ZERO EMISSION COAL STUDY
Final Report
Prepared for
THE NEW YORK STATE
ENERGY RESEARCH AND DEVELOPMENT AUTHORITY
Albany, NY
Barry N. Liebowitz
Project Manager
Prepared by
Columbia University
New York, NY
Klaus S. Lackner
Xinxin Li
Agreement No. 10087
NYSERDA December2010
Notice
This report was prepared by Klaus Lackner and Xinxin Li in the course of per-
forming work contracted for and sponsored by the New York State Energy Research
and Development Authority and the Columbia University. The opinions expressed
in this report do not necessarily re�ect those of the Sponsors or the State of New
York, and reference to any speci�c product, service, process, or method does not
constitute an implied or expressed recommendation or endorsement of it. Further,
the Sponsors and the State of New York make no warranties or representations, ex-
pressed or implied, as to the �tness for particular purpose or merchantability of any
product, apparatus, or service, or the usefulness, completeness, or accuracy of any
processes, methods, or other information contained, described, disclosed, or referred
to in this report. The Sponsors, the State of New York, and the contractor make
no representation that the use of any product, apparatus, process, method, or other
information will not infringe privately owned rights and will assume no liability for
any loss, injury, or damage resulting from, or occurring in connection with, the use
of information contained, described, disclosed, or referred to in this report.
ii
ZERO EMISSION COAL STUDY
Abstract
Choosing among di�erent technologies is di�cult and requires a means of mak-
ing comparisons across di�erent technologies. This paper proposes a computational
model, to evaluate di�erent technologies and to identify optimal technologies based
on a user supplied set of evaluation criteria to compare di�erent zero emission power
plant designs.
iii
Table of Contents
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiTable of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivList of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viList of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
1 Summary 41.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 Goal & Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 A numerical method for multiobjective optimization of zero emissionpower plants 112.1 A means required to compare di�erent technologies . . . . . . . . . . 122.2 Evaluation criteria based on a penalty model . . . . . . . . . . . . . . 16
3 A simple model for power plant pathway optimization 193.1 Model Formulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.2 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4 Path-dependent shortest-path algorithms for optimizing a sequenceof power plant designs 404.1 Problem statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414.2 Mathematical formulation . . . . . . . . . . . . . . . . . . . . . . . . 434.3 Literature review on shortest-path problem . . . . . . . . . . . . . . . 444.4 Path-dependent shortest-path algorithms . . . . . . . . . . . . . . . . 454.5 Branch and bound algorithm with bottom-up pruning . . . . . . . . . 474.6 Heuristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514.7 Computational results . . . . . . . . . . . . . . . . . . . . . . . . . . 554.8 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5 Optimizing CO2 post-combustion capture technologies 635.1 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645.2 Literature Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
iv
Table of Contents v
5.3 Modeling CO2 absorber physics . . . . . . . . . . . . . . . . . . . . . 685.4 Penalty model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755.5 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785.6 Discussion-Modeling Results . . . . . . . . . . . . . . . . . . . . . . . 85
6 Designing the software tool for advanced power plant modeling andoptimization 876.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 876.2 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 896.3 A model of modules and pipes . . . . . . . . . . . . . . . . . . . . . . 916.4 Reconcile - An iterative procedure . . . . . . . . . . . . . . . . . . . . 936.5 Reconcile algorithm: numerical routine for solving a system of equations 976.6 Reconcile implementation . . . . . . . . . . . . . . . . . . . . . . . . 996.7 Discussion of Newton-Raphson method . . . . . . . . . . . . . . . . . 1006.8 Penalty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1026.9 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076.10 Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076.11 Ongoing development . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A Introduction to TEX 110A.1 What is TEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110A.2 The algorithm of breaking paragraphs into lines . . . . . . . . . . . . 111
Bibliography 112
List of Figures
3.1 Environmental Penalty . . . . . . . . . . . . . . . . . . . . . . . . . . 253.2 An example of pathways connecting y0 to various future technologies 343.3 Pathways end in an environment with CO2 regulations . . . . . . . . 373.4 Pathways end in an environment without CO2 regulations . . . . . . 373.5 Plant level penalties with CO2 regulations . . . . . . . . . . . . . . . 383.6 Plant level penalties without CO2 regulations . . . . . . . . . . . . . 383.7 Environmental penalties with CO2 regulations . . . . . . . . . . . . . 393.8 Environmental penalties without CO2 regulations . . . . . . . . . . . 39
4.1 An instance of a rooted tree . . . . . . . . . . . . . . . . . . . . . . . 424.2 An instance of depth �rst search strategy in branch and bound [?] . . 484.3 An instance of a graph for shortest-path problem . . . . . . . . . . . 524.4 An instance of a tree collapsed into a graph, path-dependent . . . . . 524.5 Visited nodes in branch-and-bound(BB) algorithm . . . . . . . . . . . 564.6 The optimal results given by BB and the brute-force approach . . . . 564.7 The visited nodes comparison between BB and the heuristic . . . . . 574.8 The optimal results given by the heuristic and the brute-force approach 574.9 The optimal path as a function of x in Heuristic . . . . . . . . . . . . 594.10 Visited nodes in the branch-and-bound and the hybrid algorithm . . . 61
5.1 An instance of the cross-section of a packing tower . . . . . . . . . . . 705.2 Single plant and pathway optimization, 6 design choices for 14 decision
points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795.3 6 design results. Plant index comparison . . . . . . . . . . . . . . . . 805.4 Plant performance data of the 6 designs . . . . . . . . . . . . . . . . 815.5 21 design results. The optimal cost of a single plant and a sequence of
plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.6 21 design results. Plant index comparison . . . . . . . . . . . . . . . 825.7 Plant performance data of the 21 designs . . . . . . . . . . . . . . . . 835.8 87 design results. The optimal cost of a single plant and a sequence of
plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
vi
List of Figures vii
5.9 87 design results. Plant index comparison . . . . . . . . . . . . . . . 845.10 87 design results. 87 design results. 30 $/ton CO2 .The optimal cost
of a single plant and a sequence of plants . . . . . . . . . . . . . . . . 855.11 87 design results. 30 $/ton CO2 Plant index comparison . . . . . . . 86
A.1 Examples of breaking a pargraph into lines . . . . . . . . . . . . . . . 111
List of Tables
3.1 Regulatory factor for each item in the sequence . . . . . . . . . . . . 263.2 Summary of power plant designs and pathways designs . . . . . . . . 353.3 Module level, plant level and pathway level penalties . . . . . . . . . 36
6.1 Input File (Flowsheet) De�nition (Format) . . . . . . . . . . . . . . 109
viii
List of Tables 1
Abbreviations
z = a representation of a sequence of power plants �
y = a speci�c power plant con�guration
xi = a module, usually an operational unit, like a pump, a furnace, or an absorber
m = the number of modules in a power plant design
tj = the decision making time, j stands for its position in the sequence of decisions
Sxiis the size of a module xi
Sy(t) is the size of a power plant y(t)
PN = Penalty Number � unit
PNxi= Penalty number of a module � unit
PNy(t) = Penalty number of a power plant at time t� unit
PNz = Penalty number of a power plant pathway� unit
Di = di�usion coe�cient � m2 s−1
Dco2mea = di�usion coe�cient of co2 in mea� unit
Dmeamea = di�usion coe�cient of mea in mea� unit
cp = speci�c heat � J kg−1 K−1
List of Tables 2
Cp = molar heat capacity � J mol−1 K−1
dch = channel diameter � m
cpsi = cells per square inch - in−1
GHSV = gas hourly space velocity - h−1
k = reaction rate coe�cient
kc = mass transfer coe�cient � m s−1
kT = coe�cient of thermal conductivity � W m−1 K−1
Le = α/Di � Lewis number
mesh number = number of wires per linear inch � in−1
Nu = hL/kT � Nusselt number
Pr = cpν/kT � Prandtl number
R = reaction rate � (detailed below)
RTOF = turnover frequency � moli mol−1Pt s
−1
Rwc = reaction rate per unit washcoat volume � moli m−3 s−1
Rv = reaction rate per unit reactor volume � moli m−3 s−1
RW = reaction rate per unit catalyst weight � moli g−1 s−1
Sav = geometric surface area-to-volume ratio � m−1
SCO = 0.5 ·∆CO/∆O2 � Selectivity of CO
Sc = ν/Di � Schmidt number
Sh = kcL/Di � Sherwood number
T = temperature - Ctwc = washcoat thickness � m
v = super�cial gas velocity � m s−1
List of Tables 3
V̇ = volumetric �owrate � m3 s−1
WHSV = weight hourly space velocity - gCO gcat−1 h−1
xi = molar fraction of species i
z = axial coordinate � m
greek letters
α = kT/(ρcp)= thermal di�usivity � m2 s−1
χi = fractional conversion of species i
ε = void fraction
λ = 2 · CO2/CCO µ = dynamic viscosity � Pa s
ν = µ/ρ = kinematic viscosity � m2 s−1
ρcat - catalyst loading (grams of metal+support per reactor volume) � g m−3
ρwc - washcoat loading (grams of metal+support per washcoat volume) � g m−3
σv = volumetric site density � ρcatlPtDispMWPt
� molPt m−3
Chapter 11
Summary2
1.1 Background3
Traditional power plant modeling tools only measure the thermodynamic perfor-4
mance and economic cost of a power plant, optimization is often carried out to reach5
a compromise between plant e�ciency and generation costs of the individual plants.6
Today, increasingly stringent environmental constraints especially in response to cli-7
mate change, require a new modeling tool to evaluate di�erent power plant designs8
under various energetic, economical, environmental and infrastructural constraints.9
Choosing between di�erent low-emission power generation technologies has a pro-10
found impact not only on the cost-e�ciencies of individual power plants, but more11
importantly on the pathways connecting current power generation technologies to12
future technologies.13
The need to develop low-emission power generation technologies arose both from14
the rapid growing consensus that excess carbon dioxide will cause a signi�cant change15
4
Chapter 1: Summary 5
in climate that will have repercussions on a wide variety of human activities [Lackner 2001],16
and from the fact that power plants burning fossil fuel are a major source of carbon17
dioxide emissions, accounting for roughly one thirds of the global carbon emissions.18
In order to mitigate carbon dioxide from fossil fuel-�red power plants, a means is19
required to obtain a concentrated form of carbon dioxide with little incondensible im-20
purities, before it can be dispose of safely and permanently. The capture and storage21
of carbon dixoide (CCS) is one of the greatest challenge not only to power genera-22
tion infrastructure, but more importantly to the sustainable access to the cheap and23
abundant fossil fuel [Lackner 2001].24
A spectrum of low-emission power plants has been addressing environmental im-25
pact of impurities and undesirable combustion product from fossil fuel for some time.26
On one end of the spectrum include power plants with environmental control units27
for desulphurization, particulate removal and mercury emission control, etc. On the28
end of the spectrum is a special class of technologies zero emission power plants. Such29
plants produce power without emitting any atmospheric emissions, in some designs30
without a smoke stack. For example, a technology developed by the zero emission coal31
alliance (ZECA) generates electricity with hydrogen fuel cell producing only water,32
where clean hydrogen is derived from coal with a hydrogasi�er and a decarbonation33
reactor, followed by a calciner separating carbon dioxide together with impurities and34
underiable combustion by-product for sequestration [Lackner 2002].35
Zero emission power plants are yet to be built. Today, low-emission power plants36
minimized emissions of carbon dioxide to the atmosphere through separation and cap-37
ture of carbon dioxide by one of three general techniques: pre-combustion, oxy-fuel,38
Chapter 1: Summary 6
and post-combustion de-carbonization [IPCC, 2005]. Governments and �rms eager to39
deploy low-emission thermal power plants must choose among three distinct types of40
power plant designs: the integrated gasi�cation combined cycle design (IGCC), which41
relies on pre-combustion separation of carbon dioxide in a gasi�er [IEA GHG, 2003],42
the oxy-fuel design which uses pure oxygen combustion to yield a nearly pure stream43
of carbon dioxide after combustion [Croiset and Thambimuthu, 2000], and the post-44
combustion de-carbonation design which relies on chemical absorption processes[Henderiks, 1994].45
Currently, there is no clear technological winner [MIT, 2007]. For both the IGCC and46
the oxy-fuel processes, the chief obstacle to broad deployment is the high capital and47
operational cost associated with each technique. Opportunities exist both for incre-48
mental modi�cations leading to near-term cost e�ciencies and for major redesigns49
leading to advanced next-generation power plant designs.50
The IGCC and oxy-fuel processes are not the only possible implementations of low-51
emission power plants. Instead, there is a broad range of potential designs which might52
incorporate a variety of components and approaches. For example, advanced zero53
emission power plant (AZEP) addresses the development of a speci�c, zero emissions;54
gas turbine-based, power generation process, which relies on a mixed-oxide membrane55
for oxygen production [Gri�n 2005]. Such a device is a critical component shared56
by a variety of oxygen-enhanced combustion and gasi�cation processes. This project57
examines a family of advanced thermal power plant designs, such as conventional oxy-58
fuel power plants with a separate cryogenic air separation unit and fuel cell designs59
which combine oxygen separation, carbon oxidation, and electricity generation in a60
single unit, as well as the many potential designs which lie in between these two61
Chapter 1: Summary 7
extremes. For example, oxygen blown IGCC, oxy-fuel �uidized bed combustors and62
AZEP designs are each a variation along a continuum of plant designs.63
A wide range of choices for the next-stage designs away from the existing low64
e�ciency, and polluting fossil fuel power plants, will lead to di�erent technological65
pathways, which constitute a sequence of plant designs that builid on each other,66
connecting to the e�cient, economical and clean future technologies. The overall67
objectives of this project are to create conceptual plant designs and conduct engi-68
neering assessments of the component modules of a zero emission power plant; eval-69
uate di�erent power plant designs under various energetic, economic, environmental70
and infrastructural constraints; and perform optimization not just to the individual71
power plants alone, but pathways connecting current power generation technologies72
to future technologies.73
1.2 Goal & Objectives74
The goal of this project is to model the performance (energy and environmen-75
tal) of advanced concepts in power generation that produce zero CO2 emission from76
coal. Speci�cally, we model and evaluate di�erent power plant technologies and path-77
way options with a new metric, which will be critical in choosing between various78
low-emission power generation technologies with very di�erent design constraint and79
optimization criteria.80
The project is accomplished in phases. In Phase I, we de�ned the modules that81
can be used to build a zero-emission power plant and the range of operational criteria82
for their recombination to function in various modes by establishing the performance83
Chapter 1: Summary 8
criteria, identifying key parameters, and creating computational models for each mod-84
ule. In Phase II, we focused on developing computational capability and databases85
to model various power plant designs based on these models. Di�erent plant process86
con�guarations are established, heat and mass balance for various plant designs are87
made, and di�erent power plant designs are assessed based on e�ciency, emissions88
and technical and economic feasibility.89
Speci�cally, this report is divded into following chapters. A novel numerical90
method is presented (Chapter 2) to evaluate di�erent technologies in order to iden-91
tify optimal technologies, based on a user supplied set of evaluation criteria. The92
ranking method used here for advanced power plant designs comparison has taken its93
inspiration from the typesetting system TEX, in which Donald Knuth demonstrated94
the power of these optimization algorithms for trading o� between text layouts with95
properties that are very di�erent and very di�cult to quantify.96
In Chapter 3, a very simple example is presented to show how the model can be97
used to select appropriate power plant modules and a wide range of technologies, to98
arrive at a sequence of plant designs that provides an advantageous technology path-99
way from today's power plant designs to a future design via a number of intermediate100
steps. Eight basic modules are chosen which forms 96 possible plant designs, of which101
17 are physically valid. The permutations of the 17 power plants in a pathway con-102
sisting of �ve di�erent power plants implemented in sequence, gives 106 variations.103
As a preliminary study, we didn't explore the entire space of all solutions. Instead,104
�ve unique pathways are chosen to show various aspect of penalties when forming a105
technology pathway. For example, a shorter path is favorable, but too many changes106
Chapter 1: Summary 9
at the same time is undesirable. The modeling results are subjective because they107
depend highly on the user-supplied set of evaluation criteria. However, the bias input108
are exogenous to the model. This is because we want to give users the freedom to put109
their own preference to the model, such that they can get their customized solutions.110
This re�ects the �exibility of the model.111
To explore the entire space of solutions, we developed two combinatorial optimiza-112
tion algorithms (Chapter 4). The objective function is de�ned as the minimum of a113
nonlinear programming problem. The problem is solved by means of a branch-and-114
bound method, and a heuristic based on the label-correcting algorithm for solving115
shortest-path problem. The proposed algorithms are applied for practical problems116
on �nding the optimal sequence of various power plant designs.117
In Chapter 5, we study various post-combustion capture technologies using the118
ranking algorithms introduced in Chapter 4. In the �rst part of our work, we devel-119
oped a simple model for the absorber system. We �nd the optimum design given a120
speci�c sorbent strength by varying the packing tube radius and the absorber tower121
height. In the second part of our work, we studied various power plant designs with122
absorbers in a sequence and �nd the optimum sequence using the algorithm.123
As a part of the project, a computational software tool is developed to model124
the mass-energy balance of a module, and to implement the ranking method (Ap-125
pendix). This input-output model consists of modules and pipes, where each module126
respresent a fundamental operation unit (i.e a expander, an heat exchanger, a CO2127
absorber etc), and a pipe can be considered as a material or energy �ow. Each mod-128
ule is characterized by a set of parameters, which satisfy a system of equations. The129
Chapter 1: Summary 10
program begins with a set of complete but inconsistent parameters, and �nd a con-130
sistent set of parameters through iteration. Upon �nding a reconciled system, The131
user may set one(or a few) parameter(s) free to a range, such that the software can132
�nd the optimum. The same method is used to �nd the optimum pathway. A library133
of �ve modules are built, and the manuals on coding a new module are included in134
the Appendix.135
The main contribution of this project is developing and implementing the opti-136
mization method to the problem of choosing optimum power plant designs that are137
path-dependent.138
Chapter 2139
A numerical method for140
multiobjective optimization of zero141
emission power plants142
In this chapter, a novel numerical method to optimize(rank) advanced power plant143
designs and technology pathways is introduced. The motivation is driven by the144
lack of appropriate methods to rank various technologies that are characterized by145
very di�erent properties, which are very di�cult to quantify. For example, power146
plant owners are faced with not only economic and energetic constraints, but also147
increasingly stringent environmental, infrastructural, and social constraints. The need148
to conceptually explore new power plant designs and compare di�erent technologies149
and technology pathways, calls for new methods which are e�cient, �exible and can150
deal with very complex systems.151
This novel modeling method borrows the concept from the typesetting algorithm152
11
Chapter 2: A numerical method for multiobjective optimization of zero emissionpower plants 12
TEX, which is very powerful in ranking di�erent typesetting layout as more or less153
optimum. When applied to power plant modeling, a perfect and unattainable power154
plant design is chosen as the anchor point. The actual power plant design compared155
to the anchor point design results in a penalty number, which captures the di�erence156
in various aspects between the actual plant design and the anchor point, where the157
anchor point is characterize with a zero penalty. Since penalty number is always158
positive and the anchor point is an absolute reference that holds constant under all159
circumstances, one can stop calculating the penalty as soon as the partial sum of the160
total penalty exceeds the current minimum. The algorithm is highly e�cient and161
�exible, it can easily incorporate new constraints (which often results in additional162
penalties) into the existing structure, it also allows di�erent users assign customized163
preferences for di�erent penalties.164
In addition to rank various power plant designs, this method can also rank various165
sequences of power plants designs, in which a new design can either build upon the166
previous ones, or can be entirely new. In the next chapter, a simple model is developed167
to show the concept.168
2.1 A means required to compare di�erent technolo-169
gies170
Traditional power plant modeling tools only measure the thermodynamic per-171
formance and economic cost of a power plant, optimization is often carried out to172
reach a compromise between plant e�ciency and generation costs of the individual173
Chapter 2: A numerical method for multiobjective optimization of zero emissionpower plants 13
plants. Today, increasingly stringent environmental constraints especially in response174
to climate change, require a new modeling tool to evaluate di�erent power plant175
designs under various energetic, economical, environmental and infrastructural con-176
straints. Choosing between di�erent low-emission power generation technologies has177
a profound impact not only on the cost-e�ciencies of individual power plants, but178
more importantly on the pathways connecting current power generation technologies179
to future technologies. This project evaluate di�erent power plant technologies and180
pathway options with a new metric, which will be critical in choosing between various181
low-emission power generation technologies with very di�erent design constraint and182
optimization criteria.183
The need to develop low-emission power generation technologies arose both from184
the rapid growing consensus that excess carbon dioxide will cause a signi�cant change185
in climate that will have repercussions on a wide variety of human activities [Lackner 2001],186
and from the fact that power plants burning fossil fuel are a major source of carbon187
dioxide emissions, accounting for roughly one thirds of the global carbon emissions.188
In order to mitigate carbon dioxide from fossil fuel-�red power plants, a means is189
required to obtain a concentrated form of carbon dioxide with little incondensible im-190
purities, before it can be dispose of safely and permanently. The capture and storage191
of carbon dioxide (CCS) is one of the greatest challenge not only to power genera-192
tion infrastructure, but more importantly to the sustainable access to the cheap and193
abundant fossil fuel [Lackner 2001].194
A spectrum of low-emission power plants has been addressing environmental im-195
pact of impurities and undesirable combustion product from fossil fuel for some time.196
Chapter 2: A numerical method for multiobjective optimization of zero emissionpower plants 14
On one end of the spectrum include power plants with environmental control units197
for desulphurization, particulate removal and mercury emission control, etc. On the198
end of the spectrum is a special class of technologies zero emission power plants. Such199
plants produce power without emitting any atmospheric emissions, in some designs200
without a smoke stack. For example, a technology developed by the zero emission coal201
alliance (ZECA) generates electricity with hydrogen fuel cell producing only water,202
where clean hydrogen is derived from coal with a hydrogasi�er and a decarbonation203
reactor, followed by a calciner separating carbon dioxide together with impurities and204
underiable combustion by-product for sequestration [Lackner 2002].205
Zero emission power plants are yet to be built. Today, low-emission power plants206
minimized emissions of carbon dioxide to the atmosphere through separation and cap-207
ture of carbon dioxide by one of three general techniques: pre-combustion, oxy-fuel,208
and post-combustion de-carbonization [IPCC, 2005]. Governments and �rms eager to209
deploy low-emission thermal power plants must choose among three distinct types of210
power plant designs: the integrated gasi�cation combined cycle design (IGCC), which211
relies on pre-combustion separation of carbon dioxide in a gasi�er [IEA GHG, 2003],212
the oxy-fuel design which uses pure oxygen combustion to yield a nearly pure stream213
of carbon dioxide after combustion [Croiset and Thambimuthu, 2000], and the post-214
combustion de-carbonation design which relies on chemical absorption processes[Henderiks, 1994].215
Currently, there is no clear technological winner [MIT, 2007]. For both the IGCC and216
the oxy-fuel processes, the chief obstacle to broad deployment is the high capital and217
operational cost associated with each technique. Opportunities exist both for incre-218
mental modi�cations leading to near-term cost e�ciencies and for major redesigns219
Chapter 2: A numerical method for multiobjective optimization of zero emissionpower plants 15
leading to advanced next-generation power plant designs.220
The IGCC and oxy-fuel processes are not the only possible implementations of low-221
emission power plants. Instead, there is a broad range of potential designs which might222
incorporate a variety of components and approaches. For example, advanced zero223
emission power plant (AZEP) addresses the development of a speci�c, zero emissions;224
gas turbine-based, power generation process, which relies on a mixed-oxide membrane225
for oxygen production [Gri�n 2005]. Such a device is a critical component shared226
by a variety of oxygen-enhanced combustion and gasi�cation processes. This paper227
examines a family of advanced thermal power plant designs, such as conventional oxy-228
fuel power plants with a separate cryogenic air separation unit and fuel cell designs229
which combine oxygen separation, carbon oxidation, and electricity generation in a230
single unit, as well as the many potential designs which lie in between these two231
extremes. For example, oxygen blown IGCC, oxy-fuel �uidized bed combustors and232
AZEP designs are each a variation along a continuum of plant designs.233
A wide range of choices for the next-stage designs away from the existing low234
e�ciency, and polluting fossil fuel power plants, will lead to di�erent technological235
pathways, which constitute a sequence of plant designs that builid on each other,236
connecting to the e�cient, economical and clean future technologies. The overall237
objectives of this project are to create conceptual plant designs and conduct engi-238
neering assessments of the component modules of a zero emission power plant; eval-239
uate di�erent power plant designs under various energetic, economic, environmental240
and infrastructural constraints; and perform optimization not just to the individual241
power plants alone, but pathways connecting current power generation technologies242
Chapter 2: A numerical method for multiobjective optimization of zero emissionpower plants 16
to future technologies.243
2.2 Evaluation criteria based on a penalty model244
Power plant development leading to a zero emission plant design could move245
through a set of new plants, each designed to the best available knowledge at the246
time and with little regard to the long term goal, or to the basic knowledge that is247
embedded in previous designs. In such a strategy one may introduce technologies248
even though it is clear from the outset that they do not lend themselves to further249
advances, essentially locking-into a wrong path. For example, post combustion tech-250
nology, may well be in this category. Any R&D investment into �ue gas scrubbing251
is most likely made obsolete by the next generation of power plants. Alternatively,252
the goal could be achieved by a set of incremental improvements that are introduced253
in each new plant or in each upgraded plant, where changes are designed to build254
upon each other. In this example, by su�ering perhaps a little extra cost during each255
upgraded plant, the pathway may prevent itself from locking-into a wrong direction256
which will incur a much bigger cost to break away from. Oxyfuel combustion designs257
are likely to �t into this category.258
A consideration of the intermediate plant designs can reduce the long-term cost of259
power plant designs. However, a rational implementation of such an approach requires260
the means of making comparisons across di�erent technologies and across di�erent261
times. We propose a methodology by which we can make such an assessment. The262
method introduces a penalty function that can be applied to modules, plants, and263
sequences of plant designs. In optimizing the design, one varies design parameters so264
Chapter 2: A numerical method for multiobjective optimization of zero emissionpower plants 17
as to minimize the penalty function. The penalty function is zero for some perfect265
state of the system which is typically not attainable, and the penalty function is266
optimized by varying all the available design parameters. The penalty can be thought267
of as a sum of penalties for speci�c aspects of the plant, for example its e�ciency, its268
cost or its environmental impact. Individual modules may have component penalties.269
Some aspect of the penalty will depend on properties that can only be de�ned for the270
entire plant, or even for a sequence of plants.271
The relative weights of these penalties can be chosen appropriately by a user, who272
has speci�c goals. For example, penalties one may associate with having to build a273
new plant on a new site may vary for users in di�erent countries. Building new plants274
in China is likely to introduce a relatively small penalty for green�eld plants. The275
same decision in the West is likely to introduce a much bigger weight, because the276
political di�culties of opening up new sites are much larger. The di�erent weights277
may result in alternative development pathways.278
It is also recognized that the availability and maturity of novel technologies, as well279
as environmental thresholds for existing and potential criteria pollutants are likely280
to change over time, thus the weights for these penalties should not be considered281
as static. The dynamic nature of these penalty speci�cations, allow users to choose,282
instead of the best possible plant at a speci�c time ti, the best possible pathway283
connecting technologies from time t1 to time tn. Pursuing the optimal pathways284
on the basis of the minimum total pathway penalties helps users lower the cost of285
achieving the speci�c goals, even if it results in seemingly sub-optimal outcomes for286
individual plants.287
Chapter 2: A numerical method for multiobjective optimization of zero emissionpower plants 18
Much of the work we present is in de�ning an appropriate set of penalties on288
which the optimization rests. The underlying algorithms have been studied for other289
applications. The approach outlined here has taken its inspiration from the typeset-290
ting software TeX, in which Donald Knuth demonstrated the power of these penalty291
based optimization algorithms for trading o� between very di�erent and very di�-292
cult to quantify properties of text. We will show how very similar algorithms can be293
used to select appropriate modules, and power plants to arrive at a sequence of plant294
designs that provides an advantageous technology pathway from todays power plant295
designs to a future design that has far higher e�ciency, avoids all emissions to the296
air, and provides the CO2 produced in a concentrated stream ready for disposal.297
Chapter 3298
A simple model for power plant299
pathway optimization300
To demonstrate application of Knuth's ranking method on power plant modeling301
and optimization, a simple model is developed to show the concept. Before the con-302
struction of the simple model, let us consider a power plant explicitly in mathematical303
terms. For example, a hypothetical power plant design yj can be considered as a net-304
work of m modules (or components). yj = {x1, x2, ...xm}, where each module xi is305
an independent reactor speci�cation, iε[1,m]. Furthermore, a hypothetical pathway306
of power plant design evolvement zk can be considered as a sequence of power plant307
designs zk ={y0, y1, ...yn}, where yj is a hypothetical power plant �owsheet, jε[0, n].308
Note there are a number of possible pathways connecting initial technologies to future309
technologies, when comparing di�erent pathways, it is important to ensure the same310
initial design y0 for all possible pathways zk.311
This simple model considers eight basic modules, where three generation modules312
19
Chapter 3: A simple model for power plant pathway optimization 20
and �ve environmental modules can be combined to form three major plant designs313
in 32 di�erent ways, hence 96 di�erent power plant con�gurations. The generation314
modules include a subcritical boiler island, a supercritical boiler island, and an ul-315
trasupercritical boiler island. (The generation modules can again be divided into a316
network of water cycle modules and a sequence of fuel processing modules, which can317
again be combined di�erently, this project only considers the generation unit as a318
whole.) The environmental modules are �ue gas cleaning devices for SO2, NOx, �ne319
particulates, mercury, and CO2 emissions respectively. Each environmental module320
can be considered as an optional add-on to the main plant designs in a binary man-321
ner, hence the overall number of power plant con�gurations are 3x2x2x2x2x2 = 96.322
Besides the simplicity in notation, thinking plant con�gurations in such manner allow323
us to use the TEXalgorithm to our advantage. Since penalties are always positive, as324
soon as the penalty of one module (the partial sum of total penalties) exceeds the325
total penalty of current optimum, the class of plant con�gurations containing this326
module can be excluded from computation automatically (because the penalties are327
additive), hence considerably speeding up the algorithm. However, it's important to328
note that many of these con�gurations are not feasible in practice. For example, a329
selective catalytic reduction (SCR) can't be attached directly to a supercritical boiler330
island without adding a heat exchanger to lower the incoming �ue gas temperature.331
In another instance, the amine CO2 scrubber can't be directly added to the back332
of the boiler island, without pretreating the �ue gas with desulphurization unit to333
avoid sulfur poisoning. Infeasible con�gurations will be characterized with an in�nite334
penalty.335
Chapter 3: A simple model for power plant pathway optimization 21
The simple model considers a pathway with a �nite sequence of �ve items/ele-336
ments, where the state of each item/element is characterized with a set of di�erent337
environmental regulations. Therefore, a given plant con�guration will be charac-338
terized with a di�erent sets of regulatory states depending on its position in the339
sequence/pathway. In total, a given plant con�guration will have �ve di�erent sets of340
regulatory states for a sequence of �ve items. For the purpose of this simple model341
evaluation, the initial item of all possible pathways is a subcritical power plant con-342
�guration. Each item/element in the rest of the sequence can be chosen from the 96343
di�erent plant con�gurations. This simple model aims to rank these pathways and344
power plant designs, based on assigning penalty functions that scale with the devia-345
tion from a perfect state, which sets the anchor points against which various aspects346
in various levels of a pathway compare. The following section designs a hierarchy of347
di�erent levels of penalties incurred at the corresponding level of the model, namely:348
module level, plant level and pathway levels. Di�erent levels of penalties characterize349
performance speci�cally local to the corresponding level in the model. Together, they350
allow for rankings of di�erent power plant designs and pathways according to the ac-351
cumulated penalties respectively. In the following sections, we indenti�ed individual352
penalty variables (or aspects of penalties at di�erent penalty level), the anchor points353
for each penalty variable, and functions describing the behaviors of each penalty354
variable.355
Chapter 3: A simple model for power plant pathway optimization 22
3.1 Model Formulation356
3.1.1 Module level penalties357
Module level penalties characterize individual module performances independently358
from the rest of the plant. For example, cost and size of a module are strictly indepen-359
dent from the rest of the modules in a plant design, thus they belong to the module360
level in the penalty hierarchy. In comparison, cost per unit capacity ($/kW, M$/kW)361
or size per unit capacity (m2/kW, m3/kW) are not module level penalty variables,362
because the total power output of the whole plant (MW) measures the plant level363
performance, rather than module level performance.364
The module level penalties, their anchor points, and penalty functions for this365
simple model are summarized in Table 2. The sum of total module penalties for366
m modules in a speci�c plant design j equals a plant level penalty attribute to all367
modules in that plant, assuming there are m modules in a plant design (∑m
i=1Pjtot,i).368
One can also calculate this plant level penalty by adding the sum of each penalty369
speci�cations accounting for all modules in a plant design:370
∑m
i=1Pi =
∑m
i=1PTPI,i +
∑m
i=1POAM,i
where371
PTPI,i = α× TPI, i372
TPI,i is the Total Plant Investment for plant i;373
POAM,i = β ×OAM, i374
OAM,i is the annual Operational and Maintenance cost for plant i;375
α, β are constants;376
Chapter 3: A simple model for power plant pathway optimization 23
377
Due to the lack of data on physical size for modules examined in this example,378
the penalty calculation for size is not included in the simple model. Data on costs379
and emissions as a result of mass and energy balance calculations are produced using380
the integrated environmental control model (IECM), the plant performance data are381
attached in Appendix ??.382
3.1.2 Plant level penalty383
In addition to the sum of module level penalties as described above, plant level384
penalties also characterize energetic and environmental performance at plant level.385
3.1.3 Reconcile penalty386
This penalty Prec refers to plant con�gurations that don't reconcile. As stated387
earlier, many of the 96 con�gurations in the model are not feasible in practice. Infea-388
sible con�gurations will be characterized with an in�nite penalty. A fully reconciled389
plant con�guration has a zero penalty.390
Energy e�ciency penalty391
For energy e�ciencies, we penalize gross plant e�ciency and generation e�ciency392
separately. The former penalty measures gross power output as a fraction of total393
energy input (represented by the total potential energy embedded in the fuel); the394
latter penalty measures the net power output (which is gross output less internal395
power consumption) as a fraction of gross power output, indicating the amount of396
Chapter 3: A simple model for power plant pathway optimization 24
power consumed by the system itself. The need to separate the two speci�cation is to397
distinguish two kinds of plant designs with the same net plant e�ciency: one design398
with a high gross e�ciency but many energy-intensive additional units (i.e. auxiliary399
units and environmental control units), the other one with a low gross e�ciency to400
start with but few energy-intensive auxiliary units. It may come out to be the same,401
but the system's ine�ciency is captured separately, thus identifying the opportunities402
and incentives to reduce the ine�ciency respectively.403
Environmental penalty404
Environmental impact is penalized through a three-level environmental penalty405
hierarchy (Figure 3.1). The environmental penalty are evaluated as a product of reg-406
ulatory factor, compliance factor and quantitative factor. We consider environmental407
impacts at the plant level, because emissions are a measure of plant performance.408
For now, we assume all emissions are emitted at the smoke stack. One exception to409
this rule is when users are concerned with hazardous (poisonous) chemicals �owing410
around a plant, or with any chemical leakage from a single operation unit in a plant.411
In that case, an additional environmental penalty will be placed at the module level412
to punish poor seals, especially for modules that operate at positive pressures. This413
module level penalty is not considered in this simple model, but can be easily included414
for future optimization when required. Also, we penalize environmental impact only415
to the extent that it is due to atmospheric emissions for simplicity, of the model. At416
present, we do not penalize other environmental impacts such as solid waste discharge417
and water consumption, but they can be easily incorporated when needed.418
Chapter 3: A simple model for power plant pathway optimization 25
Figure 3.1: Environmental Penalty
Regulatory factor Regulatory factor accounts for various sets of regulatory states419
at each position, in this case time, along the pathway. If there is a regulation, the420
factor is one, if there is none, the factor is zero. It is also possible to assign a421
value that is between zero and one to capture a situation where the introduction of422
a regulation is either considered likely or desirable. The regulatory factor can be423
calculated according to the following equation.424
Freg
= 1 if there is a regulation on a speci�c kind of emissions at
a speci�c time
= 0 if there is no regulation on a speci�c kind of emissions at
a speci�c time
6= (0 ∧ 1) if there is no regulation on a speci�c kind of emissions,
but the regulation is expected to materialize at a future time
Table 3.1 describes the regulatory factors characterizing the regulatory states at425
each time along the pathway of the sequence of �ve power plant con�gurations. The426
�rst row are regulatory factors characterizing the initial plant con�guration of all427
Chapter 3: A simple model for power plant pathway optimization 26
Table 3.1: Regulatory factor for each item in the sequence
Time Freg,so2 Freg,pm Freg,nox Freg,Hg Freg,co2
t = 0 0 0 0 0 0t = 1 1 0 0 0 0t = 2 1 1 0 0 0t = 3 1 1 1 0 0t = 4 1 1 1 1 0t = 5 1 1 1 1 1
possible pathways.428
It is understandable that the regulatory states (quanti�ed as regulatory factors)429
change over time, since what's considered not harmful today might be considered430
as pollutants tomorrow, as a result of increasing scienti�c understanding on various431
emissions and their environmental impact over time. The necessity to have a top432
level regulatory factor is to capture di�erences in regulated emissions and unregulated433
discharge, and to ensure the corresponding technological and infrastructural change434
economically viable in a historical context. For example, the installation of �ue gas435
desulphurization unit (FGD) on the existing pulverize coal plants in US was driven by436
the regulation of sulfur emissions in 1990s as a result of amendments to clean air act.437
However the use of limestone to control SO2 emissions incurs unintended consequences438
of generating additional CO2 emissions 1 , which was considered not harmful at the439
time. In this situation, since no regulations on CO2 emissions were in place, the440
regulatory factor is zero. Since the environmental penalty is a product of regulatory441
1
SO2 + 12 O2 −−→ SO3 (3.1)
SO3 + CaCO3 −−→ CaSO4 + CO2 (3.2)
Chapter 3: A simple model for power plant pathway optimization 27
factor, compliance factor and quantitative factor, the overall environmental penalty442
of CO2 emissions is zero for all plant con�gurations at that time. From the algorithm443
point of view, once the regulatory factor is recognized as zero, the program does not444
have to proceed to calculate all other factors in the product function, hence speeding445
up the computational runtime by avoiding performing unnecessary calculations.446
As shown in table 3.1, this hypothetical exercise assumes environmental regula-447
tions for various emissions come in one at the time. This assumption have some448
degree of truth, because in reality, the process of introducing a new environmental449
regulation, or introducing a new criteria pollutant, is long and di�cult. It's rare that450
multiple regulations (or multiple criteria pollutants) are introduced at the same time.451
However, once the criteria pollutants are introduced (regulations are established), it452
is possible to raise the compliance standards (or lower the legal limits) for multiple453
emissions at the same time.454
Compliance factor Compliance factor evaluate whether a speci�c kind of emis-455
sions is compliant with the legal limit or not. Compliance factor hinge upon the fact456
that there is a regulatory factor for a speci�c kind of emissions. The legal limit against457
which compliance factor is measured, is normalized be an output-based emission rate458
in this study, expressed as lb/kWh, from the traditional input-based standard that459
re�ects an allowed amount of emissions per unit of fuel burned (lb/Btu). Output-460
based standards are preferable to traditional input-based standards, as they capture461
di�erences in e�ciency among sources in converting input energy (e.g., heat) to useful462
output (e.g., electricity) and therefore reward e�cient use of energy [E Roy, 1998]. In463
addition, the output-based standard capture emissions generated not only from the464
Chapter 3: A simple model for power plant pathway optimization 28
fuel source, but also from other sources that are converted to various emissions via465
both chemical process (i.e. reaction 3.2) and physical process (i.e. the injection of466
active carbon in order to control mercury emissions will introduce additional partic-467
ulates emissions), and therefore penalize the overall plant emissions, instead of only468
part of the emissions in a plant.469
If a speci�c kind of emissions is compliant with the regulation, then it receives a470
compliance factor of one, and the model proceeds to the quantitative factor calcula-471
tion. If it is not compliant with the regulation, it receives an in�nite overall environ-472
mental penalty. In this simple model, we penalized SO2, �ne particulates, NO, NO2,473
Hg, and CO2 emissions gradually for di�erent designs, assuming the corresponding474
regulations materialize over time. The legal limit for these emissions are assumed475
to be (lb/kWh)[?], (lb/kWh)[?], (lb/kWh)[?], (lb/kWh)[?], (lb/kWh)[?], (lb/kWh)[?]476
respectively, and they are assumed to be static for this exercise. Existing standards477
on the emissions are normalized to the output-based standards, the CO2 legal limit is478
chosen to be ???. The compliance factor can be calculated according to the following479
equation.480
Fcomp =
1 If a speci�c kind of emissions is compliant with the
regulation at a speci�c time
∞ If a speci�c kind of emissions is not compliant with the
regulation at a speci�c time
Quantitative factor Unlike the regulatory factor and compliance factor that ex-481
amine "qualitatively" the environmental impact of various emissions, this factor ex-482
amines the absolute emission quantitatively. Quantitative factors hinge upon the fact483
Chapter 3: A simple model for power plant pathway optimization 29
that a speci�c emission is regulated and is compliant with the regulation, the neces-484
sity to have a quantitative factor is to penalize the absolute emissions from a plant485
design, thus in essence rewarding plant designs with less emissions. For quantitative486
factors, we design di�erent functions to describe (penalize) the undesirability of a487
speci�c kind of emissions mathematically by scaling the emissions per unit output488
(lb/kWh) with a set of user-supplied scaling factor (penalty weight).489
The functions are carefully designed to characterize the environmental impact of490
various emissions. The function for CO2 is a linear function of the mass �ow rate CO2491
at the smoke stack of a power plant (equation 3.3), because its environmental impact492
is approximately linear to the amount of CO2 emitted. In comparison, the function for493
SO2 has several components as SO2 emissions have several aspects of environmental494
impact, both locally and regionally. At local level, aerosols of sulfuric acid and other495
sulfates contribute signi�cantly in the reduction of visibility and damage to material,496
it has also been recognized that there are some localized areas where asthmatics may497
be repeatedly exposed to short-term SO2 concentrations [Wark, K., 1997]. These local498
environmental impacts are not linear in the SO2 concentration, rather they show499
a much greater impact at higher concentrations []. Therefore, we design penalties500
attributed to the local impact as quadratic function to the concentration of SO2501
emissions at the smoke stack of a plant. At regional level, SO2 can be transported long502
distance by air masses and then be precipitated in the form of acid rain somewhere503
else. The function attributed to the regional impact of SO2 emissions is designed linear504
to its concentration at the smoke stack, because the amount of acid rain is linear to505
the amount of SO2 emissions. The overall quantitative factor for SO2 emissions can506
Chapter 3: A simple model for power plant pathway optimization 30
be calculated according to equation 3.4.507
Fquan,CO2 = k1 ∗ (mCO2) where mCO2 =lbCO2
kWh(3.3)
508
Fquan,SO2 = k2 ∗ (mSO2) + k3 ∗ (mSO2)2 where mSO2 =
lbSO2
kWh(3.4)
NOx like SO2 emissions, also contribute to acid rain formation, in addition to509
its local impact, thus it is penalized both locally and regionally. Regarding par-510
ticulate, we exclusively focused on their local impact. Mercury emissions has a511
more complex environmental impact, as elemental mercury emissions can be trans-512
ported and deposit in the watershed, and form methylmercury [?]. Harris and513
Rudd predicted that mercury emissions reductions will yield rapid (years) reductions514
in �sh methylmercury concentrations and will yield concomitant reductions in risk515
[Harris R. C., Rudd J.W.M. 2007]. Hence, we approximate the environment impact516
of mercury emissions linear to the mass �ow rate of the mercury emissions from the517
power plants. This function might change as we gain better scienti�c understand-518
ing of the environmental impact of mercury emissions in the future. Functions to519
calculate quantitative factors for all emissions are listed in Table 3.3520
Di�erent penalty functions for di�erent emissions show di�erent sensitivities to521
user-input weights. The relative weights depend on what users expect as conse-522
quences. For example, in the case of SO2 emissions, if users are mainly concern about523
local problems, then the penalty is dominated by the quadratic term, if the users524
are mainly concern about the long-distance problems, it's driven by the linear term.525
In essense these penalties are transferable, users that are less concerned about the526
Chapter 3: A simple model for power plant pathway optimization 31
long-distance problems may build extremely tall smokestacks hence transferring local527
sulfur pollution problems into regional sulfur problems.528
The sum of environmental penalty for a speci�c emission can be calculated by the529
following equation.530
PEM= FregM
× FcompM× FquanM
where531
M = SO2, particulates,NO,NO2,Hg,CO2.532
533
The sum of all plant level penalty speci�cations for a plant design adds up to the534
total penalty for that plant at time t, where t refers to the time in the sequence, t =535
0, 1, 2, 3, 4, 5.536
537
Ptot,t =∑m
i=1Pi,t
+Prec,t
+Pη(gross,t) + Pη(gen,t)
+PE(CO2,t)+ PE(SO2,t)
+ PE(NO,t)+ PE(NO2,t)
+ PE(Hg,t)+ PE(PM,t)
3.1.4 Pathway level penalty538
Mathematically, there are nm possible pathways, assuming there are m choic-539
es/items in the pathway, and each item can be chosen from n power plant con�g-540
urations. In the case of the simple model, the number of possible pathways are541
965 = 8.15E9. The ranking algorithm inspired by TEX can be implemented com-542
Chapter 3: A simple model for power plant pathway optimization 32
putationally such that the computer will examine all possible pathways and choose543
the optimal one. The implementation of the computational algorithm is beyond the544
scope of this project.545
Various pathways re�ect the evolution trajectory of power plant technologies. The546
simple model considers pathways with a �nite sequence of six items/elements, where547
the initial item of all possible pathways is a subcritical power plant con�guration.548
Each item/element in the rest of the sequence can be chosen from the 96 di�erent549
plant con�gurations.550
To compare and calculate penalties for di�erent pathways, we consider three as-551
pects of the penalty. The �rst penalty accounts for the sum of the plant level penalties552
for all the items in the path. The second penalty attempts to account for the ma-553
turity of a speci�c technology at the time of use, in the form of learning by doing,554
by counting the number of usage of this technology previously in the same pathway.555
This penalty is express as π2 ×Paverage ×K, where π2 is a constant, Paverage accounts556
for the average plant level penalty in a path, and K is the factor attempt to represent557
the learning gained throughout the entired pathway. The equation below explains K558
in greater details.559
K =∑5
t=1
{∑m
i=1
α
R(i) + ε
}2
Here R(i) is the number of usage of a speci�c technology i in a power plant, whose560
con�guration consists of a network of m modules. α and ε are both constant. Since561
R(i) is inversely related with K and the penalty, a larger R(i) entails smaller penalty.562
This is consistent with reality, the more we build, the more learning we have, hence563
less penalty we pay. On the other hand, if a technology has never been built before (if564
Chapter 3: A simple model for power plant pathway optimization 33
the technology is newly invented or newly introduced), R(i) is zero, hence the penalty565
function reaches its maximum. Note the summation starts with t=1, instead of t=0,566
hence all modules in the initial power plant, a subcritical power plant con�guration,567
by default is built once in any possible pathways.568
The last part of the pathway penalty accounts for the obsolete technologies through-569
out the pathway. It is expensive to introduce any new technologies, so once they are570
introduced, it is undesirable to remove them later. However, in reality, due to the571
lack of ability to "look ahead", technologies were found obsolete soon after being572
introduced at an expensive cost. For example, XXXX, TY. In author's opinion, the573
debate between post-combustion capture technology for CO2 capture versus boxful574
combustion technology �t right into this category. ANALYSIS The equation for this575
pathway level penalty is shown below:576
β ∗∑5
t=0Nobsolete
where Nobsolete is the number of technologies removed, and β is a constant.577
In summary, the total pathway penalty can be evaluated according to the following578
equation:579
Ptot = π1 ∗∑5
t=0Ptot,t
+π2 ∗ Paverage ∗∑5
t=0
{∑m
i=1
α
R(i) + ε
}2
+β ∗∑5
t=0Nobsolete
where580
Paverage =15*∑5
t=0Ptot,t581
582
Chapter 3: A simple model for power plant pathway optimization 34
Figure 3.2: An example of pathways connecting y0 to various future technologies
R(i) is the number of the times that i unit is being used before.583
π1= 0.01;584
π2= 0.000001;585
assume there are m new units, n plants. α, ε are both constants.586
587
Pursuing the optimal pathways on the basis of the minimum total pathway penal-588
ties helps users lower the cost of achieving the speci�c goals, even if it results in589
seemingly sub-optimal outcomes for individual plants.590
Table 3.3 summarize the categories of penalties at module level, plant level and591
pathway level, including the penalty variables for each category, anchor points against592
which penalty variables measure, and mathematical functions that describes the be-593
havior of each penalty variables. Figure 3.2 illustrate as an example on �ve di�erent594
pathways connecting y0 to various future technologies.595
Chapter 3: A simple model for power plant pathway optimization 35
Table3.2:
Summaryof
pow
erplantdesignsandpathwaysdesigns
y0{x
1,x
9}
subcritical
pulverized
coal
plant
y 1{x
2,x
9}
supercritical
pulverized
coal
plant
y 2{x
3,x
9}
ultra-supercritical
pulverized
coal
plant
y 3{x
1,x
4,x
5,x
9}
subcritical
plantwithSOxandparticulate
control
y 4{x
1,x
4,x
5,x
6,x
9}
subcritical
pow
erplantwithSOx,particulate
andNOxcontrol
y 5{x
1,x
4,x
5,x
6,x
7,x
9}
subcritical
pow
erplantwithSOx,particulate,NOxandmercury
control
y 6{x
1,x
4,x
5,x
6,x
7,x
8,x
9}
subcritical
pow
erplantwithSOx,particulate,NOx,mercury
and
CO
2control
y 7{x
2,x
4,x
9}
supercritical
pow
erplantwithSOxcontrol
y 8{x
2,x
4,x
5,x
9}
supercritical
plantwithSOxandparticulate
control
y 9{x
2,x
4,x
5,x
6,x
9}
supercritical
pow
erplantwithSOx,particulate
andNOxcontrol
y 10{x
2,x
4,x
5,x
6,x
7,x
9}
supercritical
pow
erplantwithSOx,particulate,NOxandmercury
control
y 11{x
2,x
4,x
5,x
6,x
7,x
8,x
9}
supercritical
pow
erplantwithSOx,particulate,NOx,mercury
and
CO
2control
y 12{x
3,x
4,x
5,x
6,x
7,x
9}
ultrasupercritical
pow
erplantwithSOx,particulate,NOxandmercury
control
y 13{x
3,x
4,x
5,x
6,x
7,x
8,x
9}
ultrasupercritical
pow
erplantwithSOx,particulate,NOx,mercury
and
CO
2control
z 1{y
0,y
2,y
4,y
5,y
6}
pathway
1z 2
{y0,y
1,y
7,y
8,y
9,y
10,y
11}
pathway
2z 3
{y0,y
1,y
7,y
8,y
9,y
10,y
12,y
13}
pathway
3z 4
{y0,y
13}
pathway
4z 5
{y0,y
1,y
7,y
8,y
9,y
10,y
12,y{1
2,tn}}
pathway
5x
1=
subcritical
boilerisland;x
2=
supercritical
boilerisland;x
3=
ultra-supercritical
boilerisland;
x4=wet
�uid
gasdesulphurization
unit(FGD);x
5=
electrostaticprecipitator
(ESP);x
6=
selectivecatalyticreductionunit(SCR);
x7=mercury
removal
unit(w
ithactive
carbon
injectionACI);x
8=
aminescrubber
(MEA);x
9=
smokestack;
Chapter 3: A simple model for power plant pathway optimization 36
Table3.3:
Modulelevel,plantlevelandpathway
levelpenalties
Penalties
Level
Penalty
Variable
Anchor
point
Behavioralfunctions
modulelevel
TPI(M$/yr)
TP
I 0=
0P
TP
I,i=α×
TP
I iOAM(M
$/yr)
OA
M0
=0
PO
AM,i
=β×
OA
Mi
plantlevel
η gro
ss,j
=M
Wgro
ss,j
HH
Vη g
ross,0
=1
Pηgro
ss,j
=γ×
(1−η g
ross,j)
η gro
ss,j
η gen,j
=M
Wn
et,j
MW
gro
ss,j
η gen
0=
1Pη
gen
,j=δ×
(1−η gen,j
)η gen,j
mC
O2,j
=C
O2em
issionsfrom
smokestackj
Net
Pow
erOutputkW
hj
mC
O2,j
=0
Pqu
anC
O2
,j=
k1×
mC
O2,j
mS
O2,j
=SO
2em
issionsfrom
smokestackj
Net
Pow
erOutputkW
hj
mS
O2,j
=0
Pqu
anSO
2,j
=k
2×
mS
O2,j+
k3×
mS
O2,j
2
mN
O,j
=N
Oem
issionsfrom
smokestackj
Net
Pow
erOutputkW
hj
mN
O,j
=0
Pqu
anN
O,j
=k
4×
mN
O,j
+k
5×
m2 N
O,j
mN
O2,j
=N
O2em
issionsfrom
smokestackj
Net
Pow
erOutputkW
hj
mN
O2,j
=0
Pqu
anN
O2
,j=
k6×
mN
O2,j+
k7×
m2 N
O2,j
mH
g,j
=H
gem
issionsfrom
smokestackj
Net
Pow
erOutputkW
hj
mH
g,j
=0
Pqu
anH
g,j
=k
8×
mH
g,j
mP
M,j
=P
Mem
issionsfrom
smokestackj
Net
Pow
erOutputkW
hj
mP
M,j
=0
Pqu
anPM
,j=
k10×
mP
M,j
2
M=
SO
2,P
M,N
O,N
O2,H
g,C
O2
PE
M,j
=0
PE
M,j
=P
regM
,j×
Pco
mpM
,j×
Pqu
anM
,j
M=
SO
2,P
M,N
O,N
O2,H
g,C
O2
PE,j
=0
PE,j
=∑ P
EM
,j
pathway
level
Pk to
t,j
Pk to
t,j=
0P
k tot,
j=∑ m i=
1P
j tot,
i+
Pη(g
ross
,j)
+Pη(g
en
,j)
+P
E(M
,j)
Kk j
Kk j
=0
Pto
t,k=∑ n j=
1(ω×
Pk to
t,j×
Kk j)
Notes:
1.α,β,γ,δ,
k1,k
2,k
3,k
4,k
5,k
6,k
7,k
8,k
9,k
10,A,B,C,Dareallpenalty
weights
tobesupplied
byusers.
2.In
thismodel,theauthor
makeassumptionsof
theweights
asbelow
.α=
20,β=
20,γ=
5000,δ=
50000,k
1=
1E5,k
2=
1E3,k
3=
1E3
k4=
1E4,k
5=
1E4,k
6=
2E3,k
7=
2E3,k
8=
1E9,k
9=
1E5
3.Thecalculation
ofmaterialandenergy
balance
andcostsarecarriedoutusingtheIECM
model.
4.irepresentthenumber
ofmodules,jrepresentpow
erplants,krepresentpathways.
Chapter 3: A simple model for power plant pathway optimization 37
3.2 Results596
The two plots in Figure ?? show the total pathway penalties in an environment597
with and without CO2 regulations respectively. In the world without CO2 regulations,598
pathway z3 has more penalty than pathway z5, this is because the former pathway end599
with a plant design that introduces CO2 capture technologies, hence su�er the cost600
penalty, but due to the lack of regulations, this cost of introducing new technology601
didn't paid o�.602
Figure 3.3: Pathways end in an environ-ment with CO2 regulations
Figure 3.4: Pathways end in an environ-ment without CO2 regulations
Figure 3.5 and 3.6 show the breakdown of plant level penalty with and without603
CO2 regulations respectively, re�ecting author's concerns on environmental impact604
more than on the cost and e�ciency.605
Figure 3.7 and 3.8 show the breakdown of environmental penalties with and with-606
out CO2 regulations respectively. Note y12 and y12,tn are exactly the same designs607
built in di�erent time. When there's no CO2 regulation, they receive the same envi-608
ronmental penalty, but when at time tn, there is a CO2 regulations, y16,tn receives a609
much greater environmental penalty on CO2 emissions. Another interesting observa-610
Chapter 3: A simple model for power plant pathway optimization 38
Figure 3.5: Plant level penalties with CO2 regulations
Figure 3.6: Plant level penalties without CO2 regulations
tion from the results in environmental penalty plots is when power plants introduces611
CO2 scrubber, the overall environmental penalties are smaller than previous designs612
on the same pathways (i.e y6, y11, y13). This is because MEA sorbent are easily poi-613
son by impurities in the �ue gas, the inlet concentration of SO2 emissions is required614
to be controlled at a very low level when CO2 scrubber is install, hence the overall615
environmental penalty for plant designs with CO2 scrubber is much lower than other616
Chapter 3: A simple model for power plant pathway optimization 39
designs. However, this model doesn't take into account of the environmental impact617
of MEA leakage from the reboiler, should the users concern with the environmental618
impact of MEA leakage, the overall environmental penalties of plant designs with619
CO2 scrubber may not have a lower numeric value.620
Figure 3.7: Environmental penalties with CO2 regulations
Figure 3.8: Environmental penalties without CO2 regulations
Chapter 4621
Path-dependent shortest-path622
algorithms for optimizing a sequence623
of power plant designs624
Two combinatorial optimization algorithms for multi-variate technology designs625
that are path-dependent are proposed. The objective function is de�ned as the min-626
imum of a nonlinear programming problem. The problem is solved by means of a627
branch-and-bound method, and a heuristic based on the label-correcting algorithm628
for solving shortest-path problem. The proposed algorithms are applied for practical629
problems on �nding the optimal sequence of various power plant designs.630
40
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 41
4.1 Problem statement631
Let us consider each power plant design in a sequence as a vertex in a path. A632
sequence of m power plant designs with a given initial design, can be represented by633
a path of m vertexes with a given source vertex S. Thus, the problem of �nding the634
optimal power plant pathway with the lowest penalty, can be considered the same as635
the problem of �nding the optimal path with the minimum path distance.636
Given a source vertex S and a sequence of m decision points, there is a pool of n637
available power plant designs from which only one design is chosen at each decision638
point. The same design can be chosen more than once in a path. All possible paths639
start with a shared source vertex S, and all paths have exactly m vertexes. The640
enumeration of all possible paths forms a rooted tree, in which any two vertexes are641
connected by exactly one arc. The �rst level for all paths is the root S. Except for the642
root, each vertex in the path has a parent, which is the vertex immediately before it643
on the same path. The vertexes on the last level of the tree are named leaves. The644
vertex that is not the root nor a leave, can be viewed as a subroot. A subtree is a645
smaller tree originated from a subroot, but with the same tree structure.646
Each path can be viewed as a branch of the tree, a path from the root to a subroot647
is named as a subbranch. Note in this discussion, subbranch always begins from the648
root. The whole tree has nm branches. On each level i (1<i<=m), there are n i649
vertexes. As an example, Fig 4.1 illustrates an instance of a rooted tree of four levels,650
the root is design S, three designs d1, d2, d3 are chosen repeatedly, forming a total of651
twenty-seven possible branches. To distinguish the same design choices on di�erent652
levels, each level of the tree is indexed with a time, i.e, t1, t2, t3, and t4.653
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 42
Figure 4.1: An instance of a rooted tree
The arc distance is characterized with a numerical value. Arc distance mea-654
sures the direct distance between the two ends. For example, the distance of arc655
S(t1)→d1(t2) is 20, the distance of arc d1(t2)→d1(t3) is 15. Each arc distance is656
non-negative, and more importantly, it is path-dependent. It depends not only on the657
pair of vertexes on both ends of the arc, but also on all previous vertexes on the same658
path. For example, consider path S(t1)→ d1(t2)→ d1(t3)→d1(t4) and path S(t1)→659
d2(t2)→ d1(t3)→d1(t4) in Figure 4.1. Both paths include arc d1(t3)→d1(t4) on the660
last level, however the arc distances are di�erent, one being 2, the other being 14.661
This is a result of di�erent path histories.662
In the case of power plant technology development, two di�erent technology path-663
ways may coincide in some choices, but the chosen technologies may cost di�erently664
in di�erent paths. On one hand, once a dominant technology is chosen, it is natural665
that one will choose new technologies compatible with the existing one. For exam-666
ple, one with an Apple computer is more likely to choose compatible Apple product667
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 43
when new electronic devices emerge (i.e. iphone). On the other hand, the cost of668
technology goes down as we gain experience in building it [?]. This has been seen669
most signi�cantly in the cost of personal computers in the last 30 years. As a result,670
technologies and components of technologies, that have been chosen in the path over671
and over again, are less costly than the same technologies in the path proceeded by672
various unrelated choices.673
The total path distance is the summation of all arc distance in a path. For674
example, the total distance of path S(t1)→ d1(t2)→ d1(t3)→d1(t4) is 20+15+2=37.675
The goal of this work is to �nd the path with the minimum distance number.676
4.2 Mathematical formulation677
min cost(Pst) (4.1)
cost(Pst) =∑
(i,j)∈Pst
c((i, j), Psi) (4.2)
where Pst is a full directed path in the tree, s is the root of the tree, t is a leaf678
on the tree. Psi is the preceding path of (i, j ) in Pst. For any arc (i, j ) where i<j,679
and any path P, let c be a function which assigns a value c((i, j), P ) to an (arc, path)680
pair. c((i, j), P ) is non-negative.681
The decision version of the problem is de�ne as PDSP = { <T, c, s, t, k>}: there682
exists a path Pst in T, s.t. cost(Pst) ≤ k. T= { s, T0, T1, T2, ...TN−1}. where PDSP683
is path-dependent shortest path, T is an N-ary rooted tree, T0, T1, T2, ...TN−1 are684
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 44
subtrees.685
The convention used here follows Bruno [?], the formulation follows Tan and Leong686
[?].687
4.3 Literature review on shortest-path problem688
Though the problem of �nding the shortest path has been studied extensively,689
the e�ort of most research has been focusing on non-path-dependent problems [?].690
Mathematical procedures to solve this set of problems often take advantage of the691
principle of dynamic programming, which states if a path is the shortest, then its692
subpath is also the shortest [?].693
There are two general procedures to solve the non-path-dependent shortest-path694
problems. Both algorithms maintain a distance label of a node, and iteratively up-695
date its distance label, until �nding the shortest path. One procedure is generic696
label-setting algorithm, which designates one label as permanent at each iteration697
(Dijkstra's algorithm [?]). The other is generic label-correcting algorithm, which698
considers all labels as temporary ones until the �nal step, when they all become per-699
manent [?]. Both algorithms require that the distance label of a current node depends700
only on the previous node, rather than the entire history.701
When taking into account of the path-dependency, the problem becomes much702
more complicated to solve. Tan and Long showed that the path-dependent shortest703
path, in general is NP-complete1 , whereas its special case can be solved by any704
1NP-complete represent the complexity of a problem in computer science. In computationalcomplexity theory, the complexity class NP-complete (abbreviated NP-C or NPC) is a class ofdecision problems. A problem L is NP-complete if it has two properties: 1)It is in the set of NP
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 45
shortest path procedure in polynomial time. The special case assumes that the cost705
doesn't depend on the entire path, but only the last su�x-k paths, therefore it can706
take advantage of the last k nodes [?].707
Unlike the partial path-dependent problem that Tan and Leong described, our708
problem is full path-dependent, which can not be transformed to a special case,709
therefore it can not be solved by shortest path procedure.710
4.4 Path-dependent shortest-path algorithms711
To �nd the true optimum, we can use brute-force search approach to examine712
every single path, and compare the distances of all possible paths. Since in total a713
tree has nm branches, the runtime2 of the brute-force search approach is O(nm). This714
is very computationally expensive, especially for a big tree.715
To improve that, we can design e�cient pruning procedures by removing the bad716
branches that are bigger than a bound, which is the current best path. Furthermore,717
we can tighten the bound by continuously updating the current best path to improve718
the e�ciency even more. When the current best is in�nity, we don't gain anything719
from pruning, as we need to explore essentially the entire space of solutions. When720
the current best is the true optimal, it prunes the tree most e�ciently. This method721
is called branch-and-bound method. It is a general algorithm for �nding optimal722
(nondeterministic polynomial time) problems: Any given solution to L can be veri�ed quickly (inpolynomial time)[?]. 2)It is also in the set of NP-hard problems: Any NP problem can be convertedinto L by a transformation of the inputs in polynomial time.
2runtime refers to the time during which a program is running (executing). The symbol O()means the complexity of the algorithm, which quanti�es the amount of resources needed to solve aproblem using an algorithm, such as time and storage.
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 46
solutions of various optimization problems, especially in discrete and combinatorial723
optimization [?]. The original branch and bound algorithm is proposed by A. H. Land724
and A. G. Doig in 1960 for linear programming [?]. The term "branch-and-bound"725
was �rst proposed by J.D.C Little in 1963 for traveling salesman problems [?]. It is726
the most widely used tool for solving large scale optimization problems that have a727
�nite but usually very large number of feasible solutions, for example vehicle routing,728
crew scheduling, and production planning[?].729
We develop a speci�c branch and bound algorithm, with a strategy that prunes730
the tree from bottom to top using best-�rst search strategy through an iterative731
procedure. The detail of the procedure is given in section4.5. This method is an732
exact approach for �nding the optimal solution, and it is very e�cient in detecting733
bad choices on the upper level of the tree. But if the bad choices are made on the lower734
level of the tree, or even on the leaves, the algorithm will not detect these bad choices735
in order to prune them o�, until the full tree is examined. In this extreme case, the736
branch and bound algorithm becomes essentially the brute-force search approach, and737
all branches are explored and compared. As mentioned before, this is computationally738
challenging.739
To gain a reasonable computational performance for solving the extreme case740
problems described above, we develop a second approach. This approach can solve741
the problem in polynomial time, rather than exponential time. However, it's not an742
exact approach that always gives the true optimum solution, rather it gives a good743
solution which is relatively close to the true optimal. To examine the accuracy of744
the second approach, we run the �rst approach (branch and bound algorithm) and745
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 47
compare the solutions of the two approaches. The detail of this approach is given in746
section 4.6.747
4.5 Branch and bound algorithm with bottom-up748
pruning749
Unlike the brute-force search approach which examines each branch independently750
and individually, this algorithm considers all possible branches forming a n-ary rooted751
tree as illustrated in Figure 4.1. For any subroot, there is a subbranch above it, and752
exactly n subtrees below it. n is the number of choices that a parent node can branch753
from at each level. For example, n is three in Figure 4.1. For subroot d1(t2), above it754
there is a subbranch S(t1)→ d1(t2), and below it there are exactly n subtrees rooted755
from d1(t3), d2(t3), and d3(t3) respectively.756
Assuming we are given a bound and a corresponding path. The distance of the757
bound is the distance of the full path. If a subbranch distance already exceeds the758
bound, one can immediately throw away the subbranch without having to look further759
into the n subtrees below it. This procedure is known as eager node evaluation [?].760
Taking advantage of the eager node evaluation approach, we �rst �nd a bound,761
and sort the tree such that we always keep the bound as the leftest branch. Then we762
re-examine the bound from its leave to its root. We can do so because the subbranch763
distance is not in�uenced by the choice behind it. In other words, future decisions do764
not change the cost of decisions in the past (i.e. past decisions are sunk cost).765
In terms of search strategy, we employ the depth �rst search(DFS) approach.766
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 48
Figure 4.2 shows a small search tree, the number in each node corresponds to the767
sequence, in which the nodes are processed when DFS is used [?]. The search strategy768
usually re�ects a trade o� between keeping the number of explored nodes in the search769
tree low, and staying within the memory capacity of the computer used [?].770
Figure 4.2: An instance of depth �rst search strategy in branch and bound [?]
Let's look at Figure 4.1 and walk over the steps in this algorithm. We assume771
the initial bound is in�nity, there is no corresponding path. First, we branch o� from772
the root to a full path by always choosing the local optimal at each step until we773
�nish. As illustrated, this path is S(t1)→d1(t2)→d1(t3)→ d1(t4) with a distance of774
37. Since 37 is less than in�nity, we update the bound as our current best and keep775
it on the leftest of all branches. Now that we have a bound and a corresponding776
path, we start pruning the tree from leaf of the current bound towards the root in777
an iterative manner. For example, in this case, we back o� from the leaf. First778
we back o� one step to d1(t3), since from d1(t3) to the last step, we only need779
to look at the local optimal, there is nothing to be changed. Therefore, we look780
at d2(t3), while maintaining the subbranch above as S(t1)→d1(t2). We notice the781
subbranch distance S(t1)→d1(t2)→d2(t3) is 20+30=50, and this is already greater782
than the 37. Immediately, we can throw away the whole subbranch, without having783
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 49
to look further. Next we look at d3(t3), while maintaining the subbranch above as784
S(t1)→d1(t2). The subbranch distance S(t1)→d1(t2)→d3(t3) is 20+20=40. It is785
greater than 37, therefore, we can throw away the whole subbranch. Now we are786
done on t3 level, we back o� two steps of the bound at d1(t2), and prune the tree in787
the same manner describe above. Whenever we �nd a full branch shorter than the788
current bound, we update the leftest branch to ensure it is always the shortest. This789
way, we have a tighter bound. We continuously tighten the bound as we prune the790
tree, it makes the algorithm even more e�cient. In this case, when we look at path791
S(t1)→d3(t2)→d1(t3)→d2(t4), we �nd the path distance to be 21+13+2=36. Since792
36 is smaller than 37, we update our bound as S(t1)→d3(t2)→d1(t3)→d2(t4). When793
we �nish pruning the tree, we �nd the current bound as the best path. In this case,794
the best path is S(t1)→d3(t2)→d1(t3)→d2(t4).795
This method is especially useful for problems in which very bad choices are made796
on the upper level of the tree. For problems in which very bad choices are made797
on the upper level of the tree, this method is very useful as one can prune the bad798
branches pretty quickly. But if the bad choices are on the lower level of the tree,799
or even on the leaves, the algorithm will not be able to detect them until the full800
tree is thoroughly examined. For example, if on each level except for the last level,801
the arc distance to each node are exactly the same, then one would not be able802
to throw away any subbranches, because all subbranches have the same length. If803
the di�erences only begin to appear on the last level, one would need to calculate804
and compare all branches. In this case, the branch and bound algorithm becomes805
essentially the brute-force search approach, and one ends up doing an exhaustive806
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 50
search of the full tree.807
In summary, this algorithm can �nd the optimum solution, which has the lowest808
distance number for a path-dependent problems. It is especially e�cient with prob-809
lems where bad choices are made on the upper level of the tree, and less e�cient when810
bad choices are made on the lower level of the tree. The worst case of this algorithm811
is a case of the brute-force search approach.812
The pseudocode of this algorithm is given below.813
• path is the path we are looking at (its lower level parts need to be de�ned the814
part from level on up, need not be de�ned815
• level is the current working level, all parts earlier in the path are de�ned816
• bound is the current best bound, it could be "in�nite"817
• bestpath is the current best path, it may be unde�ned at the outset, it may be818
de�ned819
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 51
Algorithm 4.5.1: FindBestPath(path, level, bound, bestPath)
Input:path, level, bound, bestpath
if (level ≡ nstep)
then
if (Penalty < bound)
then
bestPath← path;
bound← Penalty;
for i← 1 to nstep
Penalty(level, path, PowerP lant, allnodes);
for i← 1 to nstep
s[i]← i;
Bubblesort(Penalty[s[i]])
for i← 1 to nstep
do
if (P [s[i]] > bound)
then break;
FindBestPath(path, level + 1, bound, bestPath);
820
4.6 Heuristic821
To solve problems in which the distances of all branches are very similar to each822
other, it may be too expensive to use the branch and bound algorithm. In order to823
reach a reasonable computational cost , we seek alternative methods that would �nd824
a solution which is close to the best possible answer, i.e. a heuristic. The outcome of825
the heuristic may not be the optimum path, but it is a good path that is close to the826
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 52
optimum. The results can be compared with the results of the brute-force approach827
algorithm to verify the accuracy of the heuristic.828
This heuristic is based on the label-correcting algorithm, which is very e�cient in829
solving the shortest-path problem in polynomial time. In the shortest-path problem,830
a multi-ary or n-ary tree is collapsed into a graph. On each level of the graph, there831
are exactly n nodes, and each node represents a unique design choice. Di�erent paths832
are represented by connecting the nodes on each level with directed arc. An instance833
of the graph is shown in Figure 4.3.834
Figure 4.3: An instance of a graph forshortest-path problem
Figure 4.4: An instance of a tree collapsedinto a graph, path-dependent
The shortest-path problem is not path-dependent, each arc only has one value,835
regardless its past history. Therefore we can associate a numerical value or a distance836
label with each node, representing the subbranch distance from the root to that node.837
Di�erent paths give di�erent distance labels.838
Since it's not path-dependent, one can calculate the distance label of a node by839
considering only local information, namely the length of single arc. Therefore, instead840
of having to remember the full tree, one needs only remember the best path reaching841
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 53
each node on the that level. Since there are exactly n nodes on every level, one needs842
to keep the best n paths, each being the shortest for each node.843
One always works on two neighboring levels, each level has exactly n nodes, there-844
fore, the total number of enumeration for every pair of levels is n2 paths. On each845
level for each node, one iteratively reduces the distance label until the best path to846
reach that node is found.847
The procedure described above is essentially a label-correcting algorithm, which848
is a general procedure for successively updating the distance label until they satisfy849
the shortest path optimality condition. The total runtime of this algorithm is O(n2).850
The critical di�erence between our problem and the shortest-path problem lies851
in the di�erence in path-dependency. Figure 4.4 illustrates an instance of a tree852
that is path-dependent collapsed into a graph. As illustrated, the same arc may853
have multiple values, instead of just one value. For example, arc d1(t3)→d1(t4)854
has three values, and each one corresponds to a unique path histories. Speci�-855
cally, the distance of S(t1)→d1(t2) is 5 after subpath S(t1)→d1(t2)→d1(t3), 14856
after subpath S(t1)→d2(t2)→d1(t3), and 31 after subpath S(t1)→d3(t2)→d1(t3).857
What is more, the principal of dynamic programming no longer holds. For example,858
path S(t1)→d1(t2)→d1(t3)→d1(t4) is the shortest path in graph, however, subpath859
S(t1)→d1(t2)→d1(t3) is suboptimal compared to subpath S(t1)→d3(t2)→d1(t3).860
If we use the label-correcting algorithm to solve Figure 4.4, subpath S(t1)→ d1(t2)861
→ d1(t3) will be pruned out before reaching the last level. To avoid pruning out a862
good path early on, we modify the label-correcting algorithm, such that on every863
level, we keep more than n paths. In addition, we keep another x good paths, such864
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 54
that on every level we keep the total of x+n paths. The choice of x depends on865
ones preference of runtime versus accuracy (0 ≤ x ≤ (nm-n)). On one end of the866
spectrum, when x equals zero, in total we are keeping n paths on each level, this is867
essentially the non-path-dependent shortest-path algorithm. On the other end, when868
x equals nm-n, in total we are keeping nm paths, this is essentially the brute-force869
search approach. For simplicity, we assume x=2n in this work.870
We further improve the heuristic by introducing the concept of a bound. In this871
case, we �rst get a bound by running the shortest-path algorithm (x=0 ). Then we872
run the heuristic by assuming x=2n. We keep a maximum total of x+n subbranches873
on every level, such that all subbranch we keep are smaller than the bound. This874
way, we remember only the good path that are likely to be the best path. By using875
a bound, we prune out the bad subbranches early on, hence increasing the e�ciency876
and the accuracy of the algorithm.877
One can further improve the heuristic by gradually increase x. One can update878
the bound whenever a smaller optimal path is found for a given x. The price to pay879
in this scenario, is that one needs to prune the tree once for every value of x. Further,880
the optimal path does not change monotonically as x increases. In other words, by881
increasing the value x, one is not guaranteed to �nd a better path. A detail discussion882
is given in the following section.883
The limitation of this heuristic is that it may not be able to �nd the true optimum884
path. To examine the accuracy of the heuristic, we can compare results of the heuristic885
with the brute-force search approach. The detail of the comparison is given in the886
following section.887
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 55
4.7 Computational results888
We summarize the algorithms described in this chapter as following.889
• brute-force search or exhaustive search, explicitly enumerates the complete890
space of solutions, calculates and compares all possible solutions for optimality.891
• branch-and-bound algorithm By using a bound for the function to be opti-892
mized combined with the value of the current best solution enables the algorithm893
to search parts of the solution space only implicitly.894
• heuristic improves the label-correcting algorithm for the shortest path prob-895
lem, by remembering a few additional good subpaths (x subpaths) on each level,896
to avoid pruning out a good path early on. For simplicity, we assume x=2n.897
In this section, we present computational experiments conducted to evaluate the898
quality of the two approaches described above, namely the branch-and-bound algo-899
rithm and the heuristic. We tested the approaches on a sequence of examples with a900
feasible solution space ranging from thousands to trillions of paths. These particular901
example problems form 6-ary search trees of di�erent levels. On a small problem,902
a 5-level tree gives 1296 possible paths (64), on a big problem, a 15-level tree gives903
7.84E10 possible paths (614). Problems forming search trees with all levels between 5904
to 15 are also explored. We pruned the trees with the branch-and-bound algorithm905
and the heuristic respectively. We also provided the brute-force search approach to906
calibrate ourselves.907
The algorithms are coded in C++ and tests are carried out on a PC with AMD64908
architecture under Linux system Ubuntu. Without going into the details of the science909
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 56
and engineering aspect of the examples right now (the details are given in the later910
chapter), here is the summary of the results with a numerical method focus.911
4.7.1 Verifying branch-and-bound algorithm912
First, we compare the the branch-and-bound algorithm with the brute-force search913
approach over a set of 6-ary search trees with a height from 5 levels to 15 levels. When914
working with an extreme problem, the branch-and-bound algorithm degenerates into915
the brute-force search approach. In that case, every node on the tree has to be visited916
exactly once. Further, whenever a node is visited, the program triggers a function917
call which calculates the distant number. From a computational point of view, this918
calculation is the most expensive task for each iteration. Therefore, comparing the919
actual nodes visited using the branch-and-bound algorithm against all nodes in the920
tree, is a good measurement of the algorithm e�ciency.921
Figure 4.5: Visited nodes in branch-and-bound(BB) algorithm
Figure 4.6: The optimal results given byBB and the brute-force approach
Figure 4.5 illustrates the number of visited nodes against all nodes for all levels922
considered. First of all, we were successful in discarding bad branches and nodes using923
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 57
the algorithm over all level of problems considered. Secondly, none of the problems924
degenerate into the brute-force search approach. Lastly, as the tree level increases, the925
fraction total of the nodes visited decreases considerably. Therefore, for large trees,926
the branch-and-bound algorithm is especially e�cient compared to using brute-force927
search approach.928
We calibrated ourselves by comparing the results given by the branch-and-bound929
algorithm and the brute-force search approach. Figure 4.6 illustrates that the results930
of the branch-and-bound algorithm agrees with the brute-force search approach over931
all levels considered.932
4.7.2 Verifying Heuristic933
Secondly, we compare the visited nodes of the heuristic with the branch-and-bound934
algorithm to show that heuristic is actually more e�cient. The heuristic assumes935
x=2n, therefore it remembers a maximum total of 3n paths on each level of the tree.936
Figure 4.7 illustrates the visited nodes of both the branch-and-bound algorithm and
Figure 4.7: The visited nodes comparisonbetween BB and the heuristic
Figure 4.8: The optimal results given bythe heuristic and the brute-force approach
937
the heuristic, over a set of 6-ary search trees from 5 levels to 15 levels. As illustrated,938
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 58
the visited nodes for both branch-and-bound algorithm and the heuristic increases as939
the tree levels increases. Further, The heuristic is more e�cient compared with the940
branch-and-bound algorithm over all levels considered. Lastly, as the number of tree941
level increases, the fraction of visited nodes decreases considerably. The fraction total942
of visited nodes of the heuristic compared to the branch is bound is 47 percentage at943
5 levels, and only 2 percentage at 15 levels.944
We compare the optimal results give by the heuristic and the brute-force approach945
to calibrate ourselves. Note in this comparison, we ran the heuristic assuming x=2n.946
Figure 4.8 illustrates that for these speci�c sets of problems, the optimal results found947
using the heuristic agrees with brute-force approach at lower levels, speci�cally from948
5 levels to 11 levels. At higher levels, namely from 12 level to 15 levels, the heuristic949
gives suboptimal solutions compared to the results given by the brute force search950
approach.951
As mentioned earlier, heuristic is not an exact method, therefore it does not952
guarantee to always give the optimal results. Figure 4.9 illustrates the optimal results953
given by heuristic as the number of additional subpath x increases for a 6-ary trees of954
15 levels. Firstly, when x=0, this heuristic is essentially the shortest path algorithm.955
Since it ignores the path-dependency nature in the problem, the results given is956
suboptimal. Secondly, the optimal result changes as x changes. Lastly, the change of957
the optimal result is not monotonic as x increases. The details interpretation of the958
results are given in the discussion section.959
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 59
Figure 4.9: The optimal path as a function of x in Heuristic
4.8 Discussion960
We have shown that the branch-and-bound algorithm is indeed more e�cient than961
the brute-force search approach, as illustrated in Figure 4.5. In these speci�c sets of962
problems, the branch-and-bound algorithm becomes more e�cient as the tree level963
increases. Further, Figure 4.6 illustrates that the results given by the branch-and-964
bound algorithm agrees with the brute-force search approach over all levels considered.965
Despite the improved e�ciency, the branch-and-bound algorithm can still take966
up to nine minutes in solving a 6-ary tree of 15 levels. For a large tree with a large967
number of steps and a great number of choices for each step, the runtime can increase968
considerably. To improve the algorithm even more, we proposed a heuristic to obtain969
a good solution in a reasonable time. We have shown in Figure 4.7 that the heuristic970
is indeed more e�cient than the branch-and-bound algorithm. The fraction total of971
visited nodes compared with the branch-and-bound algorithm decreases as the tree972
level increases, indicating an increased e�ciency gain with larger trees. We compare973
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 60
the results given by the brute-force approach and the heuristic assuming x=2n. We974
have shown in Figure 4.8 that the heuristic coincides with the brute-force approach975
over lower levels of the tree, but disagree at higher levels.976
The heuristic does not guarantee to �nd the optimal solution, it is not an exact977
method. To calibrate ourselves, we ran the heuristic for a 6-ary tree of 15 levels, by978
slowly increase x from zero to nine times the design options. Figure 4.9 illustrated979
that, given di�erent x, the results may not coincide with the optimal results given980
by the exact method. Further, the di�erences between the optimal and suboptimal981
results are very small, this is problem-speci�c. Given a di�erent tree, the di�erence982
may be more dramatic. Lastly, the change in the optimal results is not monotonic983
with the increase of x. This is because though some of the x partial paths look984
promising on the upper level, they can later become terrible choices. An extreme985
case is when the partial path is locked-in to a wrong path, which later becomes too986
expensive to escape from. Additionally, keeping x additional subpaths on early levels,987
can crowd out the true optimal subpath, resulting in suboptimal results. In fact, this988
is the case when x is between 2n and 8n, as illustrated in Figure 4.9. When x=n, the989
results given by the heuristic agree with the exact method. This is because keeping990
only n additional subpaths did not crowd out the true optimal. It is worth to note991
that, these results are problem-speci�c. Given a di�erent tree, the range of x value,992
in which optimal solution is crowded out may be di�erent.993
In addition to the two approaches discussed above, we can combine the two ap-994
proaches for a hybrid algorithm. Speci�cally, we can �rst run the heuristic to get995
a good bound, then we can run the branch-and-bound algorithm with the bound996
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 61
obtained from the heuristic. Theoretically, the hybrid algorithm should be more ef-997
�cient than the branch-and-bound because it starts with a tighter bound, therefore998
making the pruning more e�cient. We implemented the hybrid algorithm. Figure999
4.10 illustrates the number of discarded nodes using the branch-and-bound and the1000
hybrid algorithm over a set of 6-ary trees of 5 levels to 15 levels, the di�erences are1001
illustrated as dots. The results showed that, �rst there are di�erence in the number1002
of discarded nodes over all levels considered. Secondly, the di�erences are very small.1003
We believe this is a re�ection of the nature of this speci�c set of problems, rather1004
than generic to the algorithm.
Figure 4.10: Visited nodes in the branch-and-bound and the hybrid algorithm
1005
So far we have presented the results of deterministic discrete optimization. Firstly,1006
we have assume that the decision maker is a rational economic person, and is willing1007
invest the cost upfront, and receive the bene�t much later. However, if the decision1008
maker wants immediate grati�cation, rather than the true global optimal, he may1009
prefer a suboptimal solution, which gives the optimal bene�t in the short run. Sec-1010
ondly, although the cost of technology and the environmental penalty are expected to1011
change over time, we do not intend to forecast the technology development. Rather,1012
Chapter 4: Path-dependent shortest-path algorithms for optimizing a sequence ofpower plant designs 62
we treat these changes as exogenous to the model, and are given by the user as1013
input to the model. Finally, the uncertainties in the technology development, and1014
potentially emerging new technology choices over time are beyond the scope of this1015
research.1016
Chapter 51017
Optimizing CO2 post-combustion1018
capture technologies1019
In this chapter, we study various post-combustion capture technologies using the1020
ranking algorithms described in Chapter 4. In the �rst part of our work, we developed1021
a simple model for the absorber system. We are given a CO2 mitigation target,1022
by varying parameters like the sorbent strengh, the packing tube radius and the1023
absorber tower height, we can �nd the optimum design. In the second part of our1024
work, we studied various power plant designs with absorbers in a sequence and �nd1025
the optimum sequence using the algorithms described in the previous chapter. By1026
comparing the results from the �rst part and the second part, we can that one can1027
get di�erent answers when looking at the same problem di�erently.1028
63
Chapter 5: Optimizing CO2 post-combustion capture technologies 64
5.1 Motivation1029
Post-combustion capture technology captures carbon dioxide in a large point1030
source (i.e coal-�red power plant or cement plant), by separating carbon dioxide1031
from the �ue gas via chemical or physical absorption. This procedure can be used for1032
capturing carbon dioxide from power plants as an �end-of-the-pipe" approach, leaving1033
the existing technology designs relatively unchanged. Therefore, it is especially at-1034
tractive for governments and companies who are eager to deploy low-emission power1035
plants.1036
The technology of absorbing carbon dioxide from a mixed gas stream is well stud-1037
ied and widely used in chemical industry for gas treatment. However, it has not1038
been used in coal-�red power plant for CO2 separation. Traditionally, gas treatment1039
systems are designed to absorb as much CO2 as possible while meeting the economic1040
constraints. Drawing from the experience in chemical industry, power plant designs1041
with CO2 capture using post-combustion capture technology, often target for 90 per-1042
cent capture percentage or even higher are assumed (i.e. DOE, ieaghgt). Further,1043
technoeconomic studies of the power plant system with CO2 absorber, often takes1044
the CO2 absorber as a preoptimized module. While the absorber itself is optimized1045
locally, it may not be the optimal design when evaluating the entire power plant.1046
It is our view that, low capture percentage range may o�er economic opportunities1047
for reoptimizing the absorber system integrated with the power plant, by taking1048
advantage of weaker and cheaper sorbent.1049
On one end of the spectrum, as one attempt to capture the last percentage of CO21050
from the �ue stack, it is conceivable that the capture cost rises signi�cantly. This1051
Chapter 5: Optimizing CO2 post-combustion capture technologies 65
is because as the partial pressure of CO2 approaches equilibrium, the driving force1052
for absorption decreases signi�cantly, making it very di�cult to collect the last bit.1053
Theoretically, to capture one hundred percent of CO2, one needs to build an in�nitely1054
tall absorber tower. Though one can capture as much as CO2 possible, the cost per1055
ton of CO2 captured is very expensive in this case.1056
On the opposite extreme, if one were to capture only very little CO2, the cost1057
is very little. For example, by licking one's �nger tip and simply put it in the air,1058
one can capture in�nitely small percentage CO2 from the air on the wetted �nger tip1059
surface. The cost of doing so is nill.1060
Between the two ends of the spectrum, there is an optimum capture cost ($/ton1061
CO2), which is associated with an optimum absorber design using an optimum sor-1062
bent. In such a design, design parameters like the sorbent strength, packing geometry,1063
and �ow pattern and �ow rates, are reoptimized at each targeted capture percentage1064
for the lowest cost per ton of CO2 captured, (rather than the lowest cost per ton of1065
gas treated.)1066
By connecting optimality at each capture percentage, one can generate a cost1067
curve of optimum capture costs in a power plant, at di�erent capture percentage.1068
Such curve is useful to decision-makers not only in building one plant at a time, but1069
more importantly, building a smoother pathway in the large scale carbon sequestration1070
project deployment and technology commercialization.1071
This chapter studies the subject of optimizing post-combustion capture power1072
plants via redesigning absorber-desorber system for various capture percentage using1073
various sorbent. In the �rst part of this chapter, we optimize a single plant design.1074
Chapter 5: Optimizing CO2 post-combustion capture technologies 66
In the second part of this chapter, we optimize a sequence of plant designs using the1075
algorithms introduced in Chapter 4.1076
A post-combustion capture power plant using monoethanolamine is modeled with1077
the program introduced in the Chapter X. The modeling procedure strictly followes1078
Perrys' chemical engineering handbook and take (Oexemanne,2008) as reference (sec-1079
tion 5.3). The cost model is described in section 5.4. Optimization parameters include1080
packing tube radius, column height, capture percentage, choice of sorbent, etc. Re-1081
sults are presented in section 5.5. The optimization results show that for the perfectly1082
strong sorbent, CO2 capture percentage is insensitive to the design of the column as1083
long as the pressure drop remains the same. For imperfect sorbent, the optimized1084
packing is XXX for YYY capture percentage, and XX2 FOR YYY2 captuer per-1085
centage. This result is compared to the DOE study and the Oxemanne 2008 study,1086
the implications and limitation of the result are discussed, and further research is1087
proposed.1088
5.2 Literature Review1089
Many research workers have studied optimizing post-combustion capture tech-1090
nologies (DOE, IEAGHGT, etc). In the DOE study, a 300 MW subcritical power1091
plant with 90 percent CO2 captured using MEA sorbent is considered as the refer-1092
ence case. To simulate lower capture percentage in the full-size plant, the method1093
bypasses �uegas such that lower capture percentage in the full-size plant can be con-1094
sidered equivalent (in term of CO2 captured per hour), to 90 percent capture rate in1095
a much smaller plant. The optimization result is a capture system with the largest1096
Chapter 5: Optimizing CO2 post-combustion capture technologies 67
column, due to the economies of scale. This study however, failed to account for1097
various capture system designs. For example, for various CO2 capture percentage in1098
power plants, one can choose to pack the absorption tower loosely or densely, one1099
can also choose to use weaker or stronger sorbent. For a perfectly strong sorbent1100
in the laminar �ow, when the schmit number is close to 1, the CO2 absorption rate1101
as a fraction of total is approximately the same as the pressure drop as the fraction1102
of total. If loose packing in a taller absorber give you the same pressure drop as1103
dense packing in a shorter absorber, a perfectly strong sorbent in the laminar �ow is1104
insensitive to the size and packing of the column as long as the pressure drop is the1105
same. However for imperfect sorbents, the design of column matters.1106
The DOE study also failed to take advantage of various sorbent with various1107
binding energies. For example, when the weaker sorbent is used (i.e. slightly alkaline1108
sorbent, seawater, etc), less energy per ton of carbon dioxide is needed for CO21109
regeneration.1110
In addition, when studying optimization with various sorbent, it is important1111
to fully integrate the capture system into the power plant. In the post-combustion1112
capture system, substantial amount of steam is extracted from the steam turbine1113
for CO2 regeneration in the stripper. Therefore, globally optimized power plant can1114
operate with the lowest cost and the lowest energy penalty of the entire system.1115
However, due to the lack of software tools suited for this purpose, many studies have1116
used separate softwares for power plant modeling, and for capture system modeling.1117
Since it is usually di�cult to fully integrate the two softwares, optimization is often1118
carried out locally in the capture system based on the pre-determined power plant1119
Chapter 5: Optimizing CO2 post-combustion capture technologies 68
operating condition (i.e Oexmann, 2008). With the help of the newly developed1120
software tool (described in the previous chapter), it is possible to fully integrate the1121
capture system into the power plant designs, and carry out global optimization.1122
The literature review on a DOE study (2007) on carbon capture from existing coal-1123
�red power plants, found a deceasing CO2 avoidance cost ($/ton CO2 capture) with1124
increase in CO2 capture percentage, implying the more you scrub the cheaper/easier1125
it becomes. This result is counter-intuitive, but a closer examination on this report1126
found the assumption of bypassing a portion of �ue gas, essentially equivalent to1127
scrubbing a smaller power plant. The cost reduction is caused by the economics of1128
scale with larger absorption columns at higher capture percentage. Applying absorber1129
designs for high capture percentage range (90 percent or above) to all capture ranges,1130
will likely to result in sub-optimality.1131
Unlike the DOE approach, we aim to study the CO2 avoidance cost ($/ton CO21132
capture) as a function of capture percentage without bypassing any �ue gas for a hy-1133
pothetical sorbent in a hypothetical column design. Five capture technology options1134
are identi�ed among a wide range of technological options. A cost curve (that may or1135
may not continuous) combining these candidate technologies across di�erent capture1136
ranges will be constructed.1137
5.3 Modeling CO2 absorber physics1138
A post-combustion capture power plant using monoethanolamine is modeled with1139
the program introduced in the Chapter X. For the purpose of this discussion, the1140
modeling details of the power plant island is included in the appendix, while this1141
Chapter 5: Optimizing CO2 post-combustion capture technologies 69
chapter focuses on the modeling detail of CO2 absorber.1142
Let us consider a hypothetical packed bed absorber tower for CO2 absorption us-1143
ing a hypothetical sorbent. The uptake rate of the absorption tower is characterized1144
by a surface area and a mass transfer coe�cient. Speci�cally, the surface area is de-1145
termined by the packing geometry, whereas the mass transfer coe�cient is determined1146
by the packing geometry, the sorbent strength, and the hydrodynamic condition of1147
the absorber.1148
For the simplicity of the discussion, the packing structure inside the absorber1149
can be considered as bundles of evenly divided tubes, the length of the which equals1150
the absorber height. This type of structured packing is rare in reality, however this1151
treatment greatly simpli�es the packing geometry, hence allowing us to understand1152
the physics of packed bed column with a rather simple model.1153
Consider the packing arrangement such that all tubes are identical, and are set1154
up in parallel to each other. An example of the cross sectional view of the absorber1155
column is shown in Figure 5.1, where 33 small tubes packed in a big column [?].1156
The tube wall is fully coated with sorbent which is continuously refreshed. The1157
overall tower diameter and volumetric �ue gas �ow rate are known, hence we can1158
determine the average gas velocity. For practical purposes, we don't know if the1159
sorbent combines with CO2 chemically or physically.1160
5.3.1 Di�usion process1161
In the laminar or somewhat turbulent �ow, we can make the following argument1162
about the absorption process. During CO2 absorption, momentum transfer to the1163
Chapter 5: Optimizing CO2 post-combustion capture technologies 70
Figure 5.1: An instance of the cross-section of a packing tower
wall, follows the similar di�usion equation (equation 5.2), as that of the CO2 transfer1164
to the wall (equation 5.1). Momentum transfer coe�cient and mass transfer coe�cient1165
are on the same order of magnitude, their ratio is measured with Schmidt number,1166
as given in equation 5.3. When the Schmidt number approaches unity, the value of1167
momentum transfer coe�cient equals the value of mass transfer coe�cient.1168
τ = −µ× ∂vz∂r
(5.1)
JCO2,g = −ρD∇CO2 = −ρD∂yCO2
∂r(5.2)
Sc =ν
D=
µ
ρD(5.3)
In the center of the tube, both momentum and CO2 are at their maximum. On1169
the wall, momentum always go to zero. CO2 will also go to zero if a perfect sorbent is1170
Chapter 5: Optimizing CO2 post-combustion capture technologies 71
coated on the wall, and is continuously refreshed (i.e. no CO2 loading in the sorbent).1171
Therefore, given the shared boundary conditions on the wall and at the tube center,1172
we argue that the fractional total of CO2 and the fractional total of momentum1173
across the tube radius are approximately the same. In other words, if one percent of1174
momentum is lost, then one percent of CO2 lost too.1175
Nevertheless, momentum doesn't go away as CO2 does, because the momentum1176
lost is continuously replenished by pressure drop. If one percent of momentum is1177
replenished, then one percent of pressure is lost. Therefore, if one wants to take out1178
a certain fraction of the CO2, one needs to take out the same fraction of the �ue gas1179
pressure.1180
For a sorbent which meets the boundary condition of zero CO2 concentration on1181
the wall, as long as the pressure drop is kept constant, the CO2 capture percentage1182
is also kept constant. Therefore, the packing structure inside the bed can be either1183
long tubes with big openings, or short tubes with narrow openings. Since the latter1184
is more favorable for economic reasons, one can reduce the tube opening, to the point1185
where the boundary condition doesn't hold. The tube radius at this point is de�ned as1186
critical radius rc. Each sorbent with a unique binding strength, has a unique critical1187
radius. The value of rc is relatively small for strong sorbent, and big for weak sorbent.1188
When the tube radius is smaller than rc, it is undesirable to continue reducing the1189
tube radius for higher mass transfer coe�cient. This is because with a small opening,1190
the CO2 uptake rate is small due the limitation on the wall, but one still need to pay1191
for the big pressure drop. Therefore, the proportion of the momentum taken out to1192
the CO2 taken out is suddenly unfavorable.1193
Chapter 5: Optimizing CO2 post-combustion capture technologies 72
Since the uptake rate, speci�cally the mass transfer, is greatly in�uenced by the1194
packing geometry, huge opportunities exist to redesign the packing structure for var-1195
ious sorbents. It is our view that one can redesign the packing structure for each1196
sorbent with a unique binding strength and a unique critical radius, for the lowest1197
cost per ton of CO2 capture. This optimum design correspond to a capture percent-1198
age for the chosen sorbent. Therefore, for a given capture percentage target, one can1199
select the optimum sorbent with the optimum design for the lowest cost of per ton of1200
CO2 capture.1201
5.3.2 Interfactial partial pressure and concentration1202
CO2 transfer on the wall side is given by the following equation1203
JCO2,w = kl × (PCO2,w − P ∗CO2) (5.4)
For the simplicity of the problem, we assume that the mass transfer pro�le across the1204
tube is linear, and the boundary layer in the gas side is the tube radius.1205
JCO2,g = −ρDPCO2,in − PCO2,w
rt(5.5)
Consider steady state, the CO2 �ux on the wall is always in equilibrium1206
JCO2,g = JCO2,w (5.6)
One can solve for the boundary condition as1207
PCO2,w =kl × P ∗CO2 + ρD
rt× PCO2,in
kl + ρDrt
(5.7)
PCO2,in > PCO2,w > P ∗CO2 is the condition for absorption, PCO2,in < PCO2,w < P ∗CO21208
is the condition for desorption.1209
Chapter 5: Optimizing CO2 post-combustion capture technologies 73
The CO2 �ux on the wall can be expressed as1210
JCO2 =ρDkl(PCO2,in − P ∗CO2)
ρD + klrt(5.8)
The interfatial liquid side CO2 concentration can be found with Henry's law.1211
Cco2,w = HkPco2,w (5.9)
5.3.3 Vapor Liquid Equilibrium1212
This correlation is taken from [Gabrielsen, 2005]1213
P ∗CO2 = KCO2103XCO2Xamine,0θavg
(Xamine,0 ∗ (1− 2 ∗ θavg))2(5.10)
lnKCO2 = A+B
T+ CXamine,0θavg +D
√Xamine,0θavg (5.11)
A = 30.96 ± 1.861214
B = -10584 ± 6701215
C = -7.187 ± 4.271216
D = 01217
1218
5.3.4 liquid side mass transfer coe�cient1219
Liquid size mass transfer coe�cient is determined by the packing geometry, the1220
hydrodynamic conditions, and the sorbent strength.1221
Chapter 5: Optimizing CO2 post-combustion capture technologies 74
physical mass transfer coe�cient1222
Penetration theory1223
k0l = (5.12)
Enhancement factor1224
5.3.5 CO2 absorption1225
Enhancement factor for the sorbents are:1226
E =Ha×
√(E∞−E)E∞−1
tanh×[Ha×√
(E∞−E)E∞−1
](5.13)
where1227
Ha =
√DCO2,AM × k2 × CMEA
KL
(5.14)
1228
E∞ = [1 +DMEA,amCMEA
γDCO2,am × CCO2,i
] (5.15)
k2 = 4.4× 108exp[−5400
T] (5.16)
For desorption1229
K−1 = 3.95× 1010exp[−6863.8
T] (5.17)
Sources are1230
5.3.6 Pressure Drop1231
Pressure drop is given by Hagan-Poiseuille equation.1232
Q =4Pπrt4
8µh(5.18)
Chapter 5: Optimizing CO2 post-combustion capture technologies 75
By rearranging the equation, we give the pressure drop as a function of height and1233
radius.1234
4P =8µhQ
πrt4(5.19)
To maintain the same pressure drop, one needs to maintain a constant hrt4. Hence,1235
the tube height (also the absorber height) can be expressed as a following equation1236
h =4Pπ8µQ
rt4 (5.20)
5.3.7 Uptake rate1237
rCO2 = ApJCO2 (5.21)1238
Ap = 2πhR2
rt(5.22)
5.4 Penalty model1239
5.4.1 Plant penalty model1240
The overall plant penalty model follows the same method described in Chapter1241
X. The details of other modules are listed in the appendix, since this chapter focuses1242
on the absorber.1243
5.4.2 CO2 absorber capital cost1244
For the absorber, there are two parts of the cost in capital cost, �rst it's the1245
total tower cost, secondly it's the packing cost. These calculation follows the man-1246
Chapter 5: Optimizing CO2 post-combustion capture technologies 76
ual[INCLUDE CITATION!]1247
The capital cost can be calculated based on the scaling law1248
Capex = C0× V α
V0α (5.23)
Assume the absorber height is 25 percent taller than the tube height, to account for1249
the sorbent distributor, the volume of the absorber column is given as below.1250
V = πR21.25h (5.24)
If we replace h with equation ??, we give the volume as below1251
V = 1.25πR24Pπ8µQ
rt4 (5.25)
5.4.3 CO2 absorber operation and Maintenance(OAM) cost1252
For the absorber, operation and maintenance cost here includes variable oam cost1253
and �xed oam cost. Variable oam costs include sorbent makeup cost, and the pump1254
cost. Fixed oam costs is estimated to be 2 percent of the absorber capital cost.1255
5.4.4 Unit cost of CO2 captured1256
Since we keep the pressure drop constant, if we only account for capital cost in1257
the total capture cost, the unit cost of CO2 captured is given as1258
$
tonCO2
=Capex
rCO2
(5.26)
This equation can be simpli�ed to1259
$
tonCO2
= kart(4α−3) + kbrt
(4α−2) (5.27)
Chapter 5: Optimizing CO2 post-combustion capture technologies 77
where1260
ka = ktotD
Pin− P ∗CO2
(5.28)
kb = ktotktotkl
Pin− P ∗CO2
(5.29)
ktot =C0παR2αCα
C1DklV0α (5.30)
Equation 5.27 gives the unit cost of CO2 captured as a function of tube radius1261
and α. Since α is usually 0.6 for chemical reactor [?, ?, ] the minimum unit cost of1262
CO2 captured correspond to a tube radius between zero and in�nity.1263
5.4.5 Parameters1264
We would like to �nd the optimum absorber by changing the radius and the height1265
of the packing tube. So the two parameters we have are tube radius rt, and height h.1266
State the source of constant Equilibrium1267
5.4.6 Mass conservation1268
Two mass conservation equations are postulated in this model. Firstly, the di�er-1269
ence between mathrmCO2 �ow rate (kg/s) on both sides of the absorber equals the1270
total mathrmCO2 absorption.1271
φCO2 = CO2, in− CO2, out (5.31)
Secondly, the di�erence between �ue gas �ow rate (kg/s) on both sides of the absorber1272
are only caused by mathrmCO2 absorption. This is a gross assumption, assuming1273
Chapter 5: Optimizing CO2 post-combustion capture technologies 78
zero mathrmSOx or mathrmH2O reacts with the sorbent. In reality, this equation1274
needs to take into account the e�ect of mathrmSOx and mathrmH2O. For the1275
simplicity of the model, we use the following equation.1276
FlueGas, in− FlueGas, out = CO2, in− CO2, out (5.32)
5.5 Results1277
• Single plant optimizaiton gives the optimal single plant at time t (t =t1,1278
t2, ... tn). It is a discrete optimization, in which the penalty of all designs1279
at the corresponding decision time are calculated. The one with the lowest1280
penalty is the optimum design. At each decision time t, one can �nd an optimal1281
design. Since each decision is viewed as independent, the factor of learning and1282
transitional costs are ignored. Therefore, the cost of the same design does not1283
change when it is chosen repeatedly.1284
• Local plant optimization simply puts the optimized single plant designs in1285
a sequence, giving a sequence of n designs for n decision points. In this case,1286
the decisions are viewed as a sequence of interdependent choices. Therefore,1287
learning and transitional costs between immediate decisions play a role in the1288
penalty of each choice in the sequence.1289
• Global optimization �nds the optimal sequence of designs, by comparing1290
all possible sequences of designs. In this case, an earlier cost may prevent the1291
sequence from locking in to the wrong path, incurring a much bigger costs later.1292
Chapter 5: Optimizing CO2 post-combustion capture technologies 79
5.5.1 Global optimum favors earlier costs for future bene�t1293
In this section, we �rst ran the model with 6 design choices for a 14 plant sequence.1294
Then we ran it with 21 designs for a 15 plant sequence. Finally, we increases the1295
number of designs to 87 designs, and optimize for a 15 plant sequence. In1296
Result1. 6 design choices with 14 decision times1297
Figure 5.2 illustrates the single plant optimum at 14 decision points, both in-1298
dependently and sequentially. It also illustrates the global optimum of a 14-plant1299
sequence in comparison. In both optimizations, we are given 6 design choices at each1300
time. The 6 choices are: NoScrubber, WeakAbsorber, StrongAbsorber, Absorber.
Figure 5.2: Single plant and pathway optimization, 6 design choices for 14 decisionpoints
1301
As illustrated in Figure 5.2, Firstly, when viewed as independent decisions, the1302
same designs chosen repeatedly have the same cost. In comparison, when they are1303
viewed as a sequence of decisions, the cost decreases as more units are built. Secondly,1304
we can see that single plant optimum favors immediate bene�t at the cost of lock-in1305
Chapter 5: Optimizing CO2 post-combustion capture technologies 80
at time t11. Sequence optimum favors early costs for future bene�t. Thus by paying1306
a little extra at time t2 and t6, it gains the bene�t of learning for the rest of the1307
sequence.1308
Figure 5.6 compares the series of chosen plant index for both single plant opti-1309
mization and sequence optimization. As seen, they are di�erent
Figure 5.3: 6 design results. Plant index comparison
1310
Chapter 5: Optimizing CO2 post-combustion capture technologies 81
Figure 5.4: Plant performance data of the 6 designs
Figure 5.5: 21 design results. The optimal cost of a single plant and a sequence ofplants
Result2. 21 design choices with 15 decision times1311
Result 3. 87 design choices with 15 decision times. Only CO2 cap1312
Result 3. 87 design choices with 15 decision times. CO2 cap and trade,1313
assume 30 $/ton CO21314
5.5.2 Parametric study of technical performance based on mo-1315
noethanolamine1316
This should be part of the sorbent chapter1317
Chapter 5: Optimizing CO2 post-combustion capture technologies 82
Figure 5.6: 21 design results. Plant index comparison
Impact of MEA%, loading1318
The �rst part of the results look at choosing the optimized packing structure for1319
sorbents with di�erent concentration. Three cases are chosen for comparison, in case1320
1, MEA concentration is chosen to be 45% by weight, in case 2, MEA concentration1321
is chosen to be 35% by weight, in case 3, MEA concentration is chosen to be 25% by1322
weight.1323
The preliminary results show that to choose the optimum tube radius, di�erent1324
MEA concentration does not have a signi�cant impact. Di�erent loading also does1325
not have a signi�cant impact. This is because, given the choice of tube radius, MEA1326
concentration can have a impact on the equilibrium partial pressure of the CO2 with1327
regard to the sobent, and hence change the the CO2 �ux. But this impact is in-1328
signi�cant, compared with the impact of the di�erent packing area as a result of the1329
Chapter 5: Optimizing CO2 post-combustion capture technologies 83
Figure 5.7: Plant performance data of the 21 designs
decreasing tube radius. The same case is true with di�erent loading.1330
This result compared with literature XXX, BBB, CCC1331
Chapter 5: Optimizing CO2 post-combustion capture technologies 84
Figure 5.8: 87 design results. The optimal cost of a single plant and a sequence ofplants
Figure 5.9: 87 design results. Plant index comparison
Chapter 5: Optimizing CO2 post-combustion capture technologies 85
Figure 5.10: 87 design results. 87 design results. 30 $/ton CO2 .The optimal cost ofa single plant and a sequence of plants
5.6 Discussion-Modeling Results1332
5.6.1 Limitation1333
: The advantage of optimizing over the entire integrated system is mostly obvious1334
in green�eld plants. When it comes to retro�t, it may or may not be more advanta-1335
geous than using two separate softwares, due to the limitation in how much you can1336
improved on the existing power plant, and the room for improvement/remodi�cation1337
due to the age of that power plant. If the existing power plant is relatively new,1338
Chapter 5: Optimizing CO2 post-combustion capture technologies 86
Figure 5.11: 87 design results. 30 $/ton CO2 Plant index comparison
changed operating conditions from the design operation conditions may be allowed,1339
for older generation power plants, this may be too di�cult hence one can get the same1340
result using two separate softwares. In addition, retro�t is highly site-speci�c. It is1341
yet another question (and still an open question) whether it's better o� to retro�t the1342
existing �eet or build new ones. From purly engineering point of view, it is likely to1343
retire the existing �eet and build new ones, however, this will be subject to a range1344
of factors like policies, public opinion, and the economy.1345
Chapter 61346
Designing the software tool for1347
advanced power plant modeling and1348
optimization1349
6.1 Summary1350
In this chapter, a software tool for advance power plant modeling and optimiza-1351
tion is designed and developed. The motivation for this work is driven by the lack of1352
process modeling and optimization tool for advanced power plant optimization exer-1353
cise. This is con�rmed by the observation in the limitation of chapter 3, where the1354
existing software can not meet the requirement of the optimization exercise. This1355
chapter will explain in detail the design and the development of the software tool.1356
The software is designed as a model of modules and pipes, in which a module is1357
a basic operation unit (i.e. pressure pump, absorber, boiler, etc), and a pipe is the1358
87
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 88
material and energy �ow that connects the modules, each pipe is connected on both1359
ends. A module is characterized by a set of parameters, some of the parameters are1360
properties and �ow rate carried in the pipes, others are known only the module itself.1361
The program starts with a user-provided input �le which describes a power plant of1362
modules and pipes characterized by a complete but inconsistent set of parameters.1363
The program then reconciles the inconsistencies in the over-determined parameters1364
through an iterative process, until it �nds the solution. The penalty of the reconciled1365
power plant is then calculated. Up to this point, the program has calculated the1366
penalty number for a physically consistent(coherent) power plant which operates in1367
one speci�c conditions and of one speci�c size. To study the impact of parameters1368
of interest on the power plant penalty, instead of specifying a �xed value for the1369
parameter, one needs to specify a range and a current value of the parameter if1370
it is continuous, otherwise one need to specify a set of discrete values for discrete1371
parameters. The program calls the reconcile routine to �nd each possible physically1372
consistent system provided the parameters fall into the range speci�ed above. Each1373
reconciled system has one unique penalty number. The optimization routine compares1374
the penalty numbers of all reconciled systems and �nd the optimized system with the1375
lowest penalty number. In this way, one can �nd the optimized plant design and the1376
optimized operating condition for systems of interest.1377
Similarly, one can use this method to �nd the optimum pathway for a sequence of1378
power plant designs. First reconcile will �nd the physically consistent set of parame-1379
ters for each plant design. Then the penalty of the sequence will be calculated, where1380
the pathway penalty is the sum of all plant level penalty in addition to pathway level1381
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 89
penalties (see Chapter X). A sequence of power plant designs is a discrete parameter,1382
where each plant design is an element in the set. Optimization will run through each1383
possible combination of elements in the set, calculate the pathway penalty for each1384
combination, and �nd the optimized pathway with the lowest penalty.1385
This chapter will describe in detail the program design, and introduce its main1386
functionality. Currently seven modules and six pipes are developed. The module li-1387
brary includes boiler, steam turbine, condenser, pressure pump, CO2 absorber, split-1388
ter, generic source and sink. The pipe library includes heat �ow, work �ow, �ue gas1389
�ue, water �ow, coal �ow, and sorbent �ow.1390
6.2 Motivation1391
There is a lack of process modelling and simulation, in particular to evaluate1392
the potential of CO2 capture by various sorbent for various capture percentage, in1393
comparison to solvents such as MEA, which is often aiming for 90-95 % capture1394
percentage only.1395
When considering the integration of the capture and compression sub-processes1396
into the overall process of a coal-�red power plant, the simulation of the CO2 capture1397
process and the power plant modeling are often carried out in two independent soft-1398
ware respectively (i.e Oexmann, 2008). Therefore, it becomes very di�cult (unstable)1399
and in�exible to conduct optimization, which will �nd optimum process parameters1400
for the overall system (instead of only part of the system, i.e. the power plant, or the1401
CO2 capture process) that shows the lowest penalty.1402
Furthermore, the objective function of the optimization is often minimizing energy1403
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 90
loss in CO2 post-combustion capture process (due to the nature of such modeling1404
tools), capital cost of the overall integrated system are subsequently calculated based1405
on the result of the optimization. In reality, business decisions are made often with1406
the goal of minimizing cost, where the capital cost of the entire plant is not only a1407
function of power loss, but also a number of other factors, for example the operating1408
temperature of the furnace, the number of stages in steam turbine, etc.1409
Nonetheless, power plants today are faced with multiple competing objectives, in1410
addition to the objective of minimize the cost. The objectives to meet environmen-1411
tal constraints, infrastructural constraints, and energetic constraints, in addition to1412
economic constraints, demand a tool that will allow users (�rms and policy maker)1413
make informed decisions to choose the optimum power plant design, and the optimum1414
pathways for building a sequence of power plants.1415
To satisfy the need and requirement stated above, a software tool which allows1416
users to conduct multi-objective optimization on very complex systems, and highly1417
�exible is developed.1418
The author uses this software to �nd the optimum sorbent in post-combustion pro-1419
cess for various capture percentage which would give the lowest penalty.(environmental1420
impact, infrastructural impact, energetic impact, and economic impact).1421
6.2.1 Limitation1422
The advantage of optimizing over the entire integrated system is mostly obvious1423
in green�eld plants. When it comes to retro�t, it may or may not be more advanta-1424
geous than using two separate softwares, due to the limitation in how much you can1425
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 91
improved on the existing power plant, and the room for improvement/remodi�cation1426
due to the age of that power plant. If the existing power plant is relatively new,1427
changed operating conditions from the design operation conditions may be allowed,1428
for older generation power plants, this may be too di�cult hence one can get the same1429
result using two separate softwares. In addition, retro�t is highly site-speci�c. It is1430
yet another question (and still an open question) whether it's better o� to retro�t the1431
existing �eet or build new ones. From purly engineering point of view, it is likely to1432
retire the existing �eet and build new ones, however, this will be subject to a range1433
of factors like policies, public opinion, and the economy.1434
6.3 A model of modules and pipes1435
The purpose of "design" is to create a clean and relatively simple internal struc-1436
ture, sometimes also called architecture, for a program [B Stroustrup, 2000]. This1437
program is designed with a modules-and-pipes structure which I will explain in greater1438
details below.1439
A module is a generic concept as illustrated in (Figure ??), the module can be at1440
some level any thing you like it to be (for example it could be an operation unit, it1441
can also be a power plant). A module has a number of inputs and it has a number of1442
outputs . A model (�owchart) of a power plant has only two fundamental components:1443
they are modules and pipes, a fully developed plant can be think of as combination1444
(a network) of modules and pipes. For a �owchart of a power plant design, the blocks1445
of the �owcharts are the modules, the streams and pipes are the lines (or streams)1446
connecting them.1447
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 92
A module has to have the feature that it is connected with a number of pipes. For1448
example, a furnace is a module that takes coal and air, and puts out heat and �ue1449
gas. The �ue gas is the combustion product of coal and air, air is air, and coal we1450
can specify some ten parameters that is speci�c to coal, thus we de�ne the furnace.1451
The pipes connect the furnace are the coal coming in, the air coming in, the �ue gas1452
going to the stack, and the heat going out the other end. We decided as a structural1453
decision, that we have a handful of modules which only has pipes that going out1454
or pipes coming in, as sources and sinks. For example, the atmosphere is a source1455
module that would give you as much as you like.1456
A pipe can be think of as a stream carrying material and/or energy, every pipe1457
has to have the feature that both ends of a pipe is connected to a module . A pipe1458
stores three copies of datasets, a copy of a dataset at the inlet of the pipe, a copy1459
of a dataset at the outlet of the pipe, and a iterative copy of a dataset, with which1460
the pipe reinitialize (writes to) both the inlet copy and the outlet copy after each1461
iteration (Figure ??). Note the inlet of the pipe is the outlet of the block that pipe1462
connects to at the front end, the outlet of the pipe is the inlet of the block that the1463
pipe connects to at the back end.1464
We can describe any network (or �owcharts) as a set of pipes and modules, so1465
every module has a name, every pipe has a name, and both ends of every pipe is1466
connected to a module. We describe any power plant as a network with the format1467
in the input �le(Table 6.1). Once all modules and pipes are connected, we make sure1468
that it is connected properly, by iteratively optimize the inputs and outputs until1469
every connection is converged (internally consistent). The pipe can also count and1470
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 93
store the number iterations before they are internally consistent.1471
The system is hierarchical, a module can be a network of modules and pipes itself.1472
The structure of the program allow us to build very complicated things out of very1473
simple things, hence making it easy to extend the complexity a power plant design1474
relatively easily.1475
6.4 Reconcile - An iterative procedure1476
Think of the stream as being de�ned by a number of parameters p1, p2, ?, pn. On1477
the base class level this all you really know. A stream has a direction, it is supposed1478
to go from left to right (although there is nothing wrong with a physical �ow that1479
points in the opposite direction; some �ows may change directions). As a result we1480
have three �avors of the parameters: those on the input side of the pipe (which is1481
the output of the module), those on the output side, and a reconciled version. The1482
pipe has functions, to take the reconciled version and write it into the input and the1483
output. The pipe has a function that creates the reconciled version from the input1484
and output version. The pipe will need to know the number of parameters is has.1485
During construction of the �ow chart, the user can (must?) set all the values in the1486
reconciled version. These amount to the �rst guesses and they are then automatically1487
propagated to the input and output versions. In additions there have to be functions1488
for the modules to read, and to write the end of the pipe they are connected to. This1489
pretty much de�nes the base class of the pipe. One more important feature is that each1490
pipe has a �ag of how it reconciles. There are in e�ect three options for the reconcile.1491
One is the input will overwrite the output, and thus de�ne the reconciled value. The1492
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 94
second is that the output overwrites the input and thus de�nes the reconciled value.1493
The third is that the reconciled value is constructed as an average of the input and1494
the output, and both input and output are overwritten. The �rst option is used if1495
the input is �xed from the outside. (For example the amount of coal coming in is1496
speci�ed.) Because the input is �xed the iteration cannot change it. You could get1497
around this by de�ning a module which only has an output, which is held constant1498
in every iteration. (This may be a simpler implementation). The other case handled1499
by the �rst option is that the pipe is an output pipe that drains to the outside and1500
that is not speci�ed in its output, it takes whatever it can get. This, too could be1501
handled by a trivial module that can absorb anything coming in. An example is that1502
the electric output of the power plant is speci�ed. The second option has two cases1503
analogous to those handled in option one. Now the input is unspeci�ed, whatever1504
the downstream module "sucks in" is OK. For example, the amount of coal shoveled1505
in, will ultimately be determined by the amount of electricity generated. The other1506
situation is on the downstream end, if the output of the pipe overrules the input, then1507
the output is predetermined. E..g, the electricity is �xed. Finally, the third option is1508
sort of typical, the two sides of the pipe must agree and they have equal voting rights,1509
because both of them are attached to a module. In the future it is also possible, to1510
have an algorithm, which takes the entire �ow chart and tries to reconcile all the �ows1511
everywhere. E.g. think of all the mismatches adding up in squares, and then �nding1512
a solution directly.1513
On the module side one can load in all the input and output pipe parameters. It1514
probably would be useful to allocate space for a single array, x1, ?, xm, which contains1515
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 95
all those parameters. Then there is again an option to reconcile these numbers, by1516
using a set of equations Fkx1,?xm=0 There is a special subset of these functions,1517
Gkx1,?xm;x01,?,x0m=0 Here, the parameters with the subindex 0, refer to a �xed1518
set of parameters, which for example give the starting value of the parameters at the1519
beginning of an iteration. For example, the constraining equations may relate in�ows1520
and out�ows in a way that mass and energy is conserved, but they can be scaled by1521
an arbitrary factor. The "0-parameter" could introduce the average size of the plant1522
measured by all the in�ows and out�ows and it will hold this parameter constant1523
during the optimization. In other words, the "0-parameters" would be �xed during1524
one cycle of reconciliation of parameters, but they would be reset every time the1525
module is connected to new �ux values. The idea is that between the F constraints,1526
and G constraints, there are just enough equations to exactly �nd one solution to the1527
problem. (In some future implementations, we will �ag out, if we do not have enough1528
equations, or if we have too many, or if it is just impossible to solve the equations.)1529
The module now needs a set of methods which call in the stu� from the pipelines,1530
�ll all the parameters, and then call the reconciliation routine. By default this may1531
be a steepest descend iteration scheme, that starts with the initial guesses, and then1532
moves forward until the proper solution has been found. You may want to de�ne an1533
error bar you would accept. In e�ect, you will work out the solutions for each module1534
separately. Then you have all modules internally consistent, but the pipelines are1535
now inconsistent. Then you make the pipelines internally consistent, but this will1536
ruin the modules again. Hopefully, the iterations converge toward a global solution.1537
Then we can create an iterative scheme. We begin with a user guess which is fed into1538
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 96
all the streams. These by de�nition are consistent. Each module will internally re-1539
adjust all the inputs and outputs until we have a consistent solution for the module.1540
This, however, will create a discrepancy across the length of the pipe, which is �xed1541
in the next iteration step, but this will destroy the balance in the module again.1542
We do this until things have converged. Better convergence may be achieved, if we1543
create intermediate modules. I.e, at some point we can create a hierarchy of modules,1544
which will make it easier to do all the plumbing. Immediate actions: Create the full1545
structure in the pipes and in the base module. Decide whether the pipes come in three1546
�avors, or whether you want to add an out-side world module. E.g. a coal supply1547
unit, which only has an output, and it can either deliver as much coal as you like, e.g.1548
its reconciliation step is to accept the out�ow it has, or it could be a predetermined1549
�ow, in which case its reconciliation will bring it back to the design in�ow. The same1550
of course works for the out�ow side.1551
The advantage of the latter method is that it removes an additional layer of1552
complexity from the pipes. It may become even more interesting if the boundary1553
conditions become more complex. For example, you may decide that air �ow has to1554
be adjusted so that the air coming through has 1So my suggestion for the decision is1555
to handle the outside world on the module level. Try out a simple steepest descend.1556
My suggestion is to create a trial unit with the furnace. You have air, coal as input1557
streams, heat, �ue gas as output streams. Temperature is for now a �xed parameter.1558
Excess oxygen (could be zero) is a �xed parameter, heat �ow follows from the heat of1559
combustion. Air �ow, coal �ow, and heat �ux and �ue gas stream are tied together1560
with equations. You could �x the heat �ux with one more equation (e.g. x3 - x03 =1561
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 97
0), or you could impute three heat �uxes from coal input, heat output, and air input.1562
The goal is to hold this average constant. This last equation will �x the size of the1563
unit, and it depends on the initial guess, so it will change from guess to guess, as it1564
must in order to provide just the right amount of electricity.1565
6.5 Reconcile algorithm: numerical routine for solv-1566
ing a system of equations1567
A set of m parameters x1, x2...xm satisfy a set of equations as below.1568
Fi(x1, x2, ...xm) = 0
where i is the equation number, i∈ [1, k] , k ≥ m.1569
This can be simpli�ed to1570
Fi(xj) = 0
where j∈ [1,m] .1571
For a complete system, with the initial guess of all the parameters, you'll get1572
Fi(x(0)j ) = A
(0)i
After n'th iteration, you'll get1573
Fi(x(n)j ) = A
(n)i (6.1)
Take Fi(x(n)j + ∆x
(n)j ) for Taylor series expansion including the �rst derivatives,1574
you'll get.1575
Fi(x(n)j + ∆x
(n)j ) = Fi(x
(n)j ) +
m∑j=1
(δFi(x
(n)j )
δxj×∆x
(n)j ) (6.2)
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 98
Assume at n'th iteration the system converges. You'll have1576
Fi(x(n)j + ∆x
(n)j ) = 0 (6.3)
Given Equation(1) (2) and (3), you can have1577
m∑i=1
(δFi(x
(n)j )
δx(n)j
×∆x(n)j ) = −A(n)
i (6.4)
Equation(4) can be simpli�ed to a linear system of equations of ∆x(n)j :1578
Gi(∆x(n)j ) = 0 (6.5)
For each iteration of n, you can use a linear solver (i.e matrix solve) to �nd ∆x(n)j .1579
Subsequently, you can solve for x(n+1)j based on the following equation1580
x(n+1)j = x
(n)j + ∆x
(n)j (6.6)
The iteration continues, until∑m
j=1 |∆x
(n)j
x(n)j
| < ε, where ε = 0.1%. 0.1 is generically1581
conservative assumption, it's somewhat arbitrary [?].1582
Finding the optimized step for the true optimum But you may say, I don't1583
dare to go this far because the steps are too large. But the direction is correct1584
because it follows the gradient. So if this is not stable, you can go in smaller steps1585
by introducing λi, and modify Equation (4) to1586
m∑i=1
(δFi(x
(n)j )
δx(n)j
×∆x(n)j ) = −λi × A(n)
i (6.7)
If assume λi = 1, you are actually directly solving Equation (4), but the system1587
may be unstable (or fail to converge). λi = 13is a generically conservative assumption,1588
it is more stable, but it needs more iterations.1589
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 99
The next thing you can do is to vary λi such that1590
min ‖A(n+1)i (λi)‖
or1591
min∑k
{A(n+1)i (λi) · A(n+1)
i (λi)}
where λi ∈ [0, 1]. When λi = 0, A(n+1)i (λi) = A
(0)i .1592
Equation (6) is modi�ed to1593
x(n+1)j (λi) = x
(n)j + λi ×∆x
(n)j (6.8)
If you plot ‖A(n+1)i (λi)‖ against λi, the slope of the plot is negative because if it's1594
all di�erentiable, it starts with a negative slope.1595
Typically the lowest point is neither 13or 1. The more nonlinear it is, the further it1596
is away from 1. If the problem is strictly linear, then the optimum is λi = 1.1597
6.6 Reconcile implementation1598
Let M(n)ij be a k-by-k Jacobian matrix, where1599
M(n)ij =
δFi(x(n)j )
δx(n)j
You need a linear solver to solve equation1600
Ci ×M (n)ij = Bj (6.9)
where1601
Ci = ∆x(n)j
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 100
1602
Bj = −λi × A(n)i
Ci = Bj × (M(n)ij )−1
Once this is solved, you can solve for xj iteratively.1603
1604
Once xj is solved, you can calculate Ani by plug in the xj into equation (1).1605
Then you can say, let me calculate various value of ‖A(n+1)i (λi)‖ for various choice of1606
λi.1607
1608
λi =λi2
else1609
you found the optimum.1610
6.7 Discussion of Newton-Raphson method1611
The method described above is essentially Newton-Raphson method. It is a highly1612
e�cient and powerful method for �nding successively better approximations to zeroes1613
(or roots) of a real-value function[?]. In general its convergence rate is quadratic (the1614
error is essentially squared at each step), which means that the number of accurate1615
digits roughly doubles in each step.1616
Though it's a powerful technique, there are some limitation with the method. For1617
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 101
example, the method may fail to converge if the derivative of the function is not1618
continuous, or if the derivative is zero (where the tangent line overshoots the desired1619
root), or if the initial guess is too far from true zero.1620
To increase the convergence stability, a number of studies (Press et al.(1992))1621
presented various improvement of Newton-Raphson method. However, the imple-1622
mentation of the improved method is beyond the scale of this work.1623
Another limitation on Newton's method, comes from the requirement that the1624
derivative be calculated directly. This is di�cult in most practical problems, where1625
functions may be given by a long and complicated formula, and hence an analytical1626
expression for the derivative may be di�cult to obtainable. In these situations, it may1627
be appropriate to approximate the derivative by using the slope of a line through two1628
points on the function, or the Secan method. This has slightly slower convergence1629
than Newton's method but does not require the existence of derivatives. The Secan1630
method is a popular choice by developers of large scale computer systems, because the1631
use of a di�erent quotient in place of the derivative in Newton's method implies that1632
the addition code to compute the derivative need not be maintained. In practice,1633
the advantages of maintaining a smaller code base usually outweigh the superior1634
convergence characteristics of Newton's method.[?] Having said that, this work chose1635
Newton-Raphson method because of the current development is still relatively small1636
scale, Secant method may be a consideration for future development.1637
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 102
6.8 Penalty1638
As described in the previous chapter, there are three levels of penalties in the1639
program: module level penalty, plant level penalty, and pathway level penalty.1640
Module level Penalty1641
Module level penalty characterize various module properties attribute to the mod-1642
ule alone, compared to a perfect anchor point. For example, module capital cost,1643
module operating and maintenance cost, etc.1644
Module capital cost is calculated by scaling the capital cost of the individual1645
operating units in a reference plant (equation 6.8). Inline with EPRITAG[], the1646
reference plant is chosen to be a 500 MW plant, the capital cost of pulverize PC,1647
subcrital PC, and supercritical PC is taken from the DOE Parson 2000 study. The1648
breakdown of module size and cost of the reference plant are listed in table ??. Scaling1649
factor is chosen to be 0.28 based on EPRI TAG [?]. Unit size are measure by di�erent1650
parameters in di�erent modules (Table ??).1651
CapCost = CapCostref ∗ ScalingFactor
1652
ScalingFactor = { size
sizeref}α
1653
Pm,capcost = Constant1× CapCost
Module operating and maintenance costs consists of �xed cost, and variable cost.1654
The breakdown of the operating and maintenance costs can be found in table ??.1655
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 103
Labor cost is included in plant operating and maintenance costs, rather the module1656
operating and maintenance costs, to account for researcher and other workers in1657
addition to the operating labor at the at the power plant.1658
Pm,oamcost = Constant2×OAMCost
Implementation of the module level penalty is relatively easy. A penalty function1659
is created as virtual function in each module, to account for the calculation of module1660
level penalty. A size function is created also as virtual function in each module, to1661
account for di�erent measurement of unit sizes.1662
Plant level penalty1663
On plant level, penalties includes thermal e�ciency penalty, plant capital cost,1664
plant operating and maintenance (OAM) cost, plant infrastructural penalty, and emis-1665
sion penalty, in which capital cost and emission penalty are functions of time. There1666
are a number of assumptions: �rst, we assume that the same technology becomes1667
cheaper as time passes by. In other words, the same power plant design has unique1668
a capital cost number at each time, but multiple cost numbers for a period of time.1669
Since we calculate the plant cost by adding up the module capital cost and module1670
OAM cost, a correction factor at plant level is added to account for the time.1671
Plant footprint and e�ciencies are physical measures and the preference of the1672
footprint and e�ciencies are considered to be constant. However, one can argue that1673
as time goes by, less land is available hence the penalty of plant footprint should be1674
a function of time as well.1675
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 104
In terms of emissions, we assume each time is characterized by a set of emissions1676
regulatory state. In this work, we designed regulatory states as shown in table X.1677
Instead of trying to predit when CO2 regulation comes into force, we use ti to represent1678
the time that CO2 regulation comes into force, whenever that is.1679
Pplant = Pη +∑
Pmodule + Pinfrtr + Pemissions
where1680
Pη = checkproposal1681 ∑
Pmodule = TF ×∑
Pm,capcost +∑
Pm,oamcost1682
TF = tbeta1683
Pinfrtr = 1.25 ∗∑
Pm,footprint1684
Pm,footprint = Constant× footprint
where the fudge factor 1.25 accounts for additional room in the power plant that's1685
not occupied by any modules. The cross section area of each module can be found in1686
table ??.1687
Pemissions =∑
Pemissions,M
where M include SO2, PM, NOX, Hg and CO2 emissions.1688
Pemissions,SO2 = KSO2 × SO2Emissions1689
Pemissions,PM = KPM × PMEmissions
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 105
1690
Pemissions,NOx = KNOx ×NOxEmissions1691
Pemissions,Hg = KHg ×HgEmissions1692
Pemissions,CO2 = KCO2 × CO2Emissions
Implementation of plant level penalty is straight forward. A penalty function at1693
�owsheet (plant) level is created, to account for various aspect of plant level penalty,1694
i.e. e�ciency, emissions, and module level penalty summation.1695
Pathway level penalty1696
Pathway level penalties characterize penalties due to three aspects. Firstly, the1697
introduction of a new technology, which was not used in the immediately previous1698
design; Secondly, the removal of an existing technology which was used in the imme-1699
diately previous design; Lastly, the introduction of a brand new technology, which1700
was not used in any of the previous designs.1701
Additionally, each choice in the sequence is characterized by a regulatory state,1702
describing the stringency and the threshold of the emission level one has to obey,1703
otherwise, an in�nite penalty will be applied. For example, in the �rst choice, no1704
emission regulation is applied. Gradually, SOx,NOx,PM,Hg and CO2 regulations1705
and emission standards will be added to characterize the regulatory states for each1706
additional choice.1707
Ppathway = checkproposal
CONSTANTS ARE CHOSEN TO BE BECAUSE...1708
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 106
Implementation of pathway level penalties applies exhaustive search in this work.1709
In order to �nd the best sequence of �owsheets from a list of all possible �owsheets,1710
one needs to build the sequence as you go. This is similar to Knuth's line breaking1711
algorithm, in which a paragraph layout is being built as one optimize for the best1712
layout. Potential breakpoints are identi�ed and grouped into a list (named "active1713
list"), the penalties of breaking at each individual breakpoints are calculated and1714
compared for the best layout. Similarly, in the �owsheetlist (or pathway construction),1715
the penalties of connecting the existing but incomplete pathway, with all possible1716
plant designs, towards a complete pathway, are calculated and compared. Such that1717
the choice with the lowest pathway penalty is chosen.1718
First-�t, best-�t and optimum-�t. In order to look ahead, demerits are calculated1719
such that the square of pathway level penalties are summed up, rather than simple1720
addition. Understand and explain why doing so will help you look ahead, redesign1721
and implement the pathway penalty functions.1722
Discuss whether one needs to stop as soon as the partial sum exceed the local1723
optimum??1724
Discuss weather one needs to compare every two �owsheets thoroughly, concep-1725
tually.1726
Optional: Implementation procedure First, one need to extract the block1727
names of the two �owsheets under comparison.1728
During the implementation, when a module is created, the count will increase by1729
one, if the count is zero, then the module is a new technology that has been used1730
before.1731
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 107
A list of existing modules, routine that compares the existing module with the1732
module being created, if used before, counts adds one, otherwise, additional penalty1733
for new technology.1734
6.9 Parameter1735
Continuous Parameter1736
The parameters at �owsheet level are continuous. It has a range and a current1737
value. The value within the range is continuous.1738
Discrete Optimization1739
The parameters at �owsheetlist level are discrete. For example, the choice of the1740
plant designs at a speci�c time.1741
6.10 Optimization1742
The optimization at both �owsheet level and �owsheetlist level are discrete. The1743
method is an exhaustive search. The basic assumption is that between any steps, we1744
assume it's monotonic. The limitation is that the choice of steps is very important.1745
If the step is too big, then it may or may not be monotonic between any steps. If the1746
steps are too small, then it's expensive computationally.1747
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 108
6.11 Ongoing development1748
6.11.1 FlowsheetBlock: Creating types on the �y1749
By connecting basic modules from the software library, one can create new modules1750
with new con�gurations that do not exist before. One can further use the new modules1751
repeatedly as new "basic modules" in future designs. Therefore, one is no longer1752
limited to using only the library that came with the software, instead, one can create1753
his/her own library serving for a speci�c purpose. This is especially attractive to1754
engineers with speci�c focus of research. The ability to allow researchers build their1755
own libraries on the �y, and the ability to use the new libraries repeatedly in future1756
work, is revolutionary compared to existing modeling tools (for example Aspen Plus).1757
The implementation of such feature is hierarchical, where a graph consists of1758
subgraphs. For example, given a graph consists of many basic modules, one can1759
replace a basic module(s) with a subgraph(s), which consists of a number of basic1760
modules or subgraphs, creating di�erent levels of details based on one's preference.1761
This allows researchers describe the module physics/chemistry at the level of details1762
in a customized manner.1763
Chapter 6: Designing the software tool for advanced power plant modeling andoptimization 109
Table 6.1: Input File (Flowsheet) De�nition (Format)
%Flowsheet: 〈name〉: size : e�ciency : fuel type%Blocks: Block NumberType1: Name1, Name2, ..., NamekType2: Name1, Name2,......, Namej...Type i: Name1, Name2,......, Namej%Streams: Stream NumberType1: Name1, Name2, ....., NamekType2: Name1, Name2,......, Namej...Type i: Name1, Name2,......, Namej%ConnectName1: (inputS1,....,inputSi) B1 (outputS1,....,outputSi)Name2: (inputS1,....,inputSi) B2 (outputS1,....,outputSi)...Namei: (inputS1,....,inputSi) Bi (outputS1,....,outputSi)%End Flowsheet :〈name〉
Appendix A1764
Introduction to TEX1765
This report is written in LATEX a typesetting program using TEX language.1766
A.1 What is TEX1767
TEX is a typesetting language invented by Donald Knuth. It is famous for a well1768
designed and extremely e�cient strategy and computational algorithm for ranking1769
di�erent typesetting layouts as more or less optimal [Knuth 1981]. In this approach,1770
an ideal typesetting layout is considered as the anchor point, the di�erences between1771
the actual typesetting layout and the anchor point is penalized with a numeric penalty.1772
Di�erent aspects of the layout incur di�erent penalties. The relative weights of these1773
penalties can be chosen appropriately by a user, who has speci�c goals, as in the1774
typesetting example, a speci�c aesthetic approach. The algorithm calculates the1775
penalties and determines an optimal layout with the least penalty.1776
TEX penalize an actual layout compare to an ideal layout, in several aspects. For1777
110
Appendix A: Introduction to TEX 111
example, if a paragraph is too dense, there is a penalty, if it's too sparse, there's1778
another penalty. If there is hyphenation, there's additional penalty. Users can choose1779
their own weights on these penalties. For example, a user with weak vision may1780
choose to put a relatively big weight on dense penalty, while preferring sparse layout1781
with large font. On the other hand, a user who's motivated to save space, might put a1782
relatively big weight on sparse penalty, while concerns little with a dense layout. An1783
optimal layout for a user with weak vision might be a disaster for a user motivated to1784
save space. TEX provides a method to allow users choose optimal layout with their1785
own taste in a �exible and e�cient manner.1786
A.2 The algorithm of breaking paragraphs into lines1787
r
Figure A.1: Examples of breaking a pargraph into lines
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[Lackner 2002] K. Lackner Can Fossil Carbon Fuel the 21st Century. International1792
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nologies for Sustainable use of Coal Power Generation. International Journal1876
of Surface Mining Reclamation and Environment, 2001 (15), pp 52-681877
[Lackner 2002] K. Lackner Can Fossil Carbon Fuel the 21st Century. International1878
Geology Review, 2002 (44), pp 1122-11331879
[Gri�n 2005] T. Gri�n, S.G.Sundkvist, K Asen, T Bruun Advanced Zero Emission1880
Gas Turbine Power Plant Journal of Engineering for Gas Turbines and Power,1881
2005 (127), pp 81-851882
[Knuth 1981] D. E. Knuth, M.F. Plass Breaking Paragraphs into Lines Software-1883
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[MIT, 2007] Ansolabehere, S et al. The Future of Coal: An interdisciplinary MIT1885
study Massachusetts Institute of Technology, Cambridge MA, 20071886
[IPCC, 2005] IPCC IPCC special report on carbon dioxide capture and storage Cam-1887
bridge University Press, 2005, 442 p.1888
[Henderiks, 1994] Hendriks, C. Carbon dioxide removal from coal-�red power plants,1889
Dissertation Utrecht University, Netherlands, 259 pp.1890
[Croiset and Thambimuthu, 2000] Croiset, E. and K.V. Thambimuthu Coal combus-1891
tion in O2/ CO2 Mixtures Compared to Air Canadian Journal of Chemical1892
Engineering, 78, 402-407.1893
[IEA GHG, 2003] IEA GHG Potential for improvements in gasi�cation combined1894
cycle power generation with CO2 Capture IEA Greenhouse Gas R& D Pro-1895
gramme, UK, 2003.1896
[Unruh, 2000] Unruh, G. C. Understanding carbon lock-in Energy Policy 2000,28,1897
817-830.1898
[Unruh, 2002] Unruh, G. C. Escaping carbon lock-in Energy Policy 2002, 317-325.1899
[Unruh, 2006] Unruh, G. C. Globalizing carbon lock-in Energy Policy 2006,34, 1185-1900
1197.1901
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