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Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
Institute for Chemical Process EngineeringProf. Dr.-Ing. U. Nieken
Böblingerstr. 72, 70199 Stuttgart, Germany
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Object-oriented modelling,
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Object-oriented modelling,
dynamic simulation and optimization
of heat-integrated exhaust purification systems
with ProMoT and DIANA
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MODEGAT
September 14 - 15, 2009, Karlsruhe, Germany
Jens Bernnat* , Matthias Rink, Ute Tuttlies, Ulrich Nieken
and Gerhart Eigenberger
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.deInstitute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
Outline
1. Introduction
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2. Modelling and Simulation
with ProMoT and Diana
3. Simulation Results - Examples
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4. Summary and Outlook
MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
1. Automotive exhaust purification – state of the art
Diesel-
state of the art ���� multi-component exhaust lines
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NOx-storage-reduction catalystT = 250 - 450°C(sulphur removal: T ≈ 750°C)
Diesel soot filter(regeneration atT ≈ 450 - 750°C)
Diesel-oxidation-T > 250°C
Exhaust temperature:
EGR-Valve
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Exhaust temperature:150 – 800°C
MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
Commercial tools for simulation available
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.deInstitute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
1. Exhaust purification – heat-integrated approach
Exhaust treatment separated from engine control
in one compact, autonomous exhaust treatment unit
outlet DOCNSC
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sidewise
engine
exhaust in
fuel burnerair
fuel
HEX DSF
engine • Full flexibility of equation based modelling
necessary (programming languages)
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
necessary (programming languages)
• Convenience of “block oriented” tool preferred
����Lack of commercial tools
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
1. Heat integrated concepts – modeling approaches
Modular approach: Models reusable for different
constellations, complex system to solve library
exhaust out NSC
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cleaning
devices
HEX
burner
pipesFully integrated approach: new models and
extensive numerical studies necessary
exhaust out NSC
DOC
DSF
burner
exhaust in
heat exchanger
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
pipes
sensors
observer
...
extensive numerical studies necessary
NSC
DOCburner
exhaust in
exhaust out
heat exchanger
DSF
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
1. Heat integrated concepts – modeling approaches
Requirements:
• easy set-up of model constellations
and simulation scenarios
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and simulation scenarios
• user-friendly “block-oriented” modelling
• flexibility of equation based modelling
• efficient solvers for complex coupled DAE problems
• full access to the source code
• efficient tools for parameter estimation,
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
• efficient tools for parameter estimation,
optimization and numerical analysis
����our choice: ProMoT and DIANA
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
2. ProMoT and DIANA
(Max Planck Institute Dynamics of Complex Technical Systems, Magdeburg)
�Equation-based modelling
�DAE (index 1)
Modelling tool ProMoT
(Process Modelling Tool)
counter current heat-exchanger
DOCoutlet channel
inlet channel
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�Object-oriented concept
�Multiple inheritance
�Aggregation
�Model implementation
�Graphical modelling with GUI
engine burnerDOC
mixing module
burner
inlet channelengine
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
ambient heat-exchanger
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
2. ProMoT and DIANA
(Max Planck Institute Dynamics of Complex Technical Systems, Magdeburg)
�Equation-based modelling
�DAE (index 1)
Modelling tool ProMoT
(Process Modelling Tool)
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�Object-oriented concept
�Multiple inheritance
�Aggregation
�Model implementation
�Graphical modelling with GUI
�Text-based in language MDL
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
�Equation analysis and optimization
�Symbolic differentiation in ProMoT
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
2. ProMoT and DIANA
(Max Planck Institute Dynamics of Complex Technical Systems, Magdeburg)
Simulation tool DIANA
(Dynamic sImulation And Numerical Analysis Tool)
�Equation-based modelling
�DAE (index 1)
�Equation based models
�Object-oriented architecture
Modelling tool ProMoT
(Process Modelling Tool)
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�Object-oriented concept
�Multiple inheritance
�Aggregation
�Model implementation
�Graphical modelling with GUI
�Text-based in language MDL
�Modular and extensible
�Efficient numerical kernel
(solvers based on free code)
�Control via scripts
�Contains methods for
dynamic simulation and
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
�Equation analysis and optimization
�Symbolic differentiation in ProMoT
numerical analysis
• free for academic groups under GNU General Public License
• full access to source, good support (MPI) and extensibility
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
3. Simulation Results – Heat-integrated system
Favorable mode of operation:
1) Fast start-up of the unit
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Two showcases how to use DIANA concerning
heat-integrated exhaust purification systems
2) Keep unit in ignited mode
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
Dynamic simulation of heat-up
under drive-cycle conditions
to show behaviour of the system
Steady-state continuation
to show theoretical limits
of ignited states
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
3. Simulation Results – Example 1
Heat-up under drive cycle conditions (no cold-start application!)
Comparison of three system set-ups (Diesel):
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DOC (stand alone)
a) DOC with cold start burner
b) HEX with DOC and cold start burner ���� heat-integrated system
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
Set point: C350T INDOC °= C400T IN
DOC °=
Source: CaPoC8 Brussels; J. Bernnat et. al. - Heat integrated concepts for automotive exhaust purification
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.deInstitute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
3. Dynamic Simulation –
Heat-up under drive cycle conditions
200
250
300
te
mp
era
ture
[°C
] speed
temperature engine outspeed[km/h]
300
400
500
tem
pera
ture
[°
C]
DOC out (with HEX and FB)
DOC out (with FB)
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Fast heat-up due to efficient use of the burner
0 200 400 6000
50
100
150
time [s] during 4 ECE15 cycles
te
mp
era
ture
[°C
]
60
40
20
00 200 400 600
0
100
200
300
time [s]
tem
pera
ture
[°
C]
engine out
DOC out
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
Concerning DIANA:
Easy and fast set-up of simulation scenario
Efficient simulation of different coupled systems under drive-cycle conditions
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
3. Simulation Results – Example 2
Second Example: Steady-state continuation: stability of operation states
Simple model of integrated system for exhaust after treatment of CNG-engine*
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Simple model of integrated system for exhaust after treatment of CNG-engine*
counter-current
inlet
outlet
insulation
housing
catalyst section
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
counter-current heat exchanger
catalyst section (hot side)
*www.ingas-eu.org
Counter-current heat exchanger with partially catalytically coated walls
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
3. Steady-state continuation – principlew
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
Source: Mykhaylo Krasnyk, DIANA — An object-oriented tool for nonlinear analysis of
chemical processes, Max Planck Institute for Dynamics of Complex Technical Systems
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
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Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
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3. Steady-state continuation in two parameters
400Inflow temperature vs. fuel concentration
Variable: Temperature, Methane Concentration
Constant: 100 kg/h
0.2
0.4
0.6
0.8
1
Conversion vs. inflow temperature
Co
nvers
ion
[-]
upper stable branch
unstable branch
lower stable branch
2000 ppm
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200
300
400
Infl
ow
tem
pera
ture
[°° °° C
]
Cusp gives the
limits of ignition
and extinction
ignition line
extinction line
100 200 300 400 500 600
0
0.2
Inflow temperature [°°°° C]
Co
nvers
ion
[-]
2000 ppm
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
0 2000 4000 6000 8000 100000
100
Methane concentration [ppm]
Infl
ow
tem
pera
ture
[
2000 ppm
extinction line
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
3. Steady-state continuation in two parameters
400Inflow temperature vs. fuel concentration
Variable: Temperature, Methane Concentration
Constant: 100 kg/h
0.2
0.4
0.6
0.8
1
Conversion vs. inflow temperature
Co
nvers
ion
[-]
upper stable branch
unstable branch
lower stable branch
2000 ppm
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200
300
400
Infl
ow
tem
pera
ture
[°° °° C
]
Cusp gives the
limits of ignition
and extinction
ignition line
extinction line
100 200 300 400 500 600
0
0.2
Inflow temperature [°°°° C]
Co
nvers
ion
[-]
2000 ppm
1
Conversion vs. inflow temperature
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
0 2000 4000 6000 8000 100000
100
Methane concentration [ppm]
Infl
ow
tem
pera
ture
[
extinction line
100 200 300 400 500 600
0
0.2
0.4
0.6
0.8
1
Inflow temperature [°°°° C]
Co
nvers
ion
[-]
850 ppm
850 ppm
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
3. Steady-state continuation – CNG
4000
5000
Inle
t co
ncen
trati
on
Meth
an
e [
pp
m]
From the limit points we can extract more useful information! e.g.
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2000
3000
4000
Inle
t co
ncen
trati
on
Meth
an
e [
pp
m]
300 kg/h
200 kg/h
100 kg/h
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
100 200 300 400 500 6000
1000
Inlet temperature [°°°° C]
Inle
t co
ncen
trati
on
Meth
an
e [
pp
m]
50 kg/h10 kg/h
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.deInstitute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
4. Summary and outlook
• Object-oriented, equation-based modelling
• Flexible and fast set-up of model configurations
Summary:
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• Flexible and fast set-up of model configurations
• Easy set–up of simulation scenarios
• ProMoT1) and DIANA1)
• Advanced numerical packages for system design
• Simulation results
Outlook:
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MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
1) Max Planck Institute for Dynamics of Complex Technical Systems
• Extension of model library
• Analysis and optimization of after treatment systems
• Development of control strategies
Institute for Chemical Process Engineering: www.icvt.uni-stuttgart.deInstitute for Chemical Process Engineering: www.icvt.uni-stuttgart.de
Acknowledgement:
Support of the
• Deutsche Forschungsgemeinschaft (DFG),
European Community (EU)
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Thank you for your kind attention!
• European Community (EU)
• MPI Magdeburg
is gratefully acknowledged.
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Questions?
MODEGAT Karlsruhe J. Bernnat et al. - Object-oriented modelling with ProMoT and DIANA15.09.2009
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