluent solver during next fiscal year to accurately predict the carbon burnout from larger biomass particles. Anisotropy in heat transfer in radial and axial will be explored using different conductivities in radial and axial directions. The above models will be validated/tested on various fullscale industrial boilers. The current NO{sub x} modules will be modified to account for local CH, CH{sub 2}, and CH{sub 3} radicals chemistry, currently it is based on global chemistry. It may also be worth exploring the effect of enriched O{sub 2}/CO{sub 2} environment on carbon burnout and NO{sub x} concentration. The research objective of this study is to develop a 3-Dimensional Combustor Model for Biomass Co-firing and reburning applications using the Fluent Computational Fluid Dynamics Code.
Date: November 6, 2001
Creator: Mathur, M. P.; Freeman, Mark & Gera, Dinesh
Partner: UNT Libraries Government Documents Department