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Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig
2nd European sCO2 ConferenceAugust, 30th-31st 2018 - Essen - Germany
Gregor Klemencic, Markus Haider, Andreas Werner,Helmut Leibinger, Thomas Fellner, Norbert Steinschaden,
Thomas Bergthaller, Tim Nowack
Project Partners
2
FFG
Klima und Energie Fonds
Rohrdorfer Zement
Maschinenfabrik Liezen
Salzburg AG
Firma Scheuch
Firma Zauner GesmbHDesign and dynamic simulation of a 200 kWth laboratory sCO2‐test rig,
2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Overview
Design of the sCO2 test rig
Phase 1 and Phase 2
Dynamic simulation
Simulation results and first experiments
Outlook
3Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Objectives of the sCO2 project
Planning, constructing and taking into operation a sCO2 test rig at the laboratory of TU Wien
Performance of the different components of the sCO2 cycle process (heat exchangers, control valves, etc.) at different operating conditions (stationary, transient,...) should be investigated
this includes: developing control strategies for the cycle processes, validation of heat exchanger designs, influence of thermal property variations on performance, etc.
Final result: reliable overall concept for sCO2 heat recovery systems for industrial purposes (also including solutions for heat transformation and heat storage)
4Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Design of the test rig: Basic Concept
5Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Phase 1
Phase 2
Pump
high pressure level (tRC) 220 bar
low pressure level (tRC) 60 bar
min. mass flow (100 kWth) 0.2 kg/s
max. mass flow (200 kWth) 0.4 kg/s
max. CO2 temperature (hot air) 380 °C
max. CO2 temperature (thermal oil) 360 °C
Phase 1 and Phase 2 in T, s‐Diagramm
Selection of CO2 process data:
Calculation of the tRC in IPSEPro (Thermal Oil, 200 kWth)
Photo of the test rig
6Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
R&I Scheme – Phase 1:
7Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
01-E100
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01-A100 (FS)01-P111-DN50-1.4571
PIC022
TI023
TIC028
PI029
PIC021
TIC020
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TI012
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PI016
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01-P105-D
N25-1.4571
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01-SV103
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01-P102-DN40-1.4571
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cooling Water OUT
cooling Water IN01-P112-DN65-1.0345
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01-A105
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01-A116 (FC)
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01-A120 (FC)
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01-P123-D
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to drainage
01-P125-D
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01-P122-DN125-1.0345
01-A132
01-A124
01-A123
01-A131
01-A130
01-A129
01-A128
01-A127
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01-A122 (FO)
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to chimney
Thermal Oil Plant flow (TO-building)
TI013
TIC031
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trace heating circuit 1
01-P107-DN40-1.0345
Thermal Oil Plant return (TO-building)
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01-P107-DN40-1.0345trace heating circuit 2
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R&I Scheme – Phase 2:
8Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
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TI022
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CO2-Vent Line
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Natural Gas
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Ambient Air
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ater OU
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ater IN
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turbine orexpansionvalve used
air or water
cooled condenser
Dynamic Simulation I:
9Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Reason for:
• To test the process control system and the general dynamic behavior of the complete test rig,
applied to:• both operating modes of the test rig: transcritical and supercritical
Dynamic Simulation II:
10Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Simulation tool: APROS (Advanced Process Simulator, VTT)
Dynamic Simulation III: Results TC
11Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Temperature rise: Pressure increase:
Level in buffer tank:
Dynamic Simulation IV: Results SC
12Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Temperature rise: Pressure increase:
Level in buffer tank:
Filling the test rig
The temperature of the rig and the gas bottle limits the amount of CO2 that can be fed into theplant.• A heater can be used to heat the
gas bottle.• Natural circulation can be used to
cool the plant.
First Experiment
Pressure Oscillations at Pump
Lessons learned
HAZOP study revealed the need for additional safety mechanisms• Hard wired over-temperature shut-down (SIL2)• Protection of heat exchangers against rupture of CO2 tubes
Burst disks are used to protect the HEX shell, but…• Burst pressure limits pressure in thermal oil circuit.• Thermal oil pressure, in turn, limits the temperature (370 °C).• Pressure surges in may cause a rupture of the disks when
operating valves too quickly.
Acknowledgements
Recent and Current Research Projects on sCO2 at TU Wien:
SuCritDioCyc „(s)-CO2-Prozesse zur Abwärmenutzung“ (FFG, Project Number: 848889, duration: 01.04.2015‐31.03.2016)
sCO2-Phase 1 „CO2 als Arbeitsmedium in der Energierückgewinnung“ (FFG, Project Number: 853568, duration: 01.03.2016‐28.02.2019)
17Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen
Thank you very much for your
attention !
18Design and dynamic simulation of a 200 kWth laboratory sCO2‐test rig, 2nd European sCO2 Conference, Aug. 30th‐31st, 2018, Essen