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University of Warwick institutional repository: http://go.warwick.ac.uk/wrap A Thesis Submitted for the Degree of PhD at the University of Warwick http://go.warwick.ac.uk/wrap/74040 This thesis is made available online and is protected by original copyright. Please scroll down to view the document itself. Please refer to the repository record for this item for information to help you to cite it. Our policy information is available from the repository home page. Model Based Analysis of Power Plant Integrated with a Post Combustion Carbon Capture Process Thesis submitted in accordance with the requirements of the University of Warwick for the degree of Doctor of Philosophy in Engineering School By Shen Guo B.Eng., M.Phil. July 2015 to my parents Acknowledgements First and foremost, I would like to express my sincere appreciation to my supervisor, Professor Jihong Wang, for her support, guidance and patience during my PhD study. Her scientific belief and her persistent efforts constitute the essential part of the project, and her passion and knowledge in science exceptionally inspire and enrich my growth as a student, a researcher and an engineer want to be. I would also be very grateful to Prof. Qirui Gao, Dr. Yali Xue and Dr. Jianlin Wei for sharing their invaluable knowledge in the thermodynamics, control and programing. Their important advices and critical comments gave me great experiences throughout the work. Many thanks to Prof. Junfu Lv and Dr. Nan Jia for the valuable experiences from both academia and industry. It has been a great pleasure to work with and I also want to give my thanks to my colleagues Dr. Xing Luo, Dr. Hao Sun, Mr. Yue Wang, Dr. Jacek Wojcik and Dr. Mihai Draganescu in the research group. Many shining ideas in the project has come from the cooperation and discussions with them. Finally and mostly, I would like to give my special appreciates to my family and my friends. None of this would have been possible without their encouragement, support and understanding. Abstract It is well recognised that there are two main options for reducing CO2 emissions from fossil-fuelled power generation, namely, improvement of energy efficiency and Carbon Capture and Storage (CCS). Efficient power generation leads to lower fuel consumption, in turn, lower CO2 emission. Post combustion carbon capture as it can be introduced to existing power plants by retrofitting to the plant, which has attracted a lot of academic and industrial attention. A lot of research activities have been carried out to study this capture technology but most of this research focused on the steady state and the balance of the chemical reaction. As the initial investigation on the power plant response with carbon capture is a very important process before the plant is built, the dynamic simulation study can be helpful to provide the necessary guidance for the design of the plant and control system. This thesis reports the modelling and impact analysis of the supercritical power plant with integration of post combustion carbon capture. The work described in this thesis contributes to three aspects: model based dynamic study of capture plant, model based flue gas estimation and the analysis of power plant response caused by the carbon capture. A dynamic modular model of the capture plant has been built based on the mass and thermal balance for the study of plant dynamics. In this model, the methodology based on the average enthalpy has been introduced to solve the relationship between the specific enthalpy and the temperature of amine-water mixture under different conditions. A model based real-time estimation algorithm for the steam required to satisfy the heat duty is also developed in the work presented in this thesis. An accurate flow rate of the flue gas can greatly support the study of the absorption process simulation. An improved coal mill model which provides the estimation of mill status in the normal milling progress is developed in this project. The information provided by this coal mill model can further estimate the flow rate of the flue gas. In addition to supporting the study of carbon capture process, OPC based on-line implementation algorithms are proposed to enhance the mill operation. The heat duty to maintain the reaction temperature in the regeneration process is satisfied by the steam from the power plant in this thesis. Several modification plans have been tested in the simulator to study the different dynamic responses to the power plant caused by the steam extraction, and an approach that is able to meet the heat demand with least impact to the plant dynamics is proposed. As coal fired power plants are obliged to balance their output in response to the changing power demand from the grid, this thesis also provides a control strategy to overcome this power penalty by adding the equivalent power to the power demand. CONTENTS List of Figures ............................................................................................................. IV List of Tables .......................................................................................................... VIII Introduction ............................................................................................ 1 1.1 Background .................................................................................................... 1 1.2 Overview of Carbon Capture Technologies................................................... 6 1.2.1 Pre combustion Capture ......................................................................... 7 1.2.2 Carbon Captures on Conventional Power Generation ........................... 8 1.3 CO2 Storage and Utilization ......................................................................... 10 1.4 Objectives of the project .............................................................................. 12 1.5 Thesis outline ............................................................................................... 14 1.6 Publications during this period .................................................................... 15 Coal-fired Power Generation and Post Combustion Capture .............. 16 2.1 Thermal power plant process ....................................................................... 17 2.1.1 The generation process of coal-fired power plant ................................ 17 2.1.2 The Rankine cycle................................................................................ 21 2.1.3 Supercritical power generation ............................................................ 26 2.2 Post combustion captures ............................................................................. 28 2.2.1 Chemical absorption ............................................................................ 28 2.2.2 Adsorption ........................................................................................... 31 2.2.3 Membrane based separations ............................................................... 33 2.3 Amine based capture process ....................................................................... 34 2.4 Simulation of amine based capture .............................................................. 36 2.5 Summary ...................................................................................................... 37 Power Plant Process Modelling and Simulation Study ........................ 39 3.1 First principle model .................................................................................... 40 3.1.1 Model of the boiler systems ................................................................. 41 3.1.2 Model of the turbine system ................................................................ 44 I | P a g e 3.1.3 Flow rate calculations .......................................................................... 44 3.1.4 Parameters identification ..................................................................... 45 3.1.5 Limitations of the model ...................................................................... 47 3.2 Fluidic network based simulator .................................................................. 48 3.2.1 Power plant process model of the simulator ........................................ 50 3.2.2 Control system implemented in the simulator ..................................... 60 3.3 Comparison of the two modelling approaches ............................................. 62 3.4 Summary ...................................................................................................... 65 Modelling Study of Power Plant Coal Milling Process ....................... 66 4.1 Classification of coal mills........................................................................... 67 4.2 Working process of low speed tube-ball mill .............................................. 72 4.3 Mathematical modelling of the coal mill ..................................................... 74 4.3.1 Input and output variables of the process............................................. 75 4.3.2 Mass balance ........................................................................................ 76 4.3.3 Thermal balance ................................................................................... 78 4.3.4 Mill product pressure ........................................................................... 79 4.3.5 Average mill level indication ............................................................... 80 4.3.6 Improvement of the coal mill model ...................................................