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Suvi Suojanen Development of Concentrated Solar Power and Conventional Power Plant Hybrids

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Suvi Suojanen Development of Concentrated Solar Power and Conventional Power Plant Hybrids SUVI SUOJANEN DEVELOPMENT OF CONCENTRATED SOLAR POWER AND CONVENTIONAL POWER PLANT HYBRIDS Master of Science thesis Examiners: prof. Jukka Konttinen pm. Yrjö Majanne Examiners and topic approved by the Faculty Council of the Faculty of Natural Sciences on 04th November 2015 i ABSTRACT SUVI SUOJANEN: Development of concentrated solar power and conventional power plant hybrids Tampere University of technology Master of Science Thesis, 140 pages, 13 Appendix pages March 2016 Master’s Degree Programme in Environmental and Energy Engineering Major: Energy and Biorefining Engineering Examiners: professor Jukka Konttinen and project manager Yrjö Majanne Keywords: concentrated solar power (CSP), hybrid, direct steam generation (DSG), dynamic modelling and simulation (DMS), Apros CSP hybrids are one of the possible technical solutions in order to increase the share of renewable energy and decrease greenhouse gas emission levels as well as fuel consump- tion. The main objectives of the thesis are to research state-of-the-art technologies in concentrated solar power (CSP) and conventional power plants, to comprehensively study the possible integration options and to develop one CSP hybrid configuration by using Advanced Process Simulator (Apros), which is a dynamic modelling and simula- tion tool for industrial processes. Furthermore, the objectives are to develop control strategy for the hybrid and demonstrate the operation of the hybrid under steady state and transient conditions in order to find challenges of hybrid systems and future devel- opment requirements. The theory is based on the available scientific literature for CSP, conventional power plants and CSP hybrids as well as on the information available from companies and organizations working with the technologies. The model development is based on the theoretical background as well as the know-how of VTT about Apros. Based on the simulations, solar steam fed to the joint high pressure turbine increases thermal efficiency and changes the thermal balance of the steam cycle. In addition, at- tainable solar shares are studied, in which design values of live steam and reheated steam temperatures of steam boiler are reached. Furthermore, as the steam generation is decreased from the solar field, transients can be seen in steam mass flows to turbines, power output of the turbines and steam temperatures and pressures. However, the mod- elled transients could be compensated with the steam boiler and the transients are ac- ceptable for turbines. Based on the conducted research, the main challenges of the hy- brid system are identified. These are, for example, attainable solar shares, design of the steam parameters in solar field and steam boiler and combination of the two steam lines, imbalance between turbines and heat surfaces, optimization of heat surfaces and opera- tion of steam boiler under fluctuating solar irradiation conditions. The developed and modelled CSP hybrid seems to be technically feasible at least with smaller solar shares. However, the hybrid system requires more research. Thus, future development requirements include, for example, improvement of the control engineer- ing of the hybrid, research on the optimal hybrid configuration and on the possibilities to reach higher solar shares, transient simulations with higher solar shares and conduct- ing exergy and economic analyses for the hybrid system. As a conclusion, the achieved results and the developed model in this thesis provide viable information for the future development of CSP hybrids. ii TIIVISTELMÄ SUVI SUOJANEN: Keskittävän aurinkovoiman ja perinteisen voimalaitoksen hybridin kehitys Tampereen teknillinen yliopisto Diplomityö, 140 sivua, 13 liitesivua Maaliskuu 2016 Ympäristö ja energiatekniikan diplomi-insinöörin tutkinto-ohjelma Pääaine: Energia- ja biojalostustekniikka Tarkastajat: professori Jukka Konttinen ja projektipäällikkö Yrjö Majanne Avainsanat: keskittävä aurinkovoima (CSP), hybridi, suora höyryntuotanto, dy- naaminen mallinnus ja simulointi, Apros CSP hybridit ovat yksi mahdollisuus lisätä uusiutuvan energiantuotannon osuutta ja vähentää kasvihuonekaasupäästöjen määrää sekä alentaa fossiilisten polttoaineiden ku- lutusta. Diplomityön tavoitteena on tarkastella keskittävän aurinkovoiman ja perinteis- ten voimalaitosten teknologioita, vertailla kattavasti laitosten mahdollisia integrointirat- kaisuja ja kehittää yksi hybridikonfiguraatio käyttäen Aprosta, joka on dynaaminen mal- linnus- ja simulointiohjelma teollisille prosesseille. Lisäksi tavoitteena on kehittää hyb- ridilaitoksen säätötekniikkaa ja simuloida laitoksen toimintaa useilla testitapauksilla, jotta hybridilaitoksen haasteet saadaan selville ja jatkotoimenpiteet voidaan määritellä. Teknologiatarkastelut perustuvat saatavilla olevaan tieteelliseen kirjallisuuteen keskittä- västä aurinkovoimasta, perinteisistä voimalaitoksista ja hybridiratkaisuista. Lisäksi työssä hyödynnetään alan toimijoilta saatavissa olevaa informaatiota. Mallin kehitys puolestaan pohjautuu teoreettiseen taustaan sekä VTT:n tietotaitoon Apros-ohjelmasta. Simulaatioiden perusteella aurinkohöyryn syöttäminen yhteiseen korkeapaineturbiiniin nostaa laitoksen hyötysuhdetta ja muuttaa höyrypiirin sisäistä tasapainoa. Lisäksi työssä on tutkittu saavutettavia aurinko-osuuksia, joissa tuorehöyryn ja välitulistetun höyryn lämpötilojen suunnitteluarvot saavutetaan. Höyryntuotannon alentuessa aurinkokentällä gradientteja ilmenee höyryn massavirroissa turbiinille, laitoksen sähkötehossa sekä höy- ryn lämpötiloissa että paineissa. Mallinnetut gradientit ovat kuitenkin kompensoitavissa höyrykattilalla ja ne ovat turbiinille sallituissa raja-arvoissa. Lisäksi hybridilaitoksen olennaiset haasteet on tunnistettu tehdyn tutkimuksen perusteella. Näitä ovat esimerkik- si saavutettavat aurinko-osuudet, aurinkokentän ja höyryvoimalaitoksen höyrynarvojen yhteensovittaminen ja höyryvirtojen yhdistäminen, höyrylaitoksen lämpöpintojen opti- mointi ja höyrykattilan toiminta vaihtelevissa säteilyolosuhteissa. Kehitetty ja mallinnettu hybridilaitos näyttäisi olevan teknisesti toteutettavissa ainakin pienillä aurinko-osuuksilla. Toimivan hybridilaitoksen kehittäminen vaatii kuitenkin jatkotutkimusta, joten tulevaisuuden kehitystoimenpiteitä ovat esimerkiksi hybridilai- toksen säätötekniikan kehitys, optimaalisen hybridilaitoksen ja suurempien aurinko- osuuksien tutkimus, transienttisimulaatiot suurilla aurinko-osuuksilla ja exergia- analyysin sekä taloudellisten analyysien teko. Johtopäätöksenä voidaan todeta, että työssä saavutetut tulokset ja suunniteltu malli antavat hyvän pohjan CSP hybridilaitok- sien jatkokehitykselle. iii PREFACE The Master thesis “Development of concentrated solar power and conventional power plant hybrids” has been conducted for VTT Technical Research Centre of Finland under the project called “Combination of Concentrated Solar Power with Circulating Fluid- ized Bed Power Plants”. The research of the thesis was conducted from June 2015 to December 2015. First of all, the topic of the thesis was a dream come true, as one of the special interests of mine is the addition of renewable energy technologies in order to prevent climate change. In addition, the researcher exchange during the Master thesis at the German Aerospace Centre was another dream come true. Thus, I would like to ex- press my greatest gratitude towards the staff of VTT at Jyväskylä, Finland as well as towards the staff at the line focus department of DLR at Stuttgart, Germany for this amazing possibility, which was very rewarding. In addition, I would like to especially express my gratitude towards the people, who have supported and given me instructions during the thesis. First of all, I would like to express my warmest gratitude towards my supervisors at VTT, Matti Tähtinen and Elina Hakkarainen, for the daily support, instructions and comments of the work. In addition, I would also like to express my warmest gratitude towards my supervisor at DLR, Jan Fabian Feldhoff, for the daily support and guidance during my stay at DLR. Further- more, I am grateful of the guidance given by the examiners of this thesis, professor Juk- ka Konttinen and project manager Yrjö Majanne. Moreover, I would like to direct spe- cial thanks to Hannu Mikkonen, Jouni Hämäläinen, Teemu Sihvonen and Tomi Thomasson at VTT for all the help and support during this project. As one door is closed, at least two more are opened. The five years spent at Tampere University of technology have been full of new people and friendships, unforgettable moments and finding my professional interests. Therefore, I would also express my gratitude towards friends and faculty met at TUT for the joy, support and guidance throughout my studies. Most of all, I would like to thank my loving family from the bottom of my heart for all the caring and support in good times and in bad times. Espe- cially, I would like to thank my grandmother, Soile, for all the support during my stud- ies. I really don’t know what I would have done without it. And last but not least, I would like to thank my loving boyfriend, Vesa, for being my rock for all these years. Sometimes I’m quite astonished about the journey that has brought me to this day, but I wouldn’t change a single day of it. Jyväskylä, January 31st, 2016 Suvi Suojanen iv CONTENTS 1. INTRODUCTION .................................................................................................... 1 1.1 Background ...................................................................................................
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