Oxy-Coal Carbon Capture (OCCC) Dynamic Simulator
FutureGen 2.0 is a first-of-its-kind, near-zero emissions coal-fueled power plant using oxy-combustion technology to capture the plant’s carbon emissions. To help meet the Nation’s ever growing demand for clean energy, the FutureGen Industrial Alliance (Alliance) was formed to test and commercialize advanced coal-based systems fully integrated with carbon capture and geologic storage technologies. In cooperation with the U.S. Department of Energy (DOE), the Alliance and its project partners AirLiquide and Babcock & Wilcox, will upgrade an existing power plant in Meredosia, Illinois with oxy-coal carbon capture (OCCC) technology to capture and permanantly store approximately 1.0 million tonnes of CO2 each year.
The OCCC plant will be a large, highly-integrated, multi-purpose facility that requires effective operation and control of a number of processes that will provide more than 90 percent CO2 capture and take other emissions, such as SOx, NOx, mercury and particulate matter, to near-zero levels. Lessons learned from the FutureGen 2.0 project are expected to greatly improve the control, operability and efficiency of OCCC plant operations that will help to drive maximum business value from OCCC plant assets, all while reducing negative environmental impact and improving safety.
To accelerate progress toward achieving operational excellence for future OCC plants, the NETL AVESTAR Center team and its partners are conducting a scoping study to develop a real-time OCCC dynamic simulator with full-scope operator training system (OTS) and 3D virtual immersive training system (ITS). The high-fidelity dynamic model will represent a generic OCCC power plant including processes such as air separation, oxy-combustion, flue gas cleanup, and CO2 capture, purification, and compression. The key software/model components will include: 1) high-fidelity, first-principle, real-time dynamic models, 2) regulatory control system models, 3) operator human-machine interface (HMI) displays, and 3D virtual displays.
The generic OCCC virtual power plant will be deployed at the NETL AVESTAR Center and used to meet emerging industry needs for realistic, hands-on, simulation-based training, education, and research on the safe, reliable, and efficient operation and control of highly-integrated, multi-purpose oxy-combustion system with CO2 capture and compression. Tangible benefits include improved process understanding, tighter designs, smoother start-ups, enhanced controllability, improved safety, and optimized production. Without interrupting the physical OCCC plant, engineers and operators can evaluate control and operation schemes for a broad range of transient conditions, including process startups, shutdowns, upsets, malfunctions, and disturbances in coal feed compositions and flows. The dynamic simulator can be applied to optimize all phases of OCCC processing operations with respect to process and market fluctuations, CO2 pipeline specifications, and non-condensible gases (NCG) product requirements, as well as safety and environmental constraints.
In summary, the OCCC dynamic simulator and 3D virtual immersive training system is intended to accelerate operational and control advances for commercial-scale oxy-combustion projects. Using these powerful computational tools, OCCC plant performance can be visualized, analyzed, and optimized for increased operational efficiency, lower-cost electricity, and more effective CO2 removal over a wide range of operating scenarios. Achieving operational excellence for commercial-scale OCCC power plants with carbon capture and compression can have significant impact on the extent and the rate at which this technology will be scaled-up, deployed, and used in the years to come.