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4/23/10 12:02
1
of ‘Black-box' Models in Power Plant Flowsheets
Yidong Lang & Lorenz T. Biegler
Department of Chemical Engineering
Carnegie Mellon University
Energy System Initiative
March 7, 2010
Optimization and Integration
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Outline Motivation Development of ROM Wrapped yROM for flowsheet Integration of ROM into Flowsheet in GAMS Optimization and Closed loop evaluation Converting yROM into USER3 model Integrating the USER3 with IGCC in AspenPlus
for further Optimization with EO mode
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Concepts of APECS: Co-Simulation with Aspen Plus and Fluent
CFD Model
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Road map from CFD model to “Black box” model
Flowsheet of IGCC in APECS with Aspen
Plus and Fluent accommodating CFD
Model
Extracted CFD
model
Developed ROM
Developed USER3 Model According to the protocols in Aspen Plus
Equations of ROM inserted part of
IGCC flowsheet in GAMS Flowsheet of IGCC in Aspen Plus with
replacement of USER3 of ROM which can be optimized with EO
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ROM Development for CFD Model
Ref: Lang et al., Reduced Order Model Based on Principal Component Analysis for Process Simulation and Optimization†, Energy & Fuels 2009, 23, 1695–1706
xROM PCA ROM
yROM For Iterative process simulation and optimization
Display fields of states after convergence Cases of
CFD Model
ROM is a remedy to overcome CPU time prohibited of CFD model in iterative computing of co-simulated flowsheet simulation and optimization
1. Determine operation domain, Experimental design (LHS) 2. Run Fluent cases according to the results of Experimental design
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split
The predicted effect of inputs on outlet temperature given by yROM shows reasonable reliability
Development and Validation of ROM for Gasifier
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Interface
Coal
Water
Oxyg.
s41 s81
s82
s83
s84
s85
s86
s87
s88
s89
Gasifier
GFpost
Splitter
Mixer 1
Mixer 2
Wrapping yROM of Gasifier as a section of flowsheet
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AIR
FUEL
LP CONS . MP
CONS . HP CONS .
CW
DW
High Pressure ( HP ) Header
Vacuum Header
Condensate Header
Medium Pressure ( MP ) Header
Low Pressure ( LP ) Header
Deaerator
HRSG
Gas Turbine
S 1 S 58
S 2
S 3
S 59
S 4
S 60
S 61
S 5
S 6 S 7
S 8
S 9
S 15 S 20
S 16 S 12
S 11 S 17
S 10 S 37 S 38
S 34 S 35 S 36
S 41 S 46
S 43
S 42
S 45
S 40
S 39 S 47 S 54
Gas
ifier
wat
er
Coa
l
O2
Integration yROM of Gasifier and Steam Cycle
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Minimizing Objective Function Subject to
Power Demand (Net Electricity): 500 MW
Objective Function Add. Constr Optimal solutions
u1 u2 u3
1 Heating Value of Syngas No 84.6928 34.9266 84.8813
2 Coal Feed flowrate No 70.3411 25.2085 75.2154
3 Heating Value of Syngas Tout >1660 Tout < 1670
84.6928 34.9266 82.716198
4 Coal Feed flowrate Tout >1660 Tout < 1670
70.3411 25.2085 75.912813
Optimal Solution
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H2S H2O H2 CH4 CO2 CO Temp(K)
Loop test (1)
ROM 0.013172 0.305403 0.011566 0.025022 0.067842 0.552102 1709.19
Fluent 0.013149 0.305228 0.011611 0.024865 0.069569 0.550176 1712.65
Error(%) 0.17 0.06 0.38 0.63 2.48 0.35 0.20
Loop test (2)
ROM 0.015087 0.207855 0.017510 0.031057 0.065993 0.635727 1644.08
Fluent 0.015114 0.206340 0.017904 0.030502 0.065742 0.638125 1627.54
Error(%) 0.18 0.73 2.20 1.82 0.38 0.38 1.02
Loop test (3)
ROM 0.013277 0.304384 0.011538 0.027482 0.061432 0.557007 1670.00
Fluent 0.013280 0.302956 0.011573 0.028183 0.065889 0.552833 1667.49
Error(%) 0.02 0.47 0.30 2.49 6.76 0.76 0.15
Loop test (4)
ROM 0.015042 0.206258 0.017836 0.029846 0.073121 0.631096 1660.00
Fluent 0.015602 0.211528 0.016875 0.031671 0.063249 0.635083 1657.04
Error(%) 0.13 2.49 5.69 5.76 15.61 0.63 0.18
Results of closed loop test for yROM
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Closed Loop (1) for xROM
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Closed Loop (2) for xROM
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Closed Loop (3) for xROM
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Closed Loop (4) for xROM
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Converting yROM into USER3 model in Aspen Plus
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IGCC flowsheet and integration of replaced CFD model
Water shift
TSA and CO2 compression
Gas-Combustor-Turbine
Steam cycle
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Conclusions
The concept of APECS is extended to process optimization by replacing CFD model with its PCA ROM in IGCC flowsheet
ROM for gasifier is developed and validated ‘Closed loop’ tests in GAMS show that validation from converged
Fluent case is encouraging. Conversion from yROM into USER3 model is successfully
implemented and can be integrated with an existing IGCC flowsheet
We are now aiming at EO mode of the simulator, it is potentially possible to used novel NLP solver like Ipopt in process optimization for IGCC
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Future Work
ROM of Gas turbine combustor will be developed following the procedures of PCA ROM
Convert its yROM into USER3 in Aspen Plus and integrate with IGCC
Implement optimization with integrated two ‘Black-box’es using EO and open solver in Aspen Plus