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Dynamic simulation and transient analysis of a

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Article in International Journal of Greenhouse Gas Control March 2015

DOI: 10.1016/j.ijggc.2015.02.003

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 International Journal of Greenhouse Gas Control 35 (2015) 138149

Contents lists available at ScienceDirect

International Journal of Greenhouse Gas Control

journal homepage: www.elsevier.com/locate/ijggc

Dynamic simulation and transient analysis of a 3 MWth oxy-fuel

combustion system
Wei Luo, Qiao Wang, Xiaohong Huang, Zhaohui Liu , Chuguang Zheng
State Key Laboratory of Coal Combustion, Huazhong University of Science and Technology, Wuhan 430074, China

a r t i c l e i n f o a b s t r a c t

Article history: Oxy-fuel technology has been considered as a feasible way to achieve the reduction of CO2 emission. In
Received 2 December 2014 this article, an oxy-fuel combustion process model was developed using a 3 MWth oxy-fuel combustion
Received in revised form 18 January 2015 test facility as prototype. Both steady state and dynamic model were developed using Aspen Plus and
Accepted 6 February 2015
Aspen Plus Dynamics, respectively. The steady state model was validated with test data based on mass
balance and energy balance. By dening several typical periods of time which could characterize the
Keywords:
dynamic features of the control actuators and the responses of heat transfer and uid ow processes, the
Oxy-fuel combustion
combination of these periods of time was used to reect the dynamic responses of the system and the
Aspen Plus Dynamics
Dynamic simulation
simulation results were compared to the test results showing good agreement with the experimental
Transient analysis results. Based on the validated dynamic model, transient analysis of typical operation parameters have
been performed and the relationships of various inputs and output response have been investigated. All
of these results will be helpful to the facility operations and the control system design.
2015 Elsevier Ltd. All rights reserved.

1. Introduction
It is well acknowledged that the emission of CO2 plays a sig-
nicant role in global warming and the utilization of fossil fuel
contributes to most of this effect (IEA, 2010). Due to the large
demand of energy consumptions for rapid economic development,
the CO2 emission of China has increased dramatically in the last
several decades and China has become the largest emitter over
the world. To obtain sustainable development in the future, mea-
sures should be taken to mitigate the emission of CO2 , especially in
the power generation eld. Among the three possible carbon cap-
ture technologies, oxy-fuel technology is a comparatively feasible
and economic option for large scale CO2 capture and retrotting
existing coal-red power plants at present and it is selected as the
direction to reduce CO2 emission in China in the near future (Zheng,
2013).
Instead of using air as oxidizer, a mixture of O2 and recycled
ue gas is used to generate high CO2 concentration product gas;
therefore the combustion atmosphere is signicantly changed in
the boiler. Besides, air separation unit (ASU) and ue gas com-
pression and purication unit (CPU) should be integrated in the
oxy-fuel power plants, which are not included in conventional
air-ring power plant. Obviously, this would greatly increase the
Corresponding author. Tel.: +86 27 87552151; fax: +86 27 87545526.
E-mail address: zliu@hust.edu.cn (Z. Liu).
capital/operation cost and the control complexity of the plant. Thus,
the inuences of these factors on the investment and operation
must be well understood before the commercial implementation
of oxy-fuel technology.
Steady state process simulation is a useful tool for technical
analysis and system design of power plants. Kong et al. (2012)
conducted a technical analysis of a 600 MWe conceptual oxy-
fuel power plant and found that the net efciency penalty was
decreased from 12.07% to 8.96% through heat integration. Kakaras
et al. (2007a,b) performed a simulation of a greeneld oxy-fuel
lignite-red power plant of gross power output of 357 MWe and
concluded that the net efciency penalty could decrease from 12.7%
to 8.5% by applying heat integration between different subsystems,
for example, ASU and CPU with turbine. Fu and Gundersen (2010)
found that the theoretical power efciency penalty could be as low
as 3.4% by pinch analysis. This result proved that the commercial
application of oxy-fuel combustion technology was economically
feasible.
To study the technical feasibility of oxy-fuel combustion
technology, experimental studies on both fundamental research
and pilot-scale plants have also been conducted to investigate
the characteristics of oxy-fuel combustion, for example, burn out,
pollutant emissions and control strategies for operation. Yamada
et al. (2007), Tan et al. (2006) and Hu et al. (2000) performed
experimental studies to investigate the emission features of SO2
and NOx in the oxy-fuel combustion, and discussed the differences
between the air-ring and oxy-fuel conditions. To prove the

http://dx.doi.org/10.1016/j.ijggc.2015.02.003
1750-5836/ 2015 Elsevier Ltd. All rights reserved.
 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149
Fig. 1. Schematic diagram of oxy-fuel combustion system.
feasibility of oxy-fuel technology and accumulate the experience
for scale-up, Vattenfall (Stromberg et al., 2009; Rehfeldt et al.,
2011; Anheden et al., 2011; Kluger et al., 2011; Preusche et al.,
2011) had constructed a 30 MWth oxy-fuel pilot plant in Germany
and the Callide (Chris et al., 2013) Oxy-fuel Project of gross
power of 30 MWe was developed in Australia. So far, several test
campaigns have been carried out on the facilities. The test results
demonstrated that operation in oxy-fuel mode is practicable and
results on emissions control and CO2 capture had been obtained.
However, further research including optimization of operating
parameters and various operation scenarios are required to get
comprehensive understanding of oxy-fuel technology.
Dynamic simulation could analyze the relations between var-
ious input operation conditions and output responses. Therefore,
references could be obtained in how to achieve the optimum oper-
ation conditions through dynamic simulation. For example, Morini
and Piva (2007, 2008) developed a mathematical model and studied
the transients in thermal plant. Alobaid et al. (2013) also devel-
oped a dynamic model to predict the power plant behavior during
fast transients, part loads and start-up procedures. Haryanto et al.
(2011) developed a mathematical model of an oxy-fuel boiler and
investigated dynamic responses of both gas-side and water-side
on different operation conditions to achieve the optimum recycle
ratio. Besides, how to conduct air-oxy switch and oxy-air switch
is another critical problem. Yamada et al. (1999) developed a
1000 MWe supercritical pulverized coal-red (PC) boiler model,
and studied the air-oxy switch during plant start-up and step
changes to fuel/gas. Similar investigations were also performed by
Postler et al. (2011) and Jin et al. (2014). Besides PC boiler model,
Hultgren et al. (2014) developed a circulating uidized bed (CFB)
model and investigated air-oxy switches as well as step changes
to recycling ue gas ow. Lappalainen et al. (2014) also developed
a dynamic CFB model and studied the air-oxy switch. It was found
that the ring mode can be successfully switched within 2537 min
by employing simultaneous linear ramps for the mass ows of the
primary and secondary air, oxygen, and recirculated ue gas. The
experience obtained from CFB boiler model could provide good
139
insight for PC boiler simulation. Moreover, understanding of the
behaviors and dynamic responses of the plant is the basis of con-
trol system design, which is another function of dynamic simulation
(Haryanto et al., 2011; Kuczynski et al., 2011; Edge et al., 2012).
In this paper, an oxy-fuel boiler model with ue gas recycle was
developed using a 3 MWth full chain system (FCS) as prototype,
which had been constructed by Huazhong University of Science
and Technology in 2011. Both steady state and dynamic model
were created using Aspen Plus and Aspen Plus Dynamics, respec-
tively. The equipment size of heating surfaces and other devices,
and dynamic characteristics of dampers and valves were used to
specify the model. Extensive air combustion to oxy-combustion
shift, and dynamic disturbance experiments had been executed on
the 3 MW FCS during 2012 and 2013. Part of the test results were
selected to congure the model and the rest of it were reserved
as validation data. The steady state model was validated with test
data based on mass balance and energy balance. Several periods
of time which could reect the dynamic responses of the process
were dened in the dynamic simulation and these periods of time
were used to validate the dynamic model. Based on the validated
dynamic model, transient analysis of typical operation parameters
have been performed and the relationships of various inputs and
output response have been investigated, which would be used as a
basis for control system design in the future.
2. Steady state model development and validation
2.1. Process description
As shown in Fig. 1, the 3 MWth oxy-fuel full chain system (FCS)
mainly consists of four subsystems, that is, air separation unit
(ASU), boiler, air quality control system (AQCS) and ue gas com-
pression and purication unit (CPU). The ASU and the CPU are not
included in traditional thermal power plant. The ASU in this plant is
a small-scale cryogenic air separation unit with a maximum capac-
ity of 600 Nm3 /h which supplies high purity oxygen to the boiler for
coal combustion in oxy-fuel mode. The AQCS includes a bag lter
140 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149
Fig. 2. Simulation ow diagram of oxy-fuel combustion system.
unit, a wet desulfurization unit and a ue gas condenser. The CPU
is located at the downstream of AQCS, with a maximum capacity
of 600 Nm3 /h, to compress the ue gas with high concentration of
CO2 and liquefy the ue gas after removing the non-condensable
gas components, that is, N2 , O2 , Ar, and then store in a tank. One
special feature of the boiler is that it is a refractory-lined furnace
with two tube banks inside the furnace, which function as radiant
heat surface and radiant-convective heat surface respectively, and
one tube bank at the rear part of the boiler which functions as an
economizer. The boiler is the key subsystem in the overall process,
and it plays a signicant role in the system operation performance.
The process is described in detail below.
During the combustion process, a series of chemical reactions
of coal and oxygen take place in the boiler, which produce high
temperature ue gas. The heat of ue gas is transferred to water
through the tube bank 1 (TB1) located near the burner via radiative
heat transfer, and further through the tube bank 2 (TB2) in the upper
furnace via convective/radiative heat transfer. The ue gas then
passes through tube bank 3 (TB3) in the rear of furnace, and nally
the air/ue-gas pre-heater before it leaves the boiler. Part of the
heat was transferred to the refractory wall. After passing through
the AQCS, the ue gas would go to the stack or CPU, or recycle to
the boiler according to different operation modes.
The water from the cooling tower splits into three streams and
goes to TB1, TB2 and TB3 respectively. After being heated by high
temperature ue gas, the water goes out of the tube banks, merges
and then goes back to the cooling tower.
In air-ring mode, the air would be pre-heated in the air pre-
heater and then splits into three parts, i.e., primary air (PA) and
secondary air (SA) and over re air (OFA). PA is used to dry and
transport the coal; and SA and OFA are used to support coal combus-
tion. Besides, OFA could also be used to restrain the NOx formation
known as staged combustion. For oxy-fuel combustion mode, a
mixture of O2 and recycle ue gas (RFG) is used as oxidant gas
instead of using air. The O2 from ASU is injected into RFG ahead of
burner, such that PA and SA are premixed oxidant.
2.2. Model development
The process described in Fig. 1 is modeled using Aspen Plus. In
this article, to focus on the investigation of characteristics of heat
transfer and ue gas recycle processes, the modeling process only
includes models for boiler and the AQCS. As shown in Fig. 2, detailed
models on ASU and CPU are not included; only the product stream
of high purity oxygen from ASU and inlet stream of ue gas to CPU
are considered.
The boiler model mainly consists of a combustion section and
a heat transfer section. The reactor in the combustion section was
simulated by a Rstoic reactor block to model the combustion of fuel
and formation of SO2 and NO. The heat exchange section was simu-
lated using Heatx block and the heat transfer coefcient of the tube
banks obtained from the test results were used to congure the
block. In addition, the heat transferred to the refractory wall was
also simulated by Heatx block. For simplicity, a separation block Sep
was used to simulate ash removal unit, wet scrubber, as well as ue
gas condenser in the AQCS part, in which the separation efciencies
were specied according to test results either. The block Compr was
used to model the compressors and the block Vlave was used to sim-
ulate the dampers or valves to control the uid ow. Besides, the
block Fsplit and Mixer were used together to simulate the split and
mixture of streams. The detailed characteristics and usage of these
models can be found in the reference book (Aspen Technology Inc,
2001b).
The proximate analysis and ultimate analysis of coal used in
this model are shown in Table 1. In Aspen Plus, the coal is simu-
lated as a mixture of carbon, hydrogen, oxygen, nitrogen, sulfur and
ash etc. (Aspen Technology Inc, 2001b). However, the solid com-
ponents, such as carbon and ash are not supported in Aspen Plus
Dynamics. Since steady state simulation in Aspen Plus is the basis
of dynamic simulation in Aspen Plus Dynamics, substitutes should
be used to replace carbon and ash. According to proximate and ulti-
mate analysis of coal, especially the ratio of carbon and hydrogen,
the mixture of C10 H14 and C12 H14 is selected to simulate the com-
bustible substance in coal. The ash as an incombustible substance
could be simulated using the pseudo component. The unburned
carbon in ash determined in the test indicated that the combustion
efciency was very high, about 95% in air-ring mode and 98% in
oxy-fuel mode. Therefore, it is assumed that there is no unburned
carbon in the simulation. The transformed components and heat
Table 1
Proximate and ultimate analysis of coal (air dried basis, wt.%).
Cad Had Sad Nad Oad Mad Vad FCad Aad Qad (kJ/kg,
HHV)
57.48 3.29 0.68 0.86 5.59 1.31 22.67 45.23 30.79 22,390
 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149 141

Table 2 Table 5
Transformed components and heat value of coal (wt.%). Basic inputs and results in the simulation.

C14 H10 C12 H10 O2 N2 S H2 O Ash High heat value (kJ/kg) Item Value

58.28 0.04 6.76 0.86 0.68 5.59 30.79 22,550 Air-ring Oxy-fuel

Input heat load/MWth 2.6 2.6

Air/Oxygen excess ratio 1.1 1.05
Table 3 Recycle ratio 0.716
Reactions specied in Rstoic block. Total feedwater owrate/t/h 64.3 64.3
Inlet feedwater temperature/ C 29.7 29.7
Reaction Component Fractional conversion rate
Inlet feedwater pressure/bar 5.65 5.65
Air-ring Oxy-fuel Outlet feedwater temperature/ C 45.4 45.2
Outlet feedwater pressure/bar 1.6 1.6
C10 H14 + O2 ----CO2 + H2 O C10 H14 1 1
SO2 scrubber efciency 0.95 0.95
C12 H14 + O2 ----CO2 + CO + H2 O C12 H14 1 1
Fan isentropic efciency 0.85 0.85
N2 +O2 ----NO N2 0.0002 0.0009
Oxygen purity 0.99
S + O2 ----SO2 S 0.9 0.9
Oxygen pressure/KPa 50
Oxygen temperature/ C 15

Table 4
Heat tube sizing and heat transfer capacity.

Equipment Area/m2 Heat transfer coefcient/W/(m K)

Air-ring Oxy-fuel

Heat tube 1 (TB1) 4.81 61.9 62.5

Heat tube 2 (TB2) 10.13 40.6 41
Heat tube 3 (TB3) 29.9 25 25.6

value of coal are illustrated in Table 2. It should be claried that the

proximate and ultimate analysis of coal in Table 1 is based on air dry
basis. The moisture content as received is unknown. To accurately
simulate the gas compositions in the ue gas, the moisture con-
tent was considered in the modeling, which is shown in Table 2. It
can be seen that the differences of mass balance between the origi-
nal components and the transformed component was small as well
as the heat balance. The reactions of the transformed components
are illustrated in Table 3. The conversion rate of each element was
tuned based on the test data. In the combustion reaction of C12 H10 ,
it is assumed that 90% of C12 H14 transforms into CO. CO originated
from this reaction is regarded as combustion loss, which will not be
oxidized further. By regulating the spilt of CO and CO2 in this reac-
tion, we could control the concentration of CO to simulate different
combustion conditions. It should be noticed that the conversion
rate of N2 was different between air-ring and oxy-fuel mode due
to different N2 content and total ue gas owrate. Fig. 3. Temperature measuring points and location of tube banks.
The air leakage was simulated in the model and it was assumed
that the air leakage mainly took place at two locations. One was
located at the inlet of induced draft fan and another was located compositions, that is, O2 , CO2 , NO, CO, SO2 were selected as an indi-
at the inlet of primary fan, as shown in Fig. 2. The mass owrates cator of mass balance (Hu and Yan, 2012); gas temperature and the
of air leakage at these two locations were assumed to be equal for heat duty transferred in each tube bank were chosen as a measure
simplicity. The total air leakage was assumed to be 3% of the total of energy balance. The temperature measuring points and the loca-
ue gas owrate (mass basis) in air-ring mode at the steady state tion of tube banks in the boiler are shown in Fig. 3. T refers to the
model while it would be calculated automatically in the dynamic ue gas temperature and Q refers to the heat duty of the tube bank.
simulation according to the pressure balance between the system The steady state simulation results were compared with test data
and the atmosphere for both air-ring and oxy-fuel modes. The obtained from benchmark tests.
concentration of oxygen from ASU in this study is 99% and the impu- As discussed in the previous section, the mass balance was char-
rity is assumed as nitrogen. Two kinds of chemical properties were acterized by ue gas composition. The detailed gas compositions in
used in the simulation, PengRobinson for gas side and SteamNBS for both air-ring mode and oxy-fuel mode simulation are illustrated
water side (Xiong et al., 2011). The heat transfer coefcients of the and compared with test data in Table 6. The monitoring point of the
tube banks specied in the heat exchangers are shown in Table 4, ue gas composition is located after the condenser. It can be seen
which were obtained from benchmark test results of the 3 MWth that the percentage difference of CO2 and O2 between Model and
FCS. It can be seen that the heat transfer coefcient between air- Test is less than 2% indicating that the O2 and CO2 are modeled
ring and oxy-fuel mode was slightly different. Other basic inputs correctly, which is reasonable when the combustion efciency is
and results in the simulation are listed in Table 5. high. Additionally, it can be found that the concentration of NO in
oxy-fuel mode is higher than that in air-ring mode. The CO con-
2.3. Model validation tent in both air-ring and oxy-fuel mode was below 100 ppm which
indicated the sufcient combustion of coal in both cases. Further-
Mass balance and energy balance are the two factors to eval- more, the SO2 content was similar between air-ring and oxy-fuel
uate the accuracy of process modeling. In this study, the gas mode.
142 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149

1200 500
Test Test
1000
Model Model
450

Temperature (C)
800

Heat dtuy (KW)

600 400

400
350
200

0 300
T1 T2 T3 T4 T5 T6 Q1 Q2 Q3
(a) Air-firing mode
1200 500
Test Test
1000
Model Model
450
Temperature (C)

800

Heat dtuy (KW)

600 400

400
350
200

0 300
T1 T2 T3 T4 T5 T6 Q1 Q2 Q3
(b) Oxy-fuel mode
Fig. 4. Comparison of gas temperature and heat duty in tube banks.

The comparison of the gas temperatures between Test and 3. Dynamic model development and validation
Model were shown in Fig. 4. It can be seen that the simulation
results of the gas temperatures match the test results well. In air- 3.1. Model development
ring mode, T1 reaches 1170 C, and the exhaust gas temperature
(T6 ) is about 145 C. The corresponding gas temperatures in oxy- The steady state model in Aspen Plus is the basis of the dynamic
fuel mode are about 1100 C and 175 C, respectively. It could be model. After some further congurations in the existing steady
concluded that the gas temperature at the radiative section of the state model, the model then could be converted into an Aspen
furnace in oxy-fuel mode was lower than that in the air-ring Plus Dynamics model (Aspen Technology Inc, 2001a). There are
mode while the boiler outlet gas temperature in oxy-fuel mode two types of dynamic models in Aspen Plus Dynamics. One is
was higher than that in air-ring mode, which was also reported ow-driven model and another is pressure-driven model. The ow-
by Kakaras et al. (2007a,b). This can be explained by the fact that driven model assumes an ideal uid ow which is not affected by
the ue gas heat capacity in oxy-fuel mode was greater than that pressure difference. On the other hand, a pressure-driven model
in air-ring. In oxy-fuel combustion, a mixture of oxygen and recy- would take the effect of pressure difference on uid ow into
cled ue gas is used instead of air. Hence, the ue gas in the furnace account and the uid ow is determined by pressure difference.
mainly consists of CO2 instead of N2 . As a result, the heat capacity Obviously, pressure-driven model is much closer to reality and
of the ue gas increases in oxy-fuel combustion. According to the the simulation results would be more reasonable. Therefore, the
heat transfer equation Q = Cp qm dT, the dT will be smaller with the pressure-driven modeling approach is selected to investigate the
increase of Cp at a constant qm and Q. Here, Q and dT refer to heat dynamic system behaviors in this study. In this study, the test data
duty and temperature change, qm and Cp refer to mass ow rate and of pressure drop in different equipments and pipes were used to
heat capacity, respectively. Moreover, the simulation results of the congure the steady state model before it converted into dynamic
heat duties in each tube bank were also compared with test data. pressure-driven model.
Here, Q3 in oxy-fuel mode was similar to that in air-ring mode and Apart from pressure characteristics, the response time is also
Q1 and Q2 were a little smaller. However, this result was strongly of great importance in characterizing the dynamic response in
related to the ue gas recycle ratio in oxy-fuel mode. dynamic simulations. In real situations, the gas ow is controlled by
dampers and blowers/fans. However, the uid ow will not change
immediately due to the inertia of the actuators, i.e., dampers,
Table 6 fans, and this period of time could be termed as a pure time
Comparison of gas composition between test and model.
delay. Besides, there is a period from the change of uid ow to
Flue gas Air-ring Oxy-fuel the achievement of nal stable ow, which could be termed as
composition time constant, also resulting from the characteristics of actuators.
Test Model Difference% Test Model Difference% Besides pure time delay and time constant, the periods in uid ow
process and heat transfer process are also crucial to analyze the
O2 (%) 3.1 3.1 0 2.8 2.8 0
CO2 (%) 14.7 15.0 2 81.0 80.6 0.5 process responses in dynamic simulation, which could be termed
NO (ppm) 310 326 5.1 675 636 5.8 as uid ow time and heat transfer time, respectively. As a con-
CO (ppm) 66 70 6.0 55 60 9.0 sequence, accurate information associated with the volume of the
SO2 (ppm) 75 82 9.3 80 85 6.3 furnace, pipes and other devices and the dynamic features of the
 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149 143

Table 7
Descriptions of typical periods of time in dynamic processes.

Category Description

t1 Time delay The period of time before the process parameter change after actuator operation
t2 Time constant The period of time from the target parameter change to reach steady state
t3 Fluid ow time The period of time for uid ow in a vessel
t4 Heat transfer time The period of time for the heat transfer process in a heat exchanger

valves, dampers, and fans as well as the heat capacity of the heat 460

exchangers in the boiler play a signicant role in leading to a suc- 450

t1 Test
cessful simulation. Therefore, all the design and test data available Model
from 3 MW FCS were evaluated and pre-processed for use in speci- 440

Coal flowrate (kg/h)

fying the model. The detailed denitions of the four typical periods 430
of time described above are listed in Table 7.
The time delay, termed as t1 , represents the period before the 420

process parameter change after actuator operation. Taking the con-

410
trol process of coal owrate as an example, after the regulation of
coal ow valve, there exists a short period before the coal owrate 400

starts to change. This period is pure time delay and could be sim-
390
ulated by adding a dead-time block in Aspen Plus Dynamic library
(Aspen Technology Inc., 2001a). The coal owrate starts to change 380
after time delay; however, it could not reach the nal steady state t2
370
value immediately. The duration in the variation process of coal 0 5 10 15 20 25 30
owrate is the time constant, termed as t2 . The time constant could Time (min)
be modeled by switching the valve operation mode from instanta-
(a) Step change of coal feed rate
neous to dynamic and specifying the time constant of valve (Aspen
Technology Inc, 2001a). Fluid ow time, termed as t3 , refers to the 600

residence time in a vessel, which could be calculated by dividing t4

the volume owrate divided by the vessel volume. Heat transfer 1200
time, termed as t4 , refers to the period of time for the heat transfer
Gas temperature (C)

process in a heat exchanger, and it could be calculated by Eq. (1) T1 500

(Ingham et al., 2007), Test.T1
mCp Test.T5
t4 = (1) 1100
UA Model.T1
Model.T5
in which m and Cp denote the mass and heat capacity of the heat 400
exchanger, respectively. U refers to heat transfer coefcient and A
refers to area of the heat exchanger. T5
1000
Therefore, by dening the time delay and time constant of the t3
actuators as well as the heat capacity parameters and volume
of heat exchangers and pipelines, we could obtain the dynamic 300
0 5 10 15 20 25 30
response time of each device, and we could then obtain the dynamic
Time (min)
response characteristics of the global system. This method would
be explained in detail in the case studies below. (b) Dynamic response of gas temperature

Fig. 5. Validation of dynamic responses in the boiler.

3.2. Model validation

As discussed in the previous section, the magnitudes of various as Fig. 5(b). However, there was also a transition process that exists
process periods of time are the main gages to evaluate the accuracy in the reduction process of T1 due to the heat transfer delay (heat
of dynamic modeling. In this section, the four periods of time was transfer time, t4 ). Besides, the reduction process of T5 started sev-
used as criteria and two cases were used to compare the simulation eral minutes later after the reduction of T1 due to the gas traveling
result with test results. time (uid ow time, t3 ). The heat transfer time and the uid ow
time could be calculated according to the method described in the
Case 1. Validation of dynamic responses of boiler
previous section. The detailed response time of this process is listed
In this part, the system response of heat load change was used in Table 8. The results of the test and simulation showed a good
to validate the dynamic responses in the boiler, which is the most agreement, and the heat transfer time proved to be the largest
important subsystem in this study. The coal feed rate and T1 and response delay in the process.
T5 in the furnace were used to characterize the dynamic responses
of the process. As shown in Fig. 5(a), a step change of heat load
Table 8
was conducted at 8 min, and this operation was reproduced in the
Comparison of dynamic response time in step change of coal feed rate between test
model. After 0.5 minutes delay (time delay, t1 ), the coal ow rate and simulation (unit: minute).
started to decrease and then became stable after a transition pro-
t1 t2 t3 t4
cess. It was shown that the transition process in this test lasted
for about 2.5 min (time constant, t2 ). During the decrease of coal Test 0.5 2.5 0.4 3.8
ow, the heat input was decreased correspondingly and so was the Model 0.5 2.5 0.3 3.6

heat provided, which caused the gas temperature to drop, shown

144 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149

90 by Kluger et al. (2011). In that pilot plant, it was found that the
Test_CO2 transition process took 2030 min and the global system required
80
Test_O2 another 20 min to get stable. The time constant and the process
70 Air leakage response time were greater in the 30 MWth pilot plant than that in
Model_CO2
control this 3 MW facility due to its larger size. Obviously, the time constant
Gas Concentration (%)

60 Model_O2
Extraction of air injection and the process response time would be even greater in larger pilot
50 plants or commercial power plants. Additionally, another insight
obtained from this transition process was the strong inuence of
40 the air injection into the furnace on the CO2 concentration in the
30 ue gas. In this 3 MW FCS, the mass owrate of the air injected
into the furnace was about 200 kg/h, which was nearly 5% of the
20 total ue gas mass owrate. The air injection made the CO2 concen-
Purge
tration decrease about 10%, which indicated that high purity CO2
10
should be used to replace air in order to get higher CO2 concen-
0 tration ue gas, especially for the small pilot facility studied here.
The detailed analysis and discussion of how to conduct transition
14 15 16 17 18 19
operations on this facility could be found in this article (Luo et al.,
Time (Hours) 2014).
Fig. 6. Dynamic responses of the system in the transition process.
3.3. Transient analysis

Case 2. Validation of dynamic responses of global system In this section, the main objective is to study and compare the
dynamic behaviors of the plant between air-ring and oxy-fuel
In this case, the transition process from air-ring to oxy-fuel
mode under base operation condition. Hence, disturbance tests
and back to air-ring mode was simulated to validate the accu-
have been performed using the validated dynamic model to inves-
racy of model congurations in actuators, heat exchangers, pipe
tigate the effects of the changes of various input parameters (e.g.,
lines in the plant as well as to investigate the dynamic responses
heat load, excess oxygen, feedwater ow rate, O2 purity and recy-
of the global systems. The simulation result was compared with
cle ratio for oxy-fuel mode, etc.) on the output response (i.e., gas
the test result, as shown in Fig. 6. In the test result, it can be seen
temperature, heat duty, heat duty ratio and CO2 concentration for
that the CO2 concentration increased gradually as the transition
oxy-fuel mode). By means of transient analysis, the dynamic system
operation proceeded. After the transition operations and a period
responses of the given system could be simulated and its optimal
of ue gas recycle, the CO2 concentration in the dry ue gas reached
operation conditions could be evaluated and selected. Furthermore,
approximately 65%. Subsequently, the air injection used to protect
the control system could be designed based on the transient anal-
the ame monitor in the furnace was extracted and the CO2 concen-
ysis.
tration continued to rise to 75%. Then optimized operations were
In this study, the operation performance would be evaluated
conducted to reduce the air leakage, and the CO2 concentration
in terms of gas temperatures T1 and T6 , heat duties, and heat duty
started to increase again. Finally, the CO2 concentration achieved
ratios of the three tube banks. Typically, the gas temperature should
80% and became stable. In the simulation, similar operations were
be rigorously limited at a certain range. For example, if the ue gas
carried out. It could be found that the CO2 concentration reached
temperature at the inlet of tube bank 2, T1 , is too high, it may lead
about 70% after the transition process from air-ring to oxy-fuel
to slagging problems in the furnace and thus it would damage the
mode, which was higher than that in the test. This was because the
tube banks. Likewise, if the exhaust gas temperature, T6 , goes too
air leakage was controlled during the transition process rather than
high, the safety of AQCS could not be ensured. Although no steam is
after it. After the extraction of pressured air injection, the CO2 con-
generated from this test facility, the knowledge of the distribution
centration also increased about 10% and the nal concentration of
of heat duty in different tube banks is still of great signicance.
CO2 achieved 80% similar to the test result. In addition, the response
Especially the understanding of the regulatory control strategy is a
time of the global system to different operations, that is, transition
valuable experience for a large scale pilot plant and a commercial
operation, extraction of air injection, was also similar between the
power plant. For oxy-fuel mode operations only, CO2 concentration
simulation and test result. Therefore, it could be concluded that the
is also an important factor, as the CO2 concentration of the ue gas
simulation result was reasonably accurate compared with the test
would inuence the power consumption of CPU and thus affect the
result. The proximate ue gas residence time (FGRT) at each seg-
efciency of overall oxy-fuel power plant.
ment of the combustion system at base load in one recycle loop
is listed in Table 9. Besides, we can nd that, in both the simu-
3.4. Heat load disturbance
lation and test results, the total operation process lasts for about
15 minutes and it requires 10 to 15 minutes further for the sys-
The effect of changes in the heat load conditions was analyzed
tem to reach a stable condition after the transition operations. The
to determine its inuence on the performance of heat transfer pro-
same operation was conducted on Vattenfalls 30 MWth pilot plant
cess. Since the system response was opposite when the heat load
was decreased compared to the increase of the heat load at same
extent, only the decrease of heat load disturbance was discussed in
Table 9 this article. As shown in Fig. 7, a step change test was conducted for
Proximate ue gas residence time (FGRT) at each segment of the combustion system. both air-ring mode and oxy-fuel mode. In this test, the fuel valve
Category Value/s opening changed 10% suddenly at 6 min and the fuel ow rate was
FGRT1 In combustion chamber 7
decreased for a period of 3 min, approximately 2.5%. What needs
FGRT2 In boiler horizontal gas duct 3 to point out is that the response of fuel ow disturbance between
FGRT3 In boiler rear gas duct 3 air-ring mode and oxy-fuel is different and this is because the
FGRT4 From boiler outlet to stack 6 pressure changes in the pipelines are different between the two
FGRT5 From Recycle gas inlet to boiler inlet 5
modes, which indicate that the control logic used to regulate the
 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149 145

440 1200
Air 1180
Oxy

Temperature (C)
436 1160

Fuel (kg/hr)
Air.T1
1140 Air.T6
Oxy.T1
Oxy.T6
432 200

150

428 100
0 4 8 12 16 0 4 8 12 16
Time (Minutes) Time (Minutes)
410

400 0.36

Heat duty ratio (KW/KW)

390
Heat duty (kW)

Air.Q1 Oxy.Q1
380 0.34 Air.Q2 Oxy.Q2
Air.Q1 Oxy.Q1 Air.Q3 Oxy.Q3
370 Air.Q2 Oxy.Q2
Air.Q3 Oxy.Q3
0.32
360

350
0.30
0 4 8 12 16 0 4 8 12 16
Time (Minutes) Time (Minutes)

Fig. 7. Gas temperature and heat duty responses when heat load decreases 2.5%.

heat load disturbance might be different. The responses of gas tem-
perature T1 and T6 last for 45 min, and T1 decreases obviously for
both air and oxy-fuel modes, while T6 remains stable. The heat
duties in all tube banks decrease and Q1 increases more sharply
due to its faster response to the disturbance.
As shown in Fig. 8, heat load disturbance with larger variation
range was analyzed and compared with simulation results. It could
be clearly seen that the heat duty in each tube bank was decreased
with the decrease of heat load. In addition, Q3 responded to the heat
load change much slower than Q2 and Q1 . The simulation results
coincided well with the test results. Compared to the above heat
load disturbance with small variation range, the variation trends of
heat duty in each tube bank were consistent. Therefore, it could be
3.0
2.8
concluded that the effect of heat load change to the heat duty was
consistent in different heat load range.
3.5. Oxidant owrate disturbance
The effect of the changes in oxidant owrate was analyzed to
determine its inuence on the performance of overall system. As
shown in Fig. 9, a step change test was conducted for both air-
ring mode and oxy-fuel mode. In air-ring mode, the oxygen ow
rate in the air was controlled by the forced fan while the oxygen
ow rate in oxy-fuel mode was controlled by regulating the oxygen
injection valve. In the test, the oxygen ow rate was increased for
a period of 6 min in both modes, approximately 4%. It should be
mentioned that the uctuation of oxygen ow in oxy-fuel mode is
much stronger than that in air mode due to greater pressure change
500 caused by the mixture process of oxygen and ue gas. The dynamic
responses of the gas temperature T1 and T6 last for 610 min, and
T1 decreases obviously for both air and oxy-fuel mode, while T6
450 remains stable. The heat duties in all tube banks decrease and Q1
decreases more sharply than the others due to its faster response
to the change in oxygen ow rate, from 367 KW to 352 KW. The
Heat duty (KW)

Heat load_test Heat load_model

Heat load (MW)

2.6 400
change of Q3 is much smaller because the heat transfer capability
in this area is the weakest. The reduction of Q1 mainly results from
Q1_test Q1_test the decrease of ue gas temperature, that is, T1 , because most of
2.4 350
Q2_test Q2_test
Q3_test
the heat is transferred by radiation at this area and the decrease of
Q3_test
ue gas temperature dominates the reduction of Q1 .
2.2 300 As shown in Fig. 10, excess oxygen disturbance was analyzed in
the test and compared with simulation results. It can be seen that
Q1 and Q2 decreased as the oxygen concentration in the ue gas
2.0 250
increased, which was consistent with the observations in simula-
20.80 20.85 20.90 20.95 21.00
tion results. In the disturbance test, the feedwater owrate was
Time (h)
continuously increased in TB3 and therefore Q3 increased con-
Fig. 8. Comparison of test and simulation results for heat load disturbance. tinuously and greatly compared to Q1 and Q2 . Both the variation
146 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149

780 1200

Oxygen mass flowrate (kg/h)

Air
Oxy
760 1100

Temperature (C)
Air.T1
Air.T6
740 1000
Oxy.T1
Oxy.T6
200
720
150

700 100
0 4 8 12 16 0 4 8 12 16
Time (Minutes) Time (Minutes)

410 0.37

400

Heat duty ratio (KW/KW)

0.36
390
Heat duty (kW)

0.35
380 Air.Q1 Oxy.Q1
Air.Q1 Oxy.Q1 0.34 Air.Q2 Oxy.Q2
370 Air.Q2 Oxy.Q2 Air.Q3 Oxy.Q3
Air.Q3 Oxy.Q3 0.33
360

350 0.32

340 0.31
0 4 8 12 16 0 4 8 12 16
Time (Minutes) Time (Minutes)

Fig. 9. Gas temperature and heat duty responses when oxygen owrate increases 4%.

tendency and the steady state value of oxygen concentration and
heat duties coincided well between test and simulation results.
3.6. Feedwater owrate disturbance
To investigate the effect of feedwater ow rate on gas temper-
ature and heat duty, the feedwater owrate corresponding to the
tube bank 1 was selected as the disturbance variable due to higher
gas temperature in this area, which could indicate the slagging
problem, thus more attention should be paid. Only the increase
of the feedwater owrate was carried out in this section and the
details were discussed below.
As shown in Fig. 11, the step change test was conducted for both
air-ring mode and oxy-fuel mode. In the test, the feedwater ow
rate was increased immediately and rapidly because the transient
behavior was ignored in the model, which is also not apparent in the
8 400
Q1_test
O2_test
Q2_test
O2_model
Oxygen concentration (%)
test. It can be seen that the feedwater ow rate change do not have
any noticeable impact on the gas temperature and the heat duties
as well as the heat duty ratios. This phenomenon proved that when
the feedwater owrate comes to a certain range, the increase of
feedwater owrate does not cause an increase in the heat transfer
in the heat exchanger, and therefore could not cause a decrease
in the gas temperature. As a consequence, other operations should
be considered to decrease the gas temperature when it is over the
limit. This experience is useful for this kind of test facility with
limited heat exchange surfaces.
The feedwater owrate disturbance in air-ring mode was also
performed on the test facility, as shown in Fig. 12. It could be seen
that the heat duty in TB1 was increased sharply for a moment when
the water owrate increased suddenly. This was because the mea-
sured water temperature could not respond as fast as the water
owrate, therefore, the heat duty in TB1 calculated according to the
water heat absorption increased rapidly with the fast increase of
water owrate. Subsequently, Q1 went down fast as the feedwater
Q1_model temperature started to go down, and nally reached steady state. It
Q2_model could be found that Q1 did not change much after the disturbance

7 Q3_test Q3_model 380

and this result coincided well with the simulation result.

6
360
3.7. Recycle ratio disturbance
Heat duty (KW)

5
340 The effect of changes in the ue gas recycle ratio conditions was
analyzed to determine its impact on the performance of heat trans-
4
320
fer process. It should be pointed out that in order to keep the process
comparatively stable and purely investigate the inuence of the
3
ue gas recycle on the overall system, the ue gas recycle ratio
300
was intentionally set to be small and only the increase of recycle
2 ratio disturbance was discussed. As shown in Fig. 13, a step change
16.20 16.25 16.30 16.35 16.40 16.45
test was conducted at about time 6 min, and the recycle ratio was
Time (h)
increased for a period of 3 min, approximately 1%. The dynamic
Fig. 10. Comparison of test and simulation results for oxygen owrate disturbance. responses of gas temperature T1 and T6 lasted for 6 min, and T1
 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149 147

29 1200

28

Water flowrate (t/hr)

Air 1100

Temperature (C)
Oxy Air.T1
27 Air.T6
1000 Oxy.T1
Oxy.T6
26
200
25
150

24 100
0 4 8 12 16 0 4 8 12 16
Time (Minutes) Time (Minutes)

410 0.36

Heat duty ratio (KW/KW)

400
Heat duty (kW)

390
Air.Q1 Oxy.Q1
0.34
Air.Q1 Oxy.Q1 Air.Q2 Oxy.Q2
380 Air.Q2 Oxy.Q2 Air.Q3 Oxy.Q3
Air.Q3 Oxy.Q3
370

360 0.32

350
0 4 8 12 16 0 4 8 12 16
Time (Minutes) Time (Minutes)

Fig. 11. Gas temperature and heat duty responses when water owrate increases 2.5%.

decreased obviously while T6 remained stable. Q3 increased while the heat duties in tube banks and the regulation of recycle ratio
Q1 and Q2 decreased. This phenomenon occurs because the heat could be a good way to control the distribution of heat ux in the
exchangers corresponding to Q1 and Q2 have stronger heat trans- furnace.
fer capability due to higher radiative and convective heat transfer
coefcients. The response of heat duty ratio is consistent with 4. Discussion
the response of heat duty. The responses of ue gas recycle ratio
disturbance are similar to that of excess oxygen disturbance. Fur- In this study, a Rstoic block was employed to simulate the coal
thermore, the effect of recycle ratio on CO2 was also analyzed and combustion process, which was widely used in process modeling in
the CO2 concentration increased less than 1% with the increase of Aspen Plus (Hu and Yan, 2012; Jin et al., 2014). However, the Rstoic
recycle ratio. block is a simplied model which does not take the detailed reac-
The recycle ratio disturbance was also performed on the test tion kinetics and gas-solid reactions into account. In fact, reaction
facility and compared to simulation results, as shown in Fig. 14. It kinetics and gas-solid reactions could be considered by obtaining
could be seen that Q1 and Q2 were decreased and Q3 was increased accurate kinetic data for reactions and combining other simulation
with the increase of recycle ue gas owrate and this result coin- tools, that is, Fluent, to simulate detailed combustion process in
cided well with the simulation result. Both the simulation and boiler (Robinson and Luyben, 2008; Zitney, 2006, 2010.); however,
test results indicated that recycle ratio could obviously inuence it will greatly add burden to computation and needs to solve com-
patibility problems between different simulation tools (Jin et al.,
2014). To accurately simulate the reactions in the combustion pro-
30 cess, the test data was used to modify the conversion rate of the
400
reactions in Rstoic block. The simulation results showed a good
28
agreement with the test results. In addition, it should be empha-
TB1 sized that the main objective of this study is to develop a dynamic
Water flowrate (t/h)

350
26
Q1 model to investigate the dynamic responses of the oxy-fuel com-
Heat duty (KW)

bustion facility and to design the control system. Therefore, the

simplication of combustion model using Rstoic block in dynamic
24 300
simulation was reasonable and acceptable.
In terms of achieving a successful dynamic simulation, the key
22
factor is to accurately simulate the time constants of the devices
250
in the system and the response time in the dynamic process. The
20
response time in dynamic process, that is, uid ow time, heat
transfer time, could be calculated by dening the volume of vessels
18 200
and mass and heat transfer capacity of heat exchangers. However,
19.6 19.7 19.8 19.9
the time delay and time constants of each device are its inher-
Time (h)
ent characteristics, and it can be obtained only by test results.
Fig. 12. Test results of the responses for feedwater owrate disturbance. Therefore, the simulation results obtained based on our validated
148 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149

0.730 0.825 1200

0.820 1100

Recycle ratio (kg/kg)

Temperature (C)
0.725
T1
0.815 1000 T6

0.720 200
0.810
Recycle ratio
CO2 concentration 150

0.715 0.805 100

0 4 8 12 16 0 4 8 12 16
Time (Minutes) Time (Minutes)
410 0.36
Q1

Heat duty ratio (KW/KW)

400
Q2
Q3
Heat duty (kW)

390 Q1
0.34
Q2
380 Q3

370

360 0.32

350
0 4 8 12 16 0 4 8 12 16
Time (Minutes) Time (Minutes)

Fig. 13. Dynamic responses when ue gases recycle ratio increases 1%.

dynamic model are more accurate compared to other mathemat-
ical or conceptual models (Haryanto et al., 2011; Jin et al., 2014).
In addition, the response time in dynamic process directly inu-
ence the PID controller design. For example, if the response of the
controller is too slow, we may need to introduce a differential ele-
ment; if the target parameter presents an oscillation behavior, we
may need to increase the integral time constant to decrease the
integral effect (Robert, 2010). Thus it is more reliable to conduct
control system design based on this validated dynamic model.
With respect to transient analysis in this study, only the dynamic
responses of boiler and ue gas process were discussed while the
ASU and CPU were not included. In fact, the operation conditions
of ASU and CPU have a great effect on the boiler and ue gas pro-
cess, especially ASU, as it is upstream of the boiler island in the full
oxy-fuel combustion chain. For example, the disturbance in oxygen
concentration would affect the atmosphere in the furnace, and then
affect the heat transfer process as well as the ue gas composition.
The variation of ue gas composition would eventually inuence
2000
Flowrate_test
Flowrate_model
Recycled gas flowrate (m3/h)
the inlet condition of CPU. Therefore, to obtain the understanding
of dynamic characteristics of full oxy-fuel combustion chain, the
ASU and CPU models should be combined with the boiler model
and this work would be conducted in the future.
Besides, the boiler in this study is equipped with several tube
banks instead of water wall, and this is different from large-scale
utility boiler. However, the experience obtained both in the sim-
ulation and test could still provide good insight in the operation
for other oxy-fuel pilot plant or commercial plant despite the dif-
ference in heat transfer surface, that is, the controllability of water
owrate to ue gas temperature, the distribution of heat duty in
different heat transfer surfaces.
5. Conclusions
In this article, both steady state and dynamic models of the
3 MWth oxy-fuel combustion system with ue gas recycle were
developed using Aspen plus and Aspen plus dynamics, respectively.
420
Q1_test Q1_model The simulation results show that,
Q2_test Q2_model
Q3_test Q3_model
400
(1) Static and dynamic behavior of the 3 MW FCS, including mass

1600 and energy balance, temperature prole, heat transfer, switch

380
from air combustion mode to oxy-combustion mode and vice
Heat dyty (KW)

versus etc., can be well predicted by the proposed models;

360 (2) The heat transfer time proved to be the largest response delay in
3 MW FCS and it can be more signicant for large scale system;
1200
340
(3) The differences in system responses corresponding to input
disturbances, at air-ring mode and oxy-fuel mode, are cor-
rectly reproduced through the transient analysis based on the
320 dynamic model;
800 (4) All the information obtained is useful to propose a preliminary
16.70 16.75 16.80 16.85 16.90
control scheme. The model can also provide good insight for the
Time (h)
design and operation of large scale oxy-fuel combustion power
Fig. 14. Comparison of test and simulation results for recycle ratio disturbance. plants.
 W. Luo et al. / International Journal of Greenhouse Gas Control 35 (2015) 138149
Acknowledgments
The authors gratefully acknowledge support by National
Key Basic Research and Development Program (2011CB707300),
National Key Technology Research and Development Program
(2011BAC0500), and International Cooperation Program of Min-
istry of Science and Technology (2013DFB60140) of Ministry of
Science and Technology, China. Special thanks are given to Alstom
Power Boiler R&D Execution (Windsor, CT) for providing internship
to Wei Luo. The authors also acknowledge Dr. Xinsheng Lou from
Alstom Power Boiler R&D Execution for his valuable suggestions to
this paper.
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