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www.tas.com
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www.tas.com
www.tas.com
www.tas.com
Optimize Design and Operation of Renewable Energy Cycle through
HYSYS Integrated with EDR
Economic Clean Energywww.tas.com
By Guofu Chen P. E. of Mechanical and Chemical
Agenda• Introduction
– Who is TAS Energy?– What’s a renewable energy power plant?
• Setting up HYSYS process model• HYSYS optimizer to maximize power output• Rigorous exchangers modelling
– Optimize the number of Air-Cooled Condenser bays– Optimize the size of the evaporator
• What-if?• Conclusions
– Technical improvement diagram– Business benefits summary
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Introduction
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Who is TAS Energy
• Founded in 1999 and grew to $150m of revenues with minimal financing
• Headquartered in Houston, TX – Offices in Dubai and Doha
• TAS is an Innovator and Leader in Modular Thermal Energy Equipment– Invented the concept of “Turbine Inlet Cooling”– Introduced “Packaging” to the Cooling Industry– Pioneer of Renewable Energy business– Developed Innovative “Mission Critical”
offerings
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What’s a Renewable Energy Power Plant?
• Based on Rankine cycle principle, use an organic working fluid to turn geothermal fluid energy or waste heat into electricity.
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Setting up HYSYS Model
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Setting up HYSYS
• Step 1: Set up HYSYS based on "Best Engineering Practice", subject to exchangers pinch.
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HYSYS Optimizer to Maximize Output
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Optimizer Variables Setting up
• Step 2.1: Use HYSYS optimizer to get the most output of the process while respecting the pinch. The graph shows how variables are set up.
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Optimizer Goal and Constraints Setting up
• Step 2.2: The graph below shows how the goal and constraints are set up.
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Optimizer Result
• After HYSYS finishes the optimization, the optimum pressure is 50.33 bara (730 psia) and the optimum temperature is 122.67 °C (252.8 °F). At such conditions, the net power output is maximized at 8635 kW (1.158×104 HP). The net output is improved by 3.3%
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Rigorous Exchangers Modelling
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Rigorous Rating Model with Geometries
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Integrate ACHE EDR into HYSYS
• Step 3.1: Start from 30 Air-Cooled condenser bays and integrate Air-Cooled exchanger into HYSYS
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Optimize Condensing Pressure
• Step 3.2: Higher condensing pressure leads to lower expander output, and less ACC fan power as well. The net power output goes through an maximum and an optimum condensing pressure exists.
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No of Bays 24 27 30 33 36 39
ACC cost $ 3,600,000
4,050,000
4,500,000
4,950,000
5,400,000
5,850,000
Condensing Temperature °C 25.53 24.68 23.65 22.81 21.91 20.95Condensing Pressure bara 6.964 6.757 6.567 6.378 6.188 5.998
Air Flow kg/h 17,463,485
18,127,638
18,847,410
20,048,988
21,296,251
23,188,787
Net Output kW 7,835 8,039 8,209 8,346 8,464 8,572Incremental cost $/kW - 2,207 2,651 3,289 3,790 4,166
Select Optimum Number of Bays
• Step 3.3: Compare and select the number of bays
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Geothermal industry criterion
Optimize Evaporator Size
• Step 3.4: Use “Utility” to size the evaporator with variant UA.
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Choose Optimum Evaporator Size
• Step 3.5: Evaluate and choose Heater size
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Geothermal industry criterion
UA Percentage 90% 100% 110% 130% 150%
Evaporator UA kJ/°C-h20,172,31
422,413,68
224,655,05
029,137,78
633,620,52
3No. of Tubes 1,017 1,162 1,312 1,742 2,203Shell Diameter mm 889 940 991 1,118 1,245EDR Cost * $ 613,400 691,600 784,200 1,010,580 1,263,488Net Output kW 8,083 8,210 8,307 8,437 8,535Incremental cost $/kW - 864 1,337 2,438 3,612
*A cost multiplier was used to modify this cost.
What-if?
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What-if?
• Step 4: Rate the overall cycle with actual equipment geometries and do what-if studies
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Rigorous Rating Model with Geometries
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Conclusions
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Technical Improvement Diagram
Setup HYSYS, based on “Best Engineering
Practice”
Optimize HYSYS
Optimize ACC baysOptimize Heater
Generate the “Best Engineering
Practice”
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Business Benefit Summary
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• Faster: deliver projects several weeks faster by shortening the discussion time with vendors
• Better: more confident with the plant performance and exchangers design
• Cheaper: optimize the cost and performance to have overall lowest price
• Results: as a new comer in the Renewable Energy Industry, TAS has won several projects against the previous market leader with 40 years experience
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Refer to HTFS research paper RS1230 for more information.