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March 15, 2009
Dear Customer,
We are pleased to
enclose a major upgrade to our software suite, Version 19, with the following
highlights:
(1) Post-combustion
capture of CO2 from flue gas in combined cycles, and pre-combustion CO2 capture
in IGCC plants are available in GT PRO/MASTER.
(2) Post-combustion CO2
capture from flue gas is available in STEAM PRO/MASTER.
(3) CO2 capture using
physical or chemical absorption is available in THERMOFLEX to extract CO2 from
flue gas or syngas streams.
(4) GT PRO and GT
MASTER include a large-format comprehensive heat balance diagram to display
detailed heat and mass balance results for the entire plant model on a single
flowsheet. A 4ft x 3ft (1220mm x 914mm)
comprehensive heat balance printout for an IGCC plant is included to
demonstrate this new feature.
(5) STEAM PRO and STEAM
MASTER include a grate-fired boiler option for modeling plants burning low
grade fuels like municipal solid waste.
(6) THERMOFLEX/PEACE
includes additional shell-tube heat exchangers for use with a variety of fluids
in liquid, two-phase, and vapor states.
(7) THERMOFLEX Solar
Field now includes linear Fresnel collector configuration, direct steam
generation (DSG) capability, and cost estimation.
These developments along with other smaller
improvements are described in more detail below.
GT PRO / GT MASTER / PEACE
Post-combustion CO2 capture using an amine-based
chemical absorption process is available.
The model includes auxiliary power estimate and thermal interaction
between the power plant and the separation process, so the computed result
represents overall integrated plant performance. This feature facilitates analysis of the impact that
post-combustion carbon capture and sequestration (CCS) has on combined cycle
gross/net electric capacity and efficiency, installed plant capital cost, and
plant economics.
Pre-combustion CO2 capture from high pressure
syngas using a physical absorption process is available for IGCC plants. The high pressure, low temperature syngas is
treated in a physical absorption process using solvents such as Selexol, or
others. The model adds heating and
cooling loads to the plant, and consumes electricity to power CO2 compressors
that deliver relatively pure CO2 at high, often supercritical, pressures. As with post-combustion capture, this model
permits analysis of the impact that pre-combustion carbon capture and
sequestration (CCS) has on IGCC gross / net electric capacity and efficiency,
installed plant capital cost, and plant economics.
The Acid Gas Removal (AGR) model used for syngas
cleanup in IGCC plants has been improved.
The prior black-box model was replaced by a gray-box model that captures
the interactions between the power island and the gas cleanup process in more
detail. The heat required to drive the
process can be delivered from the steam cycle to the AGR reboiler. The amount of CO2 removed along with the H2S
is more easily modeled. The cost
function is more sensitive to the AGR configuration.
Historically, GT PRO and GT MASTER relied on the
Cycle Flow Schematic together with a number of sub-system graphics to present
the overall plant heat balance and sub-system details. TFLOW19 introduces a Comprehensive Heat
Balance Diagram to collectively display data from all these diagrams, plus some
additional information previously shown only in text reports. Using the mouse, the user can zoom in/out
and pan around the diagram to review results for all plant subsystems. The diagram uses AutoDesk DWF format and may
be saved in PDF format, or printed on large format printers. A sample printout is included with these
update materials to demonstrate the capability.
GT PRO now evaluates tube stress for user-defined
boiler tubes to ensure the tube wall is sufficient to withstand design stress. GT MASTER tests wall stress for all cases at
current pressure and temperature.
Additional inter-HX pressure drops are available in GT PRO and MASTER. The auxiliary power reported by GT PRO is
now the same regardless of whether PEACE is used, or not.
Gas Turbine Data Base
The gas turbine data
base, used by various Thermoflow products was updated, as shown below.
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Engines
added to the database |
|||
|
355 |
MHI 701F(4)[1] |
358 |
RR TRENT 60 DLE (50 Hz) |
|
|
|
359 |
RR TRENT 60 DLE (60 Hz) |
|
356 |
Siemens SGT 5-3000E |
360 |
RR TRENT 60 WLE (50 Hz) |
|
357 |
Siemens SGT 6-5000F |
361 |
RR TRENT 60 WLE (60 Hz) |
|
365 |
Siemens
SGT 6-2000E (33 MAC) |
|
|
|
366 |
Siemens
SGT 6-2000E (41 MAC) |
362 |
GE LM6000 PG SAC (60 Hz) |
|
|
|
363 |
GE LM6000 PG SAC (50 Hz) |
|
367 |
Ansaldo V64.3A |
|
|
|
368 |
Ansaldo
V94.2 |
372 |
Hitachi
H-25 |
|
369 |
Ansaldo V94.3A |
|
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|
|
370 |
Kawasaki GPB 80D |
|
364 |
Solar Titan 250 |
371 |
Kawasaki
GPB 180D |
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Existing
engines with modified performance |
|||
|
324 |
Siemens SGT 5-4000F |
304 |
Siemens SGT5-3000E |
Anyone using the GE
APPS program to compute GT performance in GT PRO or GT MASTER should download
APPS 3.7.6 from the GE website.
THERMOFLEX / PEACE
The
following new components were introduced in this version.
An
Intercooled Compressor component (General tab) was introduced to make it easier
to model multi-stage compressors with intercooling. Previously, an intercooled compressor model would be built using
a number of compressor + heat exchanger + moisture separator components. This is still possible, but in many cases
the Intercooled Compressor will be easier to use.
The CO2
capture features used in GT PRO/MASTER and STEAM PRO/MASTER use a number of new
THERMOFLEX components, described below.
CO2
capture from low pressure flue gases with moderate to small CO2 concentrations
is accomplished using the Chemical Absorption CO2 Capture component (Flue Gas
tab). This is a model of an amine-based
chemical absorption process, typically using MEA or other similar solvents. Heat and cooling is supplied to the process
from the network. The component
estimates auxiliary power to run pumps, and computes heating and cooling flows
based on CO2 capture rate and other inputs.
Captured CO2 can be connected to a compressor and piping system for
further processing. The model includes
cost estimation.
CO2
capture from high pressure syngas with high CO2 concentrations is accomplished
using the Physical Absorption CO2 Capture component (Gasification tab). This component models a physical absorption
process using solvents such as Selexol, etc.
Captured CO2 from flashtanks at several pressure levels may be connected
to compressors in the network. Heat and
cooling is supplied to the process from the network. The component estimates auxiliary power to run pumps, and
computes heating and cooling flowrates based on CO2 capture rate and other
inputs. The model includes cost
estimation.
An Acid
Gas Removal (AGR) component (Gasification tab) using either chemical or
physical absorption, is available for removing H2S from fuel streams. Typically used to treat cooled syngas in
IGCC plants, this component connects to heating and cooling streams in the THERMOFLEX
network. It delivers a fuel stream with
reduced H2S and somewhat less CO2. This
component includes cost estimation.
A
combined AGR/CO2 Capture component (Gasification tab) using either chemical or
physical absorption is available, primarily for use in IGCC plants with
pre-combustion CO2 capture. It removes
sulphur and carbon dioxide from CO2-rich, cooled syngas downstream of a shift
reactor. This component gets connected
to heating and cooling streams in the THERMOFLEX network. It computes auxiliary power consumption, and
heating and cooling flows. This
component includes cost estimation. The
Gas Cleanup System component (Gasification tab) has been modified to include
this combined AGR/CO2 Capture component.
A
Shell-Tube Condensing HX component (PEACE tab) was included to provide a physical-model
counterpart to the virtual-model General Condenser introduced in TFLOW18. This new component can condense steam or
NIST refrigerant vapors in the shell.
Tube-side coolants can be water/steam (blue), brine (brown), heat
transfer fluid (pink), liquid or vapor refrigerant (purple), liquid or gaseous
fuel (orange), or even gas/air (red fluid).
This component provides size, weight, and cost outputs.
A
Shell-Tube General HX component (PEACE tab) was included to provide a
physical-model counterpart to the virtual-model General HX component that has
been part of THERMOFLEX since its inception.
Like its virtual counterpart, it processes all fluid types, however,
this component does not support phase change.
This component provides size, weight, and cost outputs.
The
following summarizes improvements to existing features, introduced in this
version.
The
Shell-Tube Economizer and Superheater models were modified so the heating fluid
can flow on either the tube or shell-side.
Both components provide additional flexibility in how the flows are
established on both sides.
The
Shell-Tube Evaporator model was modified to enable evaporation of NIST
(REFPROP) refrigerants. Additional
flow-control modes are available that let the component establish vapor flowrate,
or accept the network-determined vapor flowrate.
The
Solar Field component (General tab) now includes ability to model Linear
Fresnel collectors in addition to its existing capability to model parabolic
troughs. Collector type is chosen in
Thermodynamic Design (TD) mode. The
Solar Field now supports direct steam generation (DSG) in the receiver tubes
for both the parabolic trough and linear Fresnel configurations. A new option for modeling general linear
collectors is available for those users with access to Incident Angle Modifier
(IAM) data for a known collector. The
solar field output now includes estimated cost.
Thermodynamic
property functions for red fluids (gas/air) were modified for high pressure
conditions where simplified treatment of compressibility breaks down. THERMOFLEX provides an option on the Others
tab of the Current Settings menu to use NIST properties in these cases,
or to issue a warning for states in a computed model where the low pressure /
high temperature assumption breaks down.
THERMOFLEX
files can now link to STEAM MASTER models at the stack inlet “node”; that is
after any flue gas treatment in the STM model.
The Natural Draft Cooling tower (PEACE tab) now includes size, weight,
and cost. Transport properties for
gaseous and liquid fuels were added, thereby enabling physical equipment sizing
based on pressure drop conditions for this fluid. Virtual models of the Electric and Absorption chillers can now be
connected to heat transfer fluid on the coolant and chilled liquid nodes. Additional outputs are available including
the flow and pressure matrices, useful for debugging model behavior.
ST PRO / STEAM MASTER / PEACE
Post-combustion CO2 capture using an amine-based
chemical absorption process is available.
The model includes auxiliary power estimate and thermal interaction
between the power plant and the separation process, so the computed result
represents overall integrated plant performance. This feature facilitates analysis of the impact that
post-combustion carbon capture and sequestration (CCS) has on combined plant
gross / net electric capacity and efficiency, installed plant capital cost, and
plant economics.
A grate-fired boiler
option is available from the New Session
topic to model plants burning low grade fuels like municipal solid waste. Grate cooling may be accomplished by heating
feedwater, or by preheating air. The
air handling system was modified to include configurations used by grate fired
boilers.
A second steam air
heater was introduced so a unique SAH is now available for both primary and
secondary air streams. For plants
including a natural draft cooling tower, the tower’s size, weight, and cost
estimate are provided. An option to use
the NDCT as the plant stack is also available.
Water balance and water accounting features were
added, similar to features in GT PRO/MASTER.
A new Environment topic was introduced. It includes the Emissions & Instrumentation inputs previously on the Other PEACE topic, along
with Water Accounting and CO2 Capture inputs.
Superheater and reheater tube wall thicknesses were
increased to prevent under sizing in high pressure/temperature situations such
as in ultrasupercritcal plants. This
will increase estimated cost of supercritical boilers.
DOCUMENTATION
Keeping with tradition, the context-sensitive
online help available from within each program is the primary source of
documentation. The online help is
up-to-date. Printed documentation has
been updated with the most significant changes. The following describes how to update your manuals.
·
GT PRO Chapter 15 – Use the enclosed pages, from 15-13
through 15-48, to replace pages 15-13 to the end of your present Chapter 15.
·
GT PRO Chapter 23 – Add this Chapter 23 after the existing
Chapter 22, replacing any existing pages of an earlier Chapter 23.
·
STEAM PRO Chapter 19 – Insert this new chapter after
Chapter 18.
·
THERMOFLEX Chapter 16 – Use the enclosed pages, 16-57
through 16-118, to replace the page 16-57.
·
THERMOFLEX Chapter 22 – Use the enclosed pages, 22-49
through 22-79, to replace all pages after 22-48 in your Chapter 22.
GENERAL
Currency conversion factors and regional cost
multipliers were updated based on currency data from the first quarter of
2009. Overall PEACE cost estimates,
which had been revised significantly upwards in TFLOW18, were not adjusted for
TFLOW19. Uncertainty in the global
economic picture is likely to cause significant variability in project costs
for the rest of 2009, and likely into 2010.