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Optimize Design and Operation of Renewable Energy Cycle through Aspen HYSYS Integrated with Aspen EDR Software
Guofu Chen1 and V. V. Wadekar2
1

TAS Energy, Inc. Houston, TX 77021, USA 2 HTFS, AspenTech Ltd, Reading, UK

ABSTRACT
In this R&D note, how to utilize ASPEN HYSYS optimizer and ASPEN EDR to improve power output and to reduce the cost in the renewable engineering field is described. First, the process model in HYSYS is set up based on the best engineering practice. Second, HYSYS optimizer is utilized to maximize the power output, subject to constraints such as shell and tube exchanger pinch. Third, HYSYS and EDR are used to size the most cost effective exchangers based on cost and performance evaluation. Finally HYSYS integrated with EDR is utilized to rate the whole cycle, mimic the real plant operation and do what-if studies.

Keywords: HYSYS, EDR, Optimize, ORC, Rankine Cycle, Renewable Energy

INTRODUCTION

In todays world, better, cheaper and faster products and services are expected. With ASPEN HYSYS integrated with Exchanger Design and Rating (EDR) software, the goal of delivering a project on time and achieving the performance within the budget can be reached. Renewable engineering is receiving increasing attention worldwide. At the time when this note was written, the geothermal power plant was gaining more and more popularity. This article describes how to utilize ASPEN HYSYS integrated with EDR to optimize the design and operation of a geothermal power plant. Organic Rankine Cycle (ORC) is employed in the geothermal project. It is named for its use of an organic working fluid, with liquid-vapor phase change occurring at a lower temperature than the water-steam phase change. The working principle of the organic Rankine cycle is the same as that of the Rankine cycle: the working fluid is pumped to a boiler where it is evaporated, passes through a turbine to generate power and is finally condensed before returning to the pump. Figure 1 illustrates how the working fluid flows through the system.

Figure 1 Schematic of Rankine cycle

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Figure 1 is useful as a schematic diagram but it hides the complexity of a geothermal power plant. In such a plant there is complex interaction among many operating equipment. Furthermore, optimization of the entire power plant is a challenging task which cannot be carried out without commercial software tools for process simulation and detailed exchanger modelling. In order to illustrate one out of many optimization challenges posed by a geothermal power plant, Figure 2 is prepared. This shows that, if we focus on the Expander, generating the power, and the downstream air-cooled condenser determining the condensation pressure, there is a trade-off between the energy generated by the Expander and energy consumed by the cooling fan of the aircooled condenser. The top blue curve shows that as the condensing pressure increases the power output of the expander falls linearly. The power consumed by the air-cooler fan also falls with increasing condensing pressure. The red curve shows this non-linear variation. The difference between these two curves, after the relatively constant pump power consumption is deducted, is the net power generation as shown by the green curve which goes through a maximum, i.e. the optimum condensing pressure.

Figure 2 Net power output vs. condensing pressure Figure 2 was produced for a specific working fluid and operating conditions as described later. Figure 2 will be revisited in Section 4.1 for a more detailed discussion. Through the use of HYSYS and EDR software the complex interactions of various equipment and optimisation challenges, such as that illustrated in Figure 2, can be addressed. The whole step-wise sequence of developing the process model, of increasing degree of granularity, from simple conceptual design to optimization of the plant operation is described in the following sections.

SETTING UP HYSYS PROCESS MODEL

In this application, R134a is chosen as the working fluid, with RefProp physical property package selected in HYSYS. As described in Figure 1, there are four major components in the cycle. Figure 3 shows how the cycle looks after the model is built in HYSYS. In this project, for the evaporator the hot stream flow rate of 794.9 m3/h (3500 GPM) is known and so also the inlet and outlet temperature of 140.6 C

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(285 F) and 60 C (140 F). The duty of the evaporator can be calculated as 6.0107 kcal/h (2.4108 Btu/hr). For the Air-Cooled Condensers (ACC), the ambient air dry bulb temperature of 10 C (50 F) is known. Considering 13.9 C (25 F) temperature difference between the inlet air and outlet working fluid, ACCOut temperature can be calculated as 23.9 C (75 F). Since the outlet of the ACC is at the saturated liquid condition, ACCOut pressure can be calculated as 6.436 bara (93.35 psia). The pump discharge pressure is a key process parameter to be optimized. At this time 44.82 bara (650 psia) pump discharge pressure and 81% pump efficiency are assumed, and PumpOut temperature is calculated as 26.46 C (79.63 F). After the throttling valve downstream of the pump, EvaporatorIn enthalpy is calculated as -2144 kcal/kg (-3856 Btu/lb). The working fluid outlet temperature EvaporatorOut is very critical to the process as well. The EvaporatorOut temperature of 115.6 C (240 F) is assumed as initial value, and the corresponding enthalpy of EvaporatorOut is calculated as -2093 kcal/kg (-3764.56 Btu/lb). From the heat balance, the working fluid mass flow can be calculated as 1.177106 kg/h (2.594106 lb/hr). After the expansion valve upstream of the expander, all the process conditions of flow, pressure and temperature are known. The expander efficiency of 87% is assumed. The expander discharge pressure can be calculated from the condensing pressure of ACCOut, assuming a certain pressure drop in ACC and the pipe. This corresponds to an ExpanderOut pressure of 6.781 bara (98.35 psia). Then the expander can be solved for the shaft power of 1.03104 kW (1.38104 HP). Through the isenthalpic flashing, all the process conditions of ACCIn are known. The ACC duty can be calculated as 5.205107 kcal/h (2.064108 Btu/hr) since ACCOut is at the saturated liquid condition. After HYSYS is converged, through the HYSYS spread sheet, the Expander generator electricity output and the power consumption of the pump are calculated. Thus the net output is calculated. Please note at this time, the ACC fan motor power consumption is not calculated yet.

Figure 3 Cycle schematic in HYSYS

HYSYS OPTIMIZER TO MAXIMIZE POWER OUTPUT

As mentioned in the previous section, PumpOut pressure and EvaporatorOut temperature are key process parameters to be optimized. The HYSYS optimizer is now utilized to find out the optimum combination of the pressure and temperature.

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The optimizer is set up to maximize the net output, by adjusting the PumpOut pressure and EvaporatorOut temperature, subject to the constraint that the evaporator pinch should be larger than 5.56 C (10 F). The Original Data Model is chosen in the Optimizer Configuration tab and Box Scheme is selected in the Parameters tab. The EvaporatorOut temperature is limited between 93.33 C (200 F) and 135 C (275 F). Because higher pressure will lead to more expensive exchangers, the PumpOut pressure is limited to be lower than 50.33 bara (730 psia), see High Bound column in Figure 4. Referring to Figure 5, the net output is imported to cell B2 and the minimal approach is imported to cell B3 of OptimizerSpreadSheet. By pushing the Start button, HYSYS optimizer starts to find the solution that maximizes the net power output, while respecting the constraints of exchanger pinch and the range of temperature and pressure. After HYSYS finishes the optimization, the optimum pressure is 50.33 bara (730 psia) and the optimum temperature is 122.67 C (252.8 F). At such conditions, the net power output is maximized at 8635 kW (1.158104 HP).

Figure 4 Optimizer variables set up

Figure 5 Optimizer goal and constraints set up

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RIGOROUS EXCHANGER MODELING

Now the optimum conditions are found from the thermodynamic point of view Then the question becomes, are exchangers sized at optimum conditions as well? The next step is to find cost effective designs for the air-cooled condensers and the evaporator. To describe this, Figure 6, which shows the cycle in further details, is used.

4.1 Optimize the Number of Air-Cooled Condenser Bays

To make Air-Cooled Condensers (ACC) cost effective and reliable, TAS Energy has made a standard bay size. For smaller project, only one or two bays are used, while for larger projects 30 bays or more can be deployed. To have a fair comparison regarding the evaporator size, in this calculation, the UA of the evaporator is specified, rather than the EvaporatorOut temperature. Aspen Air-Cooled Exchanger integrated with HYSYS is used to perform rigorous simulation of the ACC. To avoid the pump cavitations in case the ACC does not fully condense the working fluid, a dummy cooler is added to make sure that the outlet fluid is saturated liquid before entering the pump, see Figure 6 for more details.

Figure 6 ORC cycle simulation with exchanger geometries in HYSYS ACCIn pressure is specified and an adjust is used to adjust the ACC air flow rate so that the dummy exchanger duty is 0. Since cost and performance will be evaluated, the ACC fan power consumption is calculated through HYSYS spreadsheet and its deducted to get net power output. ACC condensing pressure can be higher if smaller air flow rate is used, which saves power on the ACC fans, but reduces the expander output (gross power) as well. Or the ACC condensing pressure can be lower to generate more expander output, but it demands more air flow that increases ACC fan power consumption. Thus an optimum condensing pressure is desired. In this project, 30 bays ACC is used as a starting point. Again through HYSYS optimizer, the maximum net power output by changing ACCIn pressure is targeted. Please notice at any fixed condensing pressure, the Adjust adjusts the air flow to make sure the outlet of the ACC is at the saturated liquid condition. After the HYSYS optimizer is finished, the optimum condensing pressure is calculated as 6.567 bara (95.25 psia), which gives the maximum net output at 8209 kW (11008 HP). This optimization can be done through Case Studies function in HYSYS as well. Figure 2 in Section 1 illustrates how condensing pressure relates to the generator output (gross output), fans power consumption and the net output.

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Next the condensing pressure for 24, 27, 33, 36 and 39 bays is optimized individually, based on the same approach. The results are summarized in Table 1 and 24 bays is considered as base case for comparison purpose. From Table 1, we can see the incremental cost per kW is 2207, 2651, 3289, 3790, and 4166 $/kW. Depending on how the desired power output is evaluated, different number of ACC bays may be chosen. Based on the prevalent geothermal industry criterion of the incremental cost of about 3000 $/kW, 30 bays for the air-cooled condensers is finally selected. See Figure 8 for details.

Figure 7 Air-cooled exchanger in HYSYS

Geothermal industrycriterion

Figure 8 Incremental cost vs. number of ACC bays

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Table1OptimizationofaircooledcondensersACC NoofBays ACCcost Condensing Temperature Condensing Pressure AirFlow NetOutput Incremental cost $ C bara kg/h kW $/kW 24 27 30 33 36 39 3,600,000 4,050,000 4,500,000 4,950,000 5,400,000 5,850,000 25.53 6.964 24.68 6.757 23.65 6.567 22.81 6.378 21.91 6.188 20.95 5.998

17,463,485 18,127,638 18,847,410 20,048,988 21,296,251 23,188,787 7,835 8,039 8,209 8,346 8,464 8,572 2,207 2,651 3,289 3,790 4,166

4.2 Optimize the Size of the Evaporator

Now we optimize the size of the evaporator. Please note that from process stand point, CoolWaterOut temperature is fixed. If EDR rating integrated with HYSYS is used, the CoolWaterOut temperature will be a variable, which will not give us fair comparison. To achieve this, UA of the evaporator is fixed in the HYSYS calculation, while using the Shell and Tube Exchanger Utility to size the exchanger dimension and estimate the cost. The Shell and Tube Exchanger Utility is able to size the exchanger with given process conditions, while not affecting HYSYS calculation. In a separate study, not discussed here, two exchangers in parallel and two in series with 18.29 m (60 ft) long tubes were found to give the most cost effective solution within these constraints. The number of tubes and the shell diameter can be varied. Within these constraints, the shell and tube exchanger utility gives us the geometry and the cost. Then the UA of the evaporator is multiplied by 0.9, 1.1 1.3 and 1.5 respectively. Following the same steps as before, exchanger size, cost and net output for each scenario are summarized in Table 2. From Table 2, incremental cost to generate one more kW is 864, 1337, 2438, and 3612 $ respectively. Based on about 3000 $/kW as the economic criterion, the exchanger with 1118 mm (44 inch) shell diameter is finally chosen, see Figure 9.

Geothermal industrycriterion

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Figure 9 Incremental cost vs. evaporator shell diameter Table 2OptimizationofevaporatorsizeUApercentage

UAPercentage EvaporatorUA No.ofTubes ShellDiameter EDRCost* NetOutput Incremental cost

kJ/Ch mm $ kW $/kW

90% 100% 110% 130% 150% 20,172,314 22,413,682 24,655,050 29,137,786 33,620,523 1,017 1,162 1,312 1,742 2,203 889 940 991 1,118 1,245 613,400 691,600 784,200 1,010,580 1,263,488 8,083 8,210 8,307 8,437 8,535 864 1,337 2,438 3,612

*Acostmultiplierwasusedtomodifythiscost.

OPTIMIZE THE PLANT OPERATION

Once the optimization of the evaporator and ACC geometry is finished, the whole system can be simulated with real exchanger dimensions. If the pump characteristic curve is available, it can be used to calculate real time efficiency and discharge pressure for the pump. Similarly if the expander characteristic curve is available, it can be used as well. Now HYSYS can be used to mimic the real plant operation by changing the ambient temperature, turning down the ACC fan speed or modifying the HotWaterIn temperature and see what the impact is. In this case, with ambient temperature at 10 C (50 F), HotWaterIn temperature at 140.56 C (285 F), the final net output is 8503 kW (11403 HP). If ambient dry bulb temperature is increased to 15.56 C (60 F), the net power output decreases to 7688 kW (10310 HP). If desired, HYSYS optimizer can be used to maximize the net output with real exchangers geometries.

CONCLUSIONS

In order to model the complexities of a power cycle based on a renewable energy process, and to model interaction among various equipment used in the process, use of commercially available process simulation and detailed heat exchanger modelling software is necessary. The R&D Note has illustrated the use of HYSYS and EDR software from simple conceptual design to optimization of the plant operation in following steps. Setting up initial process model in HYSYS following the best engineering practice. Using HYSYS optimizer to maximize the electricity output, subject to constraints such as shell and tube exchanger pinch. Sizing the most cost effective heat exchangers. Using HYSYS integrated with EDR to simulate the whole cycle, mimic the real plant operation and do what-if studies

In summary, the investigation carried out in this R&D note shows that HYSYS integrated with EDR is a very powerful tool not only to optimize the thermodynamic design, but also to have a cost effective design with appropriately

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sized heat exchangers. In addition, the integrated tool can be used to simulate the whole system to run what-if scenarios, and finally to optimize and guide the plant operation.

ACKNOWLEDGEMENTS

Authors are grateful to TAS Energy, Inc. for the permission given to publish this work.

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