Accompanying Material for the EBSILONProfessional training course

Dr.Hans-Peter Wolf

Status: 15.02.2012 / Rev 1.02

Accompanying Material for the EBSILON Professional training course

1 2
2.1

Introduction ...................................................................................................... 3 EBSILONProfessional .................................................................................... 4

Principles................................................................................................................6
Philosophy and functionality of EBSILONProfessional.............................................. 6 Structure and solution of Equation system ................................................................. 7 Fluid Properties........................................................................................................ 12 Component Physics ................................................................................................. 14
Turbine ................................................................................................................................. 14 Heat exchanger .................................................................................................................... 17 Condenser ............................................................................................................................ 19 Feedwater preheater ............................................................................................................ 20 Feedwater container............................................................................................................. 22 Steam drum .......................................................................................................................... 23 Pump and Compressor ........................................................................................................ 24 Generator ............................................................................................................................. 25 Motor .................................................................................................................................... 26 Steam generator .............................................................................................................. 27 Furnace / combustion area .............................................................................................. 28 Piping ............................................................................................................................... 29 Throttle ............................................................................................................................. 30 Splitter .............................................................................................................................. 31 Drain................................................................................................................................. 32 Dryer................................................................................................................................. 33 Selective splitter ............................................................................................................... 34 Mixers............................................................................................................................... 35 NoX removal .................................................................................................................... 36 Controller.......................................................................................................................... 37 Measured value input....................................................................................................... 38

2.1.1 2.1.2 2.1.3 2.1.4

2.1.4.1 2.1.4.2 2.1.4.3 2.1.4.4 2.1.4.5 2.1.4.6 2.1.4.7 2.1.4.8 2.1.4.9 2.1.4.10 2.1.4.11 2.1.4.12 2.1.4.13 2.1.4.14 2.1.4.15 2.1.4.16 2.1.4.17 2.1.4.18 2.1.4.19 2.1.4.20 2.1.4.21

2.2

Application of EBSILONProfessional ...............................................................39

Creation of Topology................................................................................................ 39 Component library.................................................................................................... 40 Simulation ................................................................................................................ 44 Design / Off-design .................................................................................................. 45

2.2.1 2.2.2 2.2.3 2.2.4

Literature ........................................................................................................ 49

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1 Introduction
The document Accompanying Material for the EBSILONProfessional training course is meant as a supplement to the training course. While during the training course the learning by doing-principle is prevalent, the thermodynamic and mathematical principles are not covered in detail. Therefore this document describes the main features of EBSILONProfessional, namely the mathematical and physical principles underlying the software. The purpose is to get a better understanding of the operations behind the screen. An even deeper understanding of the mathematical and physical principles can be obtained by studying the Online-help and some of the mentioned literature reference.

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2 EBSILONProfessional
EBSILONProfessional is a tool for the stationary simulation of all kinds of thermodynamic power (and even refrigeration) cycles. Its main features are: User-friendliness by intuitive handling and full-graphical user-interface with 100 % Windows functionality (see Fig. 1) Graphical objects for components and pipes Component library with presently 110 different components Excel-functionality, Import of measured data and export of simulation results Interface to external database possible Validation of measurements as an option Easy extendibility of existing simulation models regarding type and size Complete observance of first principles of physics Design calculation using key performance figures Identification of components at design and off-design load possible Complete and partial design-calculation possible No programming skills required Supply of control- and specification properties possible Calculation methods of components can be customized by user-defined adaptation-polynomials Creation of self-defined components (macros) from existing components possible Programming of self-defined components in source-code possible Many different fluids considered (water/steam, air/flue gas, refrigerants, fuels, saltwater, mixtures) Extendable by user-defined fluids Realistic design-calculation and off-design calculation of components User-friendly diagnosis of topological and specification errors User-interface and dialogs in many languages (German, English, French, Spanish, Turkish, Chinese) Different Unit-systems (SI and derived units, BTU)

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Topology and results can be exported to a variety of graphical formats and to HTML.

Fig. 1: Windows conform graphical user interface

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2.1 Principles
2.1.1 Philosophy and functionality of EBSILONProfessional
During the engineering of power-cycles for the design 2 different tasks have to be distinguished: Process simulation based on balance of mass and heat Detailed design of individual components

For the balance of the process the task is, to design the complete process, to calculate heat and mass balance of the main aspects of the power cycle operation and to optimize by applying what-if studies. Therefore process simulation is characterised by the following properties: The context of a large number of process components (for example compressors, pipes, pumps, turbines, heat-exchangers, etc.) has to be investigated. The modeling of process-oriented components has to be confined to relatively simple models The full- and part load behavior must be modeled Modeling must be possible without knowing about details of geometry and material of a specific component. During the detailed design of individual components the purpose is to find out about the details (geometry, material etc.) required for the construction of a component. Properties of this method are: High detail of modeling (for example FEM or CFD-simulation) Determine the principal thermodynamic data and Finding out the constructive details

Therefore process-simulation is the main task of EBSILONProfessional !

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The simulation is based on two types of elements: components pipes

The components are connected with each other by pipes. The physical properties of a

& , pressure fluid in a pipe are uniquely determined by specifying 3 properties: mass flow m
p and specific enthalpy h .

In the components algorithms based on physical equations are used, which correlate the properties on the outgoing lines with the properties on the ingoing lines. In EBSILONProfessional a power-cycle can be modeled as detailed as required. The components are connected through the pipes, in which mass- and energy transfer takes place. Such pipes can transport fluid, gaseous or solid media (water/steam, air/flue gas, fuels etc.) , but also mechanical or electrical power.

2.1.2 Structure and solution of Equation system

A power cycle consists of n connecting pipes between the individual components. The simulation is complete, when based on the physical laws- to every pipe i values of the following base variables can be associated
p : pressure

h : specific enthalpy

& : mass flow m

The dependant variables, like temperature T or power Q can be calculated from the base variables through

A property state function T = T ( p, h )

& h An algebraic correlation Q = m

Therefore it is necessary to solve a (non-linear) system of equations for N = n 3 unknowns ( n pipes with 3 base variables each) The mathematical relation between the N equations is formulated in the individual components.

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These relations are based on the physical laws of conversation of mass, energy and momentum. The following example of a heat-exchanger (Ebsilon component 26, Fig. 2) illustrates the creation of the system of equations

Fig. 2: Component 26, heat-exchanger

The ingoing pipes are: pipe i1 (primary flow) pipe i3 (secondary flow)

The outgoing pipes are: pipe i2 (primary flow) pipe i4 (secondary flow)

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The following balances are valid for the base variables: pressure (the pressure drop DP12 can be configured inside the component) p(i1) p(i 2) = DP12 p(i 3) p(i 4) = DP 34 enthalpy (from conservation of energy and heat-transfer) (1) (2)

& (i 2) h(i 2) m & (i1) h(i1) = k A Tm m & (i 3) h(i 3) m & (i 4) h(i 4) = k A Tm m

Mass flow (from conversation of mass)

(3) (4)

& (i1) m & ( i 2) = 0 m & ( i 4) m & (i 3) = 0 m

(5) (6)

Through those balance equations the outlet variables are correlated with ingoing variables. For a cycle, consisting of several components, a non-linear inhomogeneous system of equations is created, which correlates the base variables x i (pressure, specific enthalpy and mass-flow) of different pipes f1( x1, x 2 , x 3 , ... xN ) = 0 f2 ( x1, x 2 , x 3 , ... xN ) = 0 ...... ...... fN ( x1, x 2 , x3 , ... x N ) = 0 The system of equation is non-linear, because of
& is present also in enthalpy equations) and variable coefficients (for example m

(7)

variable right hand sides (for example the mean logarithmic temperature difference

Tm depends on p and h of all connecting pipes of a heat-exchanger)

Because of the non-linearity the system of equation can only be solved iteratively.

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In vector formulation the system of equation (7) can be written as F(x) = 0 (8)

x is the vector containing the values of all base variables x i (i =1,..., N ) and F denotes the
vector of all functions fi .

In the neighbourhood of the sought solution vector into a Taylor series f i ( x + x ) = f i ( x ) +

x any function fi can be developed

x
j =1

f i
j

x j + O(x 2 )

(9)

The matrix of the partial derivatives, which occur in the summation, is the Jacobian matrix
J of the partial derivatives of F with the matrix elements J ij given by

J ij =

fi x j

(10)

In vector formulation therefore the Taylor series expansion (9) can be written as
F( x + x ) = F( x ) + J x + O(x 2 )

(11)

Neglecting the terms with quadratic deviations x 2 and taking into account only the linear deviations and assuming
F( x + x ) = 0

(12)

For x 0 the following linear system of equation is obtained

J x = 0

(13)

The partial derivatives of the Jacobian matrix (10) are substituted by numerical derivatives (finite differences). Therefore the system of equations (13) is linear. The system of equations (13) is only sparsely populated. Direct methods (like Gaussian elimination) cannot take advantage of the sparse population because computing time depends on the square of the rank of the matrix. Therefore an iterative method (Gauss-

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Seidel) is used, because the computing time depends only linearly on the rank of the matrix: With the found values for x a new approximation for x is generated.

x k +1 = x k + x

(14)

The values x k +1 together with x k are again substituted into (13) and the method is continued in an outer iterative loop ( k = 0,....k max ) until a certain precision is reached.

A relaxation factor can accelerate the rate of convergence

x k +1 = x k + x

(15)

The method converges faster if the starting values x 0 (i.e. of the 0-th iteration step) are close to the sought solution vector x .

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2.1.3 Fluid Properties

The computation of thermophysical fluid properties is a central task of program systems for thermodynamic simulations and optimizations. Therefore EBSILONProfessional contains several libraries for the calculation of state properties of a variety of fluids and other substances. The following substances are taken into consideration : Air / Flue gas, mixtures of up to 22 components Water / Steam (either IAPWS-IF97 formulation for the actual standard or IFC-1967 for calculations based on the older standard). Seawater Solid (Coal, lignite) and liquid fuels (Oil) Gaseous fuels Raw gases Predefined 2-Phase fluids (NH3, CO2, ) Externally in DLL definable fluids, extendable Refprop Database (approx. 80 fluids) of the National Institute of Standards and Technology integrated Self-definable cp-Polynomials Binary mixtures (NH3/H2O, LiBr/H2O)

The libraries integrated into EBSILONProfessional for water/steam and the 2-Phase fluids take into account the phases liquid, gaseous and wet-steam and allow almost all conceivable combinations of variable dependencies. The libraries mentioned are not only used by the solution algorithm, but can also be accessed from the programming language EbsScript and from the User-Interface through pre-defined dialogs (Fig. 3). Fluid for a specific component or pipe can be calculated, but also for several components of a model (for example h-s diagram of turbine expansion, Fig. 4).

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Fig. 3: Dialog for water/steam table call using IAPWS-IF97 steam table

Fig. 4: HS-Diagram of turbine expansion

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2.1.4 Component Physics

In the following chapters the physics underlying the most important components is described in more detail (Literature /1/,/2/,/3/,/8/,/9/).

2.1.4.1 Turbine
2.1.4.1.1 Steam turbine

A steam turbine converts the enthalpy difference of the steam between inlet and outlet of a turbine into mechanical work. Every steam turbine can be separated into different sections, according to the number of extractions. The balances for mass, energy and pressure are then valid for each single section.
& 1, h1, p1 m

& 2 , h2 , p2 m
Fig. 5: Section of a steam turbine and fluid properties used in the balance equations

Mass balance: Energy balance: Pressure:

& 1 m &2 = 0 m
& 1h1 m & 2 h2 = Pturb m

(16) (17) (18)

p1 p2 = p12

For the calculation of the outlet enthalpy h2 the following relation is used: h2 = h1 (h1 h2s ) (19)

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denotes the isentropic efficiency. The off-design performance of the isentropic

efficiency is stored as a characteristic line and depends on other variables, for example

& , p, ) . Enthalpy losses due to exhaust losses or due to wet steam can be taken = ( m
into account.

Actual expansion <1

Fig. 6: Effect of isentropic efficiency on outlet enthalpy of a turbine

The relation between inlet and outlet pressure in off-design is described by the law of ellipses of Stodola.

&1 m m & 1N

p v 1 ( p 2 p1 ) 2 = 1 1N p1N v 1 1 ( p2 N p1 N ) 2

(20)

&, With a given outlet pressure p2 (for example condenser pressure), given mass flow m
specific volume at inlet v1 and the nominal values (denoted by subscript N) the inlet pressure p1 can be calculated for any load condition (off-design).

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Fig. 7: Relation between inlet pressure p1 , outlet pressure (law of ellipses of Stodola)

& p2 and mass flow m

2.1.4.1.2 Gas turbine

For the gas turbine the same physical laws like for the steam turbine are valid. Compared to the steam turbine no wet-steam conditions have to be taken into account and therefore the equation of state for ideal gases can be used.

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2.1.4.2 Heat exchanger

Heat is transferred form the secondary side (pipe with index 3) to the primary side (pipe with index 1) The balances for mass, energy and pressure for an ideal heat-exchanger without losses are given according to the diagram
& 3 , p3 , h3 m

& 2 , p2 , h2 m

& Q

& 1, p1, h1 m

& 4 , p4 , h4 m
Fig. 8: Fluid properties used in the balance equations

Mass:

& 1 m &2 = 0 m
& 3 m &4 = 0 m

(21) (22) (23) (24)

Enthalpy:

& & 2 h2 m & 1 h1 = Q m

& & 3 h3 m & 4 h4 = Q m

Pressure:

p1 p2 = p12
p3 p 4 = p34

For the heat transferred the following relation is used

& = k A T , Q m

(25)

which is valid for parallel flow as well as for counter-flow heat-exchangers. In this formula
k denotes the heat-transfer coefficient, A the heat-transfer area and Tm the mean

logarithmic temperature difference.

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The mean logarithmic temperature difference is calculated as:

Tm =

Parallel flow heat-exchangers: Counter flow heat-exchangers:

Tw Tk ln( Tw Tk )
Tw = T3 T1 , Tw = T3 T2 , Tk = T 4 T2 Tk = T4 T1

(26)

(27) (28)

The off-design performance for the heat-transfer is described by a characteristic line for the heat-transfer coefficient k and the nominal value (k A) N :

&1 m & 1N , m &3 m & 3 N ) (kA) N k A = f (m

The off-design behavior of the pressure drop is calculated as :

(29)

& m p = m &N
where pN denotes the nominal pressure drop.

pN

(30)

The relations given are in principal valid for all types of heat-exchangers, also for condensing heat-exchangers and desuperheaters..

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2.1.4.3 Condenser
For a condenser (where the primary side is given by the pipes 1 2) the same equations like for a heat-exchanger without condensation are valid. One additional equation describes that the secondary fluid leaving the condenser is in the saturated liquid state:

h4 = h ( p 4 )

(31)

& 1 resp. m & 2 can be calculated from the From this additional equation it follows that m
& 3 resp. m & 4 and the enthalpy h3 and pressure p3 of the steam entering energy balance if m & 5 with specific enthalpy h5 the condenser are known. If an auxiliary condensate flow m
into the condenser exists, it is additionally taken into account in the balances for mass and energy.

2.1.4.3.1 Method of the Heat Exchange Institute

For the off-design performance of the heat-transfer coefficient a characteristic line

&1 m & 1N , m &3 m & 3 N ) (kA) N k A = f (m

can be used, but also it is possible to use an

empirically found formula which is known as the method of the Heat Exchange Institute (as described in VDI-Energietechnische Arbeitsmappe, Literature /7/). Using this method a laborious off-design adaptation can be avoided. Instead geometrical data (number of pipes, wall thicknesses etc.) together with material data and degradation because of fouling are considered in the calculation. This method is valid in the temperature range 5 C < T < 40 C of the primary flow (cooling water inlet temperature).

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2.1.4.4 Feedwater preheater

For a feedwater preheater the same physical laws like for a condenser a valid. For calculating the off-design performance of the heat-transfer a characteristic line

& 1, m & 3 ) (kA)N can be used. k A = f (m

Similarly like for the turbine condenser it is possible to use a formula relation instead of a characteristic line for the off-design performance. This relation is known as the Method of Rabek.

2.1.4.4.1 Method of Rabek

This method works even without knowing the constructive or material data of the preheater. The relative change of the heat-transfer coefficient calculated by this method together with the nominal value of the heat-transfer coefficient allows calculating the offdesign-performance.

This method (Literature /6/) assumes that the following data are available in an off-design state

& 1, p1, h1 of the primary flow (feedwater) Inlet parameters m

Inlet parameters p3 , h3 of the secondary flow (extraction steam)

The Rabek-method also takes into the account that the secondary flow may be superheated. Then it separates the heat-transfer area into a desuperheating zone and a condensing zone. For the k A - value in off-design the following approximate relation is given by Rabek (Index 1 denotes primary side, index 3 secondary side):

kA =

3 (1 + V ) (k A)N 3 + V 1

0 .33

(32)

with

&1 m 1 = m & 1N

0.8

&3 m and 3 = m & 3N

and

V = 2

(33)

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For the ratio of the k A - values of the desuperheating zone (Index II) and condensing zone (Index I) the following relation is used by Rabek :

(k A)I (k A)II
with E = 15

(1 + E )
1 + V 1 3

(34)

Because the given relations include approximation and do not consider constructive and material data an exact quantitative calculation of the off-design performance is not possible. Nevertheless the results for k A are close to the actual values, with a deviation of normally less than 10 %. An advantage of the Rabek method is, that it allows to handle negative upper terminal temperature differences more accurate than is possible with characteristic lines.

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2.1.4.5 Feedwater container

A feedwater container (a.k.a. deaerator) is a mixing preheater where hot steam from an extraction of the turbine is mixed with the main and auxiliary condensate. & 3 , h3 , p3 m & 5 , h5 , p5 m

& 4 , h4 , p4 m

& 1, h1, p1 m

& 2 , h2 , p2 m
Fig. 9: Fluid properties of the feedwater container

Mass balance: Energy balance: Pressure:

&1 m &2 +m &3 +m &4 m &5 = 0 m & 1 h1 m & 2 h2 + m & 3 h3 + m & 4 h4 m & 5 h5 = 0 m p3 p2 = p32

(35) (36) (37)

The off-design behavior of the pressure drop is calculated as :

p32

&3 m = m & 3N

p32 N

(38)

&3. The condition p2 = psat . (h2 ) is used to calculate the extraction steam flow m

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2.1.4.6 Steam drum

A steam drum is used for the separation of saturated steam from saturated water.

& 2 , h2 , p2 m

& 1, h1, p1 m

& 4 , h4 , p4 m

& 5 , h5 , p5 m

& 3 , h3 , p3 m

Fig. 10: fluid properties of the steam drum

Mass balance: Energy balance: Pressure:

&1 m &2 m &3 +m &4 m &5 = 0 m & 1 h1 m & 2 h2 m & 3 h3 + m & 4 h4 m & 5 h5 = 0 m p1 = p2 = p3 = p 4 = p5

(39) (40) (41)

The enthalpies h2 ,h3 and h5 of the outlet streams are calculated from the energy balance using the conditions

h3 = h5 = h ( p1 )

h2 = h ( p1 )

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2.1.4.7 Pump and Compressor

Pumps and compressors are described by the same physics. The medium (liquid or gaseous) is brought from a low pressure level to a higher pressure level.

Pmotor

& 1, p1, h1 m

& 2 , p2 , h2 m

Fig. 11: Fluid properties of pump and compressor

Mass balance: Energy balance: Pressure:

& 1 m &2 = 0 m
& 2 h2 m & 1h1 = Pmotor m

(42) (43) (44)

p2 p1 = p21

For the calculation of the outlet enthalpy h2, especially in off-design the following relation is used:
h2 = h1 +

( h2s h1 )

(45)

The off-design performance of the isentropic efficiency can be supplied in a characteristic

& ). line (m
The outlet pressure can either be provided by other neighbouring components or it can be &) . calculated from the delivery head p21 = p21 (V In these cases the required motor power is calculated.

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2.1.4.8 Generator
The generator converts mechanical power to electrical power.

Pmech

Pelectr

Fig. 12: conversion of mechanical power to electrical power

For the calculation of the electrical power the generator efficiency is taken into account. For the calculation of the generator efficiency the following effects are considered:

Dependency of efficiency on power factor : Dependency of efficiency on H2-Pressure pH 2 : Dependency of efficiency on grid frequency :

cos = f1 (cos( ))

H 2 = f 2 ( pH 2 )
= f3 ( )
N

Gen = cos H 2 Gen

(46)

Gen denotes the nominal value (i.e. in design condition) of the generator efficiency.
N

The electrical power then is calculated as:

Pelectr = Gen Pmech

(47)

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2.1.4.9 Motor
The motor converts electrical power to mechanical power.

Pelectr

Pmech

Fig. 13: conversion of electrical power to mechanical power

For the calculation of the mechanical power the motor efficiency is taken into account. For the calculation of the motor efficiency the following effects are considered:

Dependency of electrical efficiency on power: Dependency of mechanical efficiency on power:

electr = f1(Pelectr ) mech = f2 (Pelectr )

N

Motor = electr mech Motor Motor

(48)

is the nominal value (i.e. at design conditions) of the motor efficiency.

The mechanical power then is calculated as:

Pmech = Motor Pelectr

(49)

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2.1.4.10

Steam generator

In the steam generator the feedwater is converted from a sub-cooled state to a superheated state (main steam). Additionally the reheat of the steam for the intermediate pressure turbine is considered.
& 2 , h2 , p2 m
Hot reheat Main steam

& 4 , h4 , p4 m

& 6 , h6 , p6 m
& Q

& 7 , h7 , p7 m

& 8 , h8 , p8 m
Feedwater

& 1, h1, p1 m

Cold reheat

& 3 , h3 , p3 m

Fig. 14: Fluid properties of the steam generator

Mass balance: Energy balance: Pressure:

&2 m &1 m &6 +m &8 = 0 m

und

&4 m &3 m &7 = 0 m

(50) (51) (52)

& = (m & 2 h2 m & 6 h6 m & 1 h1 + m & 8 h8 ) Q & 4 h4 m & 7 h7 m & 3 h3 ) + (m p1 p2 = p12

und
p3 p4 = p34

For the pressure drops the following relation for off-design is used: & m p = m &N

p N

(53)

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2.1.4.11

Furnace / combustion area

For the furnace a stoichiometric combustion calculation is done. For the energy balance the lower heating value hHW of the fuel and its composition must be known.
& 2 , h2 , p2 m
Flue gas

& Q Rad

& Q

& 4 , h4 , p4 , hHW m

Ash and Slag

fuel

air

& 1, h1, p1 m

& 5 , h5 , p5 m

Fig. 15: Fluid properties of the combustion area

Mass balance: Energy balance: Pressure:

&2 m &4 m &1 + m &5 = 0 m

(54) (55) (56)

& =m & & 1 h1 + m & 4 h4 + m & 4 hHW m & 2 h2 m & 5 h5 Q Q Strahl . p1 p2 = p12

For den pressure drop in off-design the following relation is used:

p12

& m = m &N

p12 N

(57)

The composition of the flue gas is calculated from the composition of the fuel and the air. If more air is added than is necessary for a complete combustion of the fuel, the excess air is calculated.

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2.1.4.12

Piping

In a piping pressure drops and heat losses of a pipe can be considered.

& Q
& 1, p1, h1 m

& 2 , p2 , h2 m

Fig. 16: Fluid properties of piping

Mass balance: Energy balance: Pressure:

& 1 m &2 = 0 m
& & 1h1 m & 2 h2 = Q m

(58) (59) (60)

p1 p2 = p12

The pressure drop in off-design is calculated according to the following relation from the nominal values and the actual mass flow:

p12

v1 = v 1N

& m m & N

g y p12N v

(61)

The dependency of the pressure drop on specific volume v for compressible fluids and a
: mean specific volume in piping, geodetic height y (g: gravitational acceleration, v

y : geodetic height) is considered in the calculation of the pressure drop.

The heat loss in off-design conditions is taken into account as:

T & = 2 Q T 2N

& m 1 m & 1N

(h2 N h1N )

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2.1.4.13

Throttle

A throttle is used to reduce the pressure.

& 1, h1, p1 m

& 2 , h2 , p2 m

Fig. 17: Fluid properties of a throttle

Mass balance: Energy balance: Pressure:

&1 m &2 = 0 m & 1 h1 m & 2 h2 = 0 m p1 p2 = p12

(62) (63) (64)

The dependency of the pressure drop on specific volume v for compressible fluids is considered in the calculation of the pressure drop:

p12

v1 = v 1N

& m m & N

p12N

(65)

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2.1.4.14

Splitter

A splitter is used to split one mass flow into two mass flows.

& 1, h1, p1 m

& 2 , h2 , p2 m

& 3 , h3 , p3 m

Fig. 18: Fluid properties of a splitter

Mass balance: Energy balance: Pressure:

&1 m &2 m &3 = 0 m & 1 h1 m & 2 h2 m & 3 h3 = 0 m p1 = p2 = p3

(66) (67) (68)

& 2 and m & 3 are determined from the splitting ratio. m

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2.1.4.15

Drain

A drain is used to reduce the water content in a wet steam flow with 0 < X < 1.

X1

X 2 > X1
& 2 , h2 , p2 m

& 1, h1, p1 m

& 3 , h3 , p3 m

X3 = 0

Fig. 19: Fluid properties of a drain

Mass balance: Energy balance: Pressure:

&1 m &2 m &3 = 0 m & 1 h1 m & 2 h2 m & 3 h3 = 0 m

(69) (70) (71)

p1 = p2 = p3

If f denotes the ratio of the water drained from the inlet, then the mass flows and the dryness fractions are calculated as follows:

& 3 = f (1 X 1 ) m &1 m

(72) (73) (74)

& 2 = (1 f (1 X 1 )) m &1 m X2 = X1 (1 f (1 X 1 ))

& 3 is saturated liquid with X 3 = 0 The mass flow m

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2.1.4.16

Dryer

A dryer is used to reduce the humidity of a gas flow

X 1H 2OL
& 1, h1, p1 m

X 2H 2OL
& 2 , h2 , p2 m

& 3 , h3 , p3 m

Fig. 20: Fluid properties of a dryer

Mass balance: Energy balance: Pressure:

&1 m &2 m &3 = 0 m & 1 h1 m & 2 h2 m & 3 h3 = 0 m

(75) (76) (77)

p1 = p2 = p3

& 3 of the separated water is calculated from the degree of drying g and The mass flow m

the mass fraction X1H2OL of liquid water (H2OL) on inlet 1.

& 3 = g X1 &1 m m H2OL & 2 = (1 g X1 &1 m )m H2OL

X 2H 2OL = X 1H 2O (1 X 1H 2O g )

(78) (79) (80)

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2.1.4.17

Selective splitter

The selective splitter is used for the selective separation of mass flows. Examples are gas cleaning, cyclones or venturi scrubbers.

& 1, h1, p1 m

& 2 , h2 , p2 m

& 3 , h3 , p3 m

Fig. 21: Fluid properties of a selective splitter

Mass balance: Energy balance: Pressure:

&1 m &2 m &3 = 0 m & 1 h1 m & 2 h2 m & 3 h3 = 0 m

(81) (82) (83)

p1 = p2 = p3

& 3 of the separated stream is calculated from the separation efficiencies The mass flow m J i of the individual components X 1i as follows :

&3 = m

J
i

&1 X 1i m

(84)

The individual components at outlet 2 are given by

X 3 i = X 1i J i

&1 m &3 m

(85)

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2.1.4.18

Mixers

Mixers are used to mix two fluid flows.

& 1, h1, p1 m

& 2 , h2 , p2 m

& 3 , h3 , p3 m

Fig. 22: Fluid properties of a mixer

Mass balance: Energy balance: Pressure:

&1 m &2 + m &3 = 0 m & 1 h1 m & 2 h2 + m & 3 h3 = 0 m

(86) (87) (88)

for example p2 = min( p1, p3 )

While for a splitter the outlet pressures are same like the inlet pressure, for the mixer there are several options how to specify the pressures in the connecting pipes.

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2.1.4.19

NoX removal

In the NoX removal ammonia (NH3) is used to reduce the fractions of nitrogen oxides in the flue gas (NO, NO2).

& 1, h1, p1 m

& 2 , h2 , p2 m

& 3 , h3 , p3 m

Fig. 23: Fluid properties of NoX removal

Mass balance: Energy balance: Pressure:

&1 m &2 + m &3 = 0 m & 1 (h1 + hreact ) m & 2 h2 + m & 3 (h3 hevap ) = 0 m

(89) (90) (91)

p1 p2 = p12

hreact is the reaction heat of the chemical reactions and hevap the evaporation heat of NH3 . The pressure drop in off-design is calculated as p12

v1 = v 1N

& m m & N

p12N

(92)

The reduction of the nitrogen oxides in the flue gas is described by 3 characteristic lines: Characteristic line 1 describes the dependency on the flue gas mass flow:

&1 m &1 ) NOX 2 NOX 1 = f (m N

Characteristic line 2 describes the dependency on the NH3 mass flow:

&3 m &3 ) NOX 2 NOX 1 = f (m N

Characteristic line 2 describes the dependency on the flue gas temperature:

NOX 2 NOX 1 = f (T1 )

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2.1.4.20

Controller

During an iteration solving the system of equations the task of a controller is, by means of a correction value to modify an actual value until a given reference value is achieved.

Fig. 24: Iterative controller

The controller works as follows: The correction value in the i+1-th iteration step is calculated from the correction value of the i-th iteration step

f i +1 = f i (1 + f i g i s i c )
With the relative difference from the reference value: si = With the relative change of the correction value from the last iteration step:

(93)

S Ai S

(94)

Ki = gi

with the gradient:

(fi fi 1 ) fi 1 K = i si

(95) (96)

and the controller characteristic:

c = 1 for a positive characteristic c = 1 for a negative characteristic

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2.1.4.21

Measured value input

A measured value input is used to specify a physical property (i.e. pressure p ,

& ) on a pipe. temperature T or mass flow m

h = h( p,T )

& ,p m

& , p, h m

Fig. 25: measured value input

A measured value input does not have its own component physics. Nevertheless if a

& , p or h an underlying physical property which is not one of the 3 base variables m
function library (for example water/steam table) can be accessed and the base variable can be calculated, for example to calculate specific enthalpy from pressure and temperature h = h( p,T ) (Fig. 25). Furthermore it is possible to access a pipe variable and to calculate a property derived from the pipe variables. For example, to calculate the saturation pressure psat (T ) from the temperature given in the pipe.

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2.2 Application of EBSILONProfessional

2.2.1 Creation of Topology
The Graphical User Interface (GUI) of EBSILONProfessional consists of a workspace (Fig. 26), on which the components are placed and connected with pipes to create models of complete power-plants. The next step is to provide specification values for the components in the design state. Having defined the design state it is also possible to define the components off-design performance by customizing the characteristic lines.

Fig. 26: workspace, used for the selection and positioning of components

The selection of components is done through the component or component wizard toolbar displayed in the upper part of the window. The components are connected by pipes. The pipes are selected according to the fluid (water, steam, air etc.) from the list of available fluids.

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2.2.2 Component library

An integral part of EBSILONProfessional is a library of presently 118 (Release 9.0 of EBSILONProfessional) components. These components can be selected in the toolbar and inserted into the workspace.

Fig. 27: Symbols for the components available in the component library

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The specification of component and process variables is done interactively through dialogs (Fig. 28).

Fig. 28: specification values

In the dialog Specification-Values specification data for a component can be provided. For every specification value a pre-defined default value is supplied. The specification values are displayed in black color. Blue color is used for reference values which are only created in Design-calculations. These reference values define the operation of components in off-design calculations and should not be modified after the Designcalculation.

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Process values can be specified by placing a General value input component on a pipe (Fig. 29). With this component it is possible to specify the physical state of a fluid (mass flow, pressure, specific enthalpy resp. temperature).

Fig. 29: specification of process values

Depending on the type of the fluid the fluids composition can be specified in the dialog Material Fractions. It is possible to use pre-defined compositions (for example for particular coal qualities) which are supplied in an underlying database. But it is also possible to supply a self-defined composition.

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In order to display the results of a simulation in the GUI, value crosses can be inserted into the model (Fig. 30).

Fig. 30: Display of process values using value crosses

The properties to be displayed can be configured. Also the layout of the value cross can be modified.

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2.2.3 Simulation
Having created the topology and having supplied the specification data for components and certain process data, it is possible to start a simulation. At the end of the simulation a message (Fig. 31) displays the simulation status and the number of iterations steps

Fig. 31: Status message at the end of the simulation (here with errors)

If an error or only a warning was recognized, or if the model is overdetermined, detailed hints about type and location of error or warning are given. (Fig. 32).

Fig. 32: Information about type and location of errors

Warnings and errors can be caused by an overdetermination of the system of equations. It is the aim to parameterize the model in such a way that the simulation is successful without warnings. Only then it can be expected that the simulation is successful and without contradictions for off-design conditions.

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There are various model-options (Fig. 33) to configure the iteration process regarding convergence and precision. Also it is possible to configure the libraries (steam tables etc.) for the calculation of fluid properties.

Fig. 33: model options of the Simulation

2.2.4 Design / Off-design

In EBSILONProfessional there exist two principally different calculation modes (Fig. 34): The full load mode (design mode) is used for the balancing of processes at the design point. i.e. the load for which the power-plant and its components are optimized. The partial load mode (off-design mode) is used to investigate the performance of the power-plant at conditions which are different from the design conditions (different load, or different ambient conditions etc.). In this mode it is possible to obtain information about the plant performance under different scenarios (for example effect of cooling water temperature on heat-rate).

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Fig. 34: Full load/partial load, i.e. design/off-design

A pre-condition for a meaningful calculation in off-design mode is, that there had been a simulation in design mode which had determined the reference values. Those reference values together with characteristic lines- are needed for the off-design calculation. The off-design performance of components is in most cases calculated from such a reference value and from characteristic lines (or adaptation polynomials). Normally such a characteristic line, for example for the total heat-transfer coefficient k A , depends on the mass-flow (or some other process property). The characteristic lines can be found in the component dialogs in a sub-dialog called Charlines. For example in the turbine (Fig. 35) the isentropic efficiency depends on the relative mass-flow (i.e. the mass-flow normalized to the reference mass-flow). For a more accurate or realistic performance the default charlines can / should be replaced with charlines from manufacturers data or charlines obtained by means of measurements. Furthermore it is possible to use an adaptation polynomial in stead of a tabulated charline. In such an adaptation polynomial the dependency on more than 1 variable can be considered.

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Fig. 35: default characteristic line of a turbine

For some components it is possible to use standardized calculation methods for the offdesign performance and to ignore the characteristic lines. Examples are the turbine condenser using the method of the Heat Exchange Institute for the calculation of the heat-transfer coefficient (Fig. ) or the preheater using the method of Rabek also for the heat-transfer coefficient (Fig. 37). As a consequence the tuning of the model for offdesign conditions is simplified. Nevertheless it has to be mentioned that the off-design performance then can slightly differ from the off-design performance of the real powerplant.

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Fig. 36: Specification of the off-design behavior of the turbine condenser using the method of the Heat Exchange Institute

Fig. 37: Specification of the off-design behavior of the feedwater preheater using the method of Rabek

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3 Literature
/1/ Thermische Kraftanlagen, Grundlagen, Technik, Probleme. Hans-Joachim Thomas, Springer Verlag, 1985 /2/ Power Plant Technology M.M.El-Wakil, McGraw-Hill International Editions, 1984 /3/ Kraftwerkstechnik K.Strau, 4.Auflage, 1998, Springer Verlag, /4/ Messunsicherheiten bei Abnahmemessungen an energie- und kraftwerkstechnischen Anlagen VDI-Gesellschaft, VDI-Richtlinien, VDI 2048 /5/ Erfahrungen bei der Erstellung und dem Einsatz eines Datenvalidierungsmodells zur Prozessberwachung und optimierung im Kernkraftwerk Isar 2 Von J.Tenner, P.Klaus und E.Schulze, VGB Kraftwerkstechnik 4/98 /6/ Die Ermittlung der Betriebsverhltnisse von Speisewasservorwrmern bei verschiedenen Belastungen G.Rabek, Energie und Technik, 1963 /7/ Wirksame Khlrohrlnge bei Kondensatoren VDI-Gesellschaft, Energietechnische Arbeitsmappe, /8/ Wrmebertragung Walter Wagner, 1981, Vogelverlag,

/9/ Thermodynamik Hans-Dieter Baehr, Springer Verlag, 2005, 12.Auflage

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