def tu(delta_temperature_callback=delta_temperature_underwood_tune_callback):
m = ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.properties = PhysicalParameterTestBlock()
m.fs.prop_steam = iapws95.Iapws95ParameterBlock()
m.fs.prop_fluegas = FlueGasParameterBlock()
m.fs.unit = BoilerHeatExchanger(
default={
"delta_temperature_callback": delta_temperature_callback,
"tube": {
"property_package": m.fs.prop_steam
},
"shell": {
"property_package": m.fs.prop_fluegas
},
"has_pressure_change": True,
"has_holdup": False,
"flow_pattern": HeatExchangerFlowPattern.countercurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Liq",
"has_radiation": True,
})
assert_units_consistent(m)
def test_config():
m = ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.properties = PhysicalParameterTestBlock()
m.fs.prop_steam = iapws95.Iapws95ParameterBlock()
m.fs.prop_fluegas = FlueGasParameterBlock()
m.fs.unit = BoilerHeatExchanger(
default={
"side_1_property_package": m.fs.prop_steam,
"side_2_property_package": m.fs.prop_fluegas,
"has_pressure_change": True,
"has_holdup": False,
"delta_T_method": DeltaTMethod.counterCurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Liq",
"has_radiation": True
})
# Check unit config arguments
# There are 8 to 10 arguments since you can add a side 1 and 2 config by
# side_1, side_2, or whatever the user named them
assert len(m.fs.unit.config) >= 12 and len(m.fs.unit.config) <= 16
assert not m.fs.unit.config.dynamic
assert not m.fs.unit.config.has_holdup
assert m.fs.unit.config.delta_T_method == \
DeltaTMethod.counterCurrent
def test_deprecated_delta_T_method(caplog):
m = ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.prop_steam = iapws95.Iapws95ParameterBlock()
m.fs.prop_fluegas = FlueGasParameterBlock()
caplog.clear()
m.fs.unit = BoilerHeatExchanger(
default={
"delta_temperature_callback": delta_temperature_lmtd_callback,
"tube": {
"property_package": m.fs.prop_steam
},
"shell": {
"property_package": m.fs.prop_fluegas
},
"has_pressure_change": True,
"has_holdup": True,
"delta_T_method": HeatExchangerFlowPattern.countercurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Liq",
"has_radiation": True,
})
n_warn = 0
n_depreacted = 0
for record in caplog.records:
if record.levelno == idaeslog.WARNING:
n_warn += 1
if "deprecated" in record.msg:
n_depreacted += 1
assert n_warn == 1
assert n_depreacted == 1
assert m.fs.unit.config.flow_pattern == HeatExchangerFlowPattern.countercurrent
def test_compressor_fan():
m = pyo.ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.properties = iapws95.Iapws95ParameterBlock()
# Add property packages to flowsheet library
m.fs.prop_fluegas = FlueGasParameterBlock()
m.fs.unit = PressureChanger(
default={
"property_package": m.fs.prop_fluegas,
"thermodynamic_assumption": ThermodynamicAssumption.isentropic,
"compressor": True
})
# # FLUE GAS Inlet from Primary Superheater
FGrate = 425.813998 # mol/s
# # Use FG molar composition to set component flow rates (baseline report)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["H2O"].\
fix(FGrate*8.69/100)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["CO2"].\
fix(FGrate*14.49/100)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["N2"].\
fix(FGrate*74.34/100)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["O2"].\
fix(FGrate*2.47/100)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["NO"].\
fix(FGrate*0.0006)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["SO2"]\
.fix(FGrate*0.002)
m.fs.unit.control_volume.properties_in[0].temperature.fix(200.335)
m.fs.unit.control_volume.properties_in[0].pressure.fix(98658.6)
m.fs.unit.deltaP.fix(101325 - 98658.6)
m.fs.unit.efficiency_isentropic.fix(0.9)
m.fs.unit.get_costing(mover_type='fan')
m.fs.unit.initialize()
# make sure costing initialized correctly
assert (pytest.approx(pyo.value(m.fs.unit.costing.purchase_cost),
abs=1e-2) == 22106.9807)
assert degrees_of_freedom(m) == 0
# Check unit config arguments
assert isinstance(m.fs.unit.costing.purchase_cost, pyo.Var)
assert isinstance(m.fs.unit.costing.base_cost_per_unit, pyo.Var)
results = solver.solve(m, tee=True)
assert results.solver.termination_condition == \
pyo.TerminationCondition.optimal
assert results.solver.status == pyo.SolverStatus.ok
assert (pytest.approx(pyo.value(m.fs.unit.costing.base_cost),
abs=1e-2) == 4543.6428)
assert (pytest.approx(pyo.value(m.fs.unit.costing.purchase_cost),
abs=1e-2) == 22106.9807)
def test_blower_build_and_solve():
m = pyo.ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.properties = iapws95.Iapws95ParameterBlock()
# Add property packages to flowsheet library
m.fs.prop_fluegas = FlueGasParameterBlock()
m.fs.unit = PressureChanger(
default={
"property_package": m.fs.prop_fluegas,
"thermodynamic_assumption": ThermodynamicAssumption.isentropic,
"compressor": True
})
# # FLUE GAS Inlet from Primary Superheater
FGrate = 8516.27996 # mol/s
# # Use FG molar composition to set component flow rates (baseline report)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["H2O"].\
fix(FGrate*8.69/100)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["CO2"].\
fix(FGrate*14.49/100)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["N2"].\
fix(FGrate*74.34/100)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["O2"].\
fix(FGrate*2.47/100)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["NO"].\
fix(FGrate*0.0006)
m.fs.unit.control_volume.properties_in[0].flow_mol_comp["SO2"]\
.fix(FGrate*0.002)
m.fs.unit.control_volume.properties_in[0].temperature.fix(200.335)
m.fs.unit.control_volume.properties_in[0].pressure.fix(99973.98)
m.fs.unit.deltaP.fix(144790 - 99973.98)
m.fs.unit.efficiency_isentropic.fix(0.9)
m.fs.unit.initialize()
m.fs.unit.get_costing(mover_type='fan')
calculate_variable_from_constraint(m.fs.unit.costing.purchase_cost,
m.fs.unit.costing.cp_cost_eq)
assert degrees_of_freedom(m) == 0
# Check unit config arguments
assert isinstance(m.fs.unit.costing.purchase_cost, pyo.Var)
assert isinstance(m.fs.unit.costing.base_cost, pyo.Var)
results = solver.solve(m, tee=True)
assert results.solver.termination_condition == \
pyo.TerminationCondition.optimal
assert results.solver.status == pyo.SolverStatus.ok
assert (pytest.approx(pyo.value(m.fs.unit.costing.base_cost),
abs=1e-2) == 56026.447)
assert (pytest.approx(pyo.value(m.fs.unit.costing.purchase_cost),
abs=1e-2) == 272595.280)
def test_thermo():
# Read in test data and add mixtures
m = pyo.ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.params = FlueGasParameterBlock()
m.fs.state = FlueGasStateBlock(default={"parameters": m.fs.params})
m.fs.state.pressure.fix(
1e5) #ideal gas properties are pressure independent
assert_units_consistent(m)
data = read_data("pure-prop-nist-webbook.csv", m.fs.params)
assert hasattr(m.fs.state, "cp_mol")
assert hasattr(m.fs.state, "enth_mol")
assert hasattr(m.fs.state, "entr_mol")
m.fs.state.cp_mol = 30
m.fs.state.enth_mol = 30000
m.fs.state.entr_mol = 30
for i in data:
for T in data[i]:
m.fs.state.temperature.fix(T)
test_entropy = True
for j, f in m.fs.state.flow_mol_comp.items():
cf = data[i][T]["comp"].get(j, 0)
if cf <= 0:
test_entropy = False
f.fix(cf)
if test_entropy:
m.fs.state.entr_mol.unfix()
m.fs.state.entropy_correlation.deactivate()
else:
m.fs.state.entr_mol.unfix()
m.fs.state.entropy_correlation.deactivate()
m.fs.state.initialize()
solver.solve(m)
assert data[i][T]["H"] == pytest.approx(pyo.value(
m.fs.state.enth_mol),
rel=1e-2)
assert data[i][T]["Cp"] == pytest.approx(pyo.value(
m.fs.state.cp_mol),
rel=1e-2)
if test_entropy:
assert data[i][T]["S"] == pytest.approx(pyo.value(
m.fs.state.entr_mol),
rel=1e-2)
def build_unit():
m = ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.properties = PhysicalParameterTestBlock()
m.fs.prop_fluegas = FlueGasParameterBlock()
m.fs.unit = HeatExchangerWith3Streams(
default={
"side_1_property_package": m.fs.prop_fluegas,
"side_2_property_package": m.fs.prop_fluegas,
"side_3_property_package": m.fs.prop_fluegas,
"has_heat_transfer": True,
"has_pressure_change": True,
"flow_type_side_2": "counter-current",
"flow_type_side_3": "counter-current",
})
return m
def build_unit():
# Create a Concrete Model as the top level object
m = pyo.ConcreteModel()
# Add a flowsheet object to the model
m.fs = FlowsheetBlock(default={"dynamic": False})
# Add property packages to flowsheet library
m.fs.prop_fluegas = FlueGasParameterBlock()
# boiler based on surrogate
m.fs.unit = BoilerFireside(
default={
"dynamic": False,
"property_package": m.fs.prop_fluegas,
"calculate_PA_SA_flows": False,
"number_of_zones": 12,
"has_platen_superheater": True,
"has_roof_superheater": True,
"surrogate_dictionary": dat.data_dic
})
return m
def test_units():
m = ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.properties = PhysicalParameterTestBlock()
m.fs.prop_steam = iapws95.Iapws95ParameterBlock()
m.fs.prop_fluegas = FlueGasParameterBlock()
m.fs.unit = BoilerHeatExchanger(default={
"side_1_property_package": m.fs.prop_steam,
"side_2_property_package": m.fs.prop_fluegas,
"has_pressure_change": True,
"has_holdup": False,
"delta_T_method": DeltaTMethod.counterCurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Liq",
"has_radiation": True})
assert_units_consistent(m)
def build_unit():
# Create a Concrete Model as the top level object
m = pyo.ConcreteModel()
# Add a flowsheet object to the model
m.fs = FlowsheetBlock(default={"dynamic": False})
# Add property packages to flowsheet library
m.fs.prop_water = iapws95.Iapws95ParameterBlock()
m.fs.prop_fluegas = FlueGasParameterBlock()
# Add a 2D cross-flow heat exchanger with header model to the flowsheet
m.fs.unit = HeatExchangerCrossFlow2D_Header(
default={
"tube_side": {
"property_package": m.fs.prop_water,
"has_pressure_change": True
},
"shell_side": {
"property_package": m.fs.prop_fluegas,
"has_pressure_change": True
},
"finite_elements": 5,
"flow_type": "counter_current",
"tube_arrangement": "in-line",
"tube_side_water_phase": "Vap",
"has_radiation": True,
"radial_elements": 5,
"tube_inner_diameter": 0.035,
"tube_thickness": 0.0035,
"has_header": True,
"header_radial_elements": 5,
"header_inner_diameter": 0.3,
"header_wall_thickness": 0.03
})
# Primary Superheater (NETL baseline report)
ITM = 0.0254 # inch to meter conversion
# m.fs.unit.tube_di.fix((2.5-2*0.165)*ITM)
# m.fs.unit.tube_thickness.fix(0.165*ITM)
m.fs.unit.pitch_x.fix(3 * ITM)
# gas path transverse width 54.78 ft / number of columns
m.fs.unit.pitch_y.fix(54.78 / 108 * 12 * ITM)
m.fs.unit.tube_length_seg.fix(53.13 * 12 * ITM)
m.fs.unit.tube_nseg.fix(20 * 2)
m.fs.unit.tube_ncol.fix(108)
m.fs.unit.tube_inlet_nrow.fix(4)
m.fs.unit.delta_elevation.fix(50)
m.fs.unit.tube_r_fouling = 0.000176 # (0.001 h-ft^2-F/BTU)
m.fs.unit.tube_r_fouling = 0.003131 # (0.03131 - 0.1779 h-ft^2-F/BTU)
# material inputs
m.fs.unit.therm_cond_wall = 43.0 # Carbon steel 1% C in W/m/K
m.fs.unit.dens_wall = 7850 # kg/m3 or 0.284 lb/in3
m.fs.unit.cp_wall = 510.8 # J/kg-K (0.05 to 0.25 % C)
m.fs.unit.Young_modulus = 2.00e5 # 200 GPa (29,000 ksi)
m.fs.unit.Possion_ratio = 0.29
m.fs.unit.coefficient_therm_expansion = 1.3e-5
m.fs.unit.emissivity_wall.fix(0.7)
m.fs.unit.fcorrection_htc_tube.fix(1.0)
m.fs.unit.fcorrection_htc_shell.fix(1.0)
m.fs.unit.fcorrection_dp_tube.fix(1.0)
m.fs.unit.fcorrection_dp_shell.fix(1.0)
m.fs.unit.temperature_ambient.fix(350.0)
m.fs.unit.head_insulation_thickness.fix(0.025)
return m
def build_boiler(fs):
# Add property packages to flowsheet library
fs.prop_fluegas = FlueGasParameterBlock()
# Create unit models
# Boiler Economizer
fs.ECON = BoilerHeatExchanger(
default={
"side_1_property_package": fs.prop_water,
"side_2_property_package": fs.prop_fluegas,
"has_pressure_change": True,
"has_holdup": False,
"delta_T_method": DeltaTMethod.counterCurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Liq",
"has_radiation": False
})
# Primary Superheater
fs.PrSH = BoilerHeatExchanger(
default={
"side_1_property_package": fs.prop_water,
"side_2_property_package": fs.prop_fluegas,
"has_pressure_change": True,
"has_holdup": False,
"delta_T_method": DeltaTMethod.counterCurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Vap",
"has_radiation": True
})
# Finishing Superheater
fs.FSH = BoilerHeatExchanger(
default={
"side_1_property_package": fs.prop_water,
"side_2_property_package": fs.prop_fluegas,
"has_pressure_change": True,
"has_holdup": False,
"delta_T_method": DeltaTMethod.counterCurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Vap",
"has_radiation": True
})
# Reheater
fs.RH = BoilerHeatExchanger(
default={
"side_1_property_package": fs.prop_water,
"side_2_property_package": fs.prop_fluegas,
"has_pressure_change": True,
"has_holdup": False,
"delta_T_method": DeltaTMethod.counterCurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Vap",
"has_radiation": True
})
# Platen Superheater
fs.PlSH = Heater(default={"property_package": fs.prop_water})
# Boiler Water Wall
fs.Water_wall = Heater(default={"property_package": fs.prop_water})
# Boiler Splitter (splits FSH flue gas outlet to Reheater and PrSH)
fs.Spl1 = Separator(
default={
"property_package": fs.prop_fluegas,
"split_basis": SplittingType.totalFlow,
"energy_split_basis": EnergySplittingType.equal_temperature
})
# Flue gas mixer (mixing FG from Reheater and Primary SH, inlet to ECON)
fs.mix1 = Mixer(
default={
"property_package": fs.prop_fluegas,
"inlet_list": ['Reheat_out', 'PrSH_out'],
"dynamic": False
})
# Mixer for Attemperator #1 (between PrSH and PlSH)
fs.ATMP1 = Mixer(
default={
"property_package": fs.prop_water,
"inlet_list": ['Steam', 'SprayWater'],
"dynamic": False
})
# Build connections (streams)
# Steam Route (side 1 = tube side = steam/water side)
# Boiler feed water to Economizer (to be imported in full plant model)
# fs.bfw2econ = Arc(source=fs.FWH8.outlet,
# destination=fs.ECON.side_1_inlet)
fs.econ2ww = Arc(source=fs.ECON.side_1_outlet,
destination=fs.Water_wall.inlet)
fs.ww2prsh = Arc(source=fs.Water_wall.outlet,
destination=fs.PrSH.side_1_inlet)
fs.prsh2plsh = Arc(source=fs.PrSH.side_1_outlet, destination=fs.PlSH.inlet)
fs.plsh2fsh = Arc(source=fs.PlSH.outlet, destination=fs.FSH.side_1_inlet)
fs.FSHtoATMP1 = Arc(source=fs.FSH.side_1_outlet,
destination=fs.ATMP1.Steam)
# fs.fsh2hpturbine=Arc(source=fs.ATMP1.outlet,
# destination=fs.HPTinlet)
# (to be imported in full plant model)
# Flue gas route ---------------------------------------------------------
# water wall connected with boiler block (to fix the heat duty)
# platen SH connected with boiler block (to fix the heat duty)
# Finishing superheater connected with a flowsheet level constraint
fs.fg_fsh2_separator = Arc(source=fs.FSH.side_2_outlet,
destination=fs.Spl1.inlet)
fs.fg_fsh2rh = Arc(source=fs.Spl1.outlet_1, destination=fs.RH.side_2_inlet)
fs.fg_fsh2PrSH = Arc(source=fs.Spl1.outlet_2,
destination=fs.PrSH.side_2_inlet)
fs.fg_rhtomix = Arc(source=fs.RH.side_2_outlet,
destination=fs.mix1.Reheat_out)
fs.fg_prsh2mix = Arc(source=fs.PrSH.side_2_outlet,
destination=fs.mix1.PrSH_out)
fs.fg_mix2econ = Arc(source=fs.mix1.outlet,
destination=fs.ECON.side_2_inlet)
def test_boiler_hx():
m = ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.properties = PhysicalParameterTestBlock()
m.fs.prop_steam = iapws95.Iapws95ParameterBlock()
m.fs.prop_fluegas = FlueGasParameterBlock()
m.fs.unit = BoilerHeatExchanger(
default={
"side_1_property_package": m.fs.prop_steam,
"side_2_property_package": m.fs.prop_fluegas,
"has_pressure_change": True,
"has_holdup": False,
"delta_T_method": DeltaTMethod.counterCurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Liq",
"has_radiation": True
})
# Set inputs
h = iapws95.htpx(773.15, 2.5449e7)
print(h)
m.fs.unit.side_1_inlet.flow_mol[0].fix(24678.26) # mol/s
m.fs.unit.side_1_inlet.enth_mol[0].fix(h) # J/mol
m.fs.unit.side_1_inlet.pressure[0].fix(2.5449e7) # Pascals
# FLUE GAS Inlet from Primary Superheater
FGrate = 28.3876e3 * 0.18 # mol/s equivalent of ~1930.08 klb/hr
# Use FG molar composition to set component flow rates (baseline report)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "H2O"].fix(FGrate * 8.69 / 100)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "CO2"].fix(FGrate * 14.49 / 100)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "N2"].fix(FGrate * 74.34 / 100)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "O2"].fix(FGrate * 2.47 / 100)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "NO"].fix(FGrate * 0.0006)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "SO2"].fix(FGrate * 0.002)
m.fs.unit.side_2_inlet.temperature[0].fix(1102.335)
m.fs.unit.side_2_inlet.pressure[0].fix(100145)
# Primary Superheater
ITM = 0.0254 # inch to meter conversion
m.fs.unit.tube_di.fix((2.5 - 2 * 0.165) * ITM)
m.fs.unit.tube_thickness.fix(0.165 * ITM)
m.fs.unit.pitch_x.fix(3 * ITM)
# gas path transverse width 54.78 ft / number of columns
m.fs.unit.pitch_y.fix(54.78 / 108 * 12 * ITM)
m.fs.unit.tube_length.fix(53.13 * 12 * ITM)
m.fs.unit.tube_nrow.fix(20 * 2)
m.fs.unit.tube_ncol.fix(108)
m.fs.unit.nrow_inlet.fix(4)
m.fs.unit.delta_elevation.fix(50)
m.fs.unit.tube_r_fouling = 0.000176 # (0.001 h-ft^2-F/BTU)
m.fs.unit.tube_r_fouling = 0.003131 # (0.03131 - 0.1779 h-ft^2-F/BTU)
if m.fs.unit.config.has_radiation is True:
m.fs.unit.emissivity_wall.fix(0.7) # wall emissivity
# correction factor for overall heat transfer coefficient
m.fs.unit.fcorrection_htc.fix(1.5)
# correction factor for pressure drop calc tube side
m.fs.unit.fcorrection_dp_tube.fix(1.0)
# correction factor for pressure drop calc shell side
m.fs.unit.fcorrection_dp_shell.fix(1.0)
assert degrees_of_freedom(m) == 0
m.fs.unit.initialize()
# Create a solver
solver = SolverFactory('ipopt')
results = solver.solve(m)
# Check for optimal solution
assert results.solver.termination_condition == \
TerminationCondition.optimal
assert results.solver.status == SolverStatus.ok
assert value(m.fs.unit.side_1.properties_out[0].temperature) == \
pytest.approx(588.07, 1)
assert value(m.fs.unit.side_2.properties_out[0].temperature) == \
pytest.approx(573.07, 1)
def th(
delta_temperature_callback=delta_temperature_underwood_tune_callback,
tout_1=809.55,
tout_2=788.53,
):
m = ConcreteModel()
m.fs = FlowsheetBlock(default={"dynamic": False})
m.fs.properties = PhysicalParameterTestBlock()
m.fs.prop_steam = iapws95.Iapws95ParameterBlock()
m.fs.prop_fluegas = FlueGasParameterBlock()
m.fs.unit = BoilerHeatExchanger(
default={
"delta_temperature_callback": delta_temperature_callback,
"tube": {
"property_package": m.fs.prop_steam
},
"shell": {
"property_package": m.fs.prop_fluegas
},
"has_pressure_change": True,
"has_holdup": False,
"flow_pattern": HeatExchangerFlowPattern.countercurrent,
"tube_arrangement": TubeArrangement.inLine,
"side_1_water_phase": "Liq",
"has_radiation": True,
})
# Set inputs
h = value(iapws95.htpx(773.15 * pyunits.K, 2.5449e7 * pyunits.Pa))
m.fs.unit.side_1_inlet.flow_mol[0].fix(24678.26) # mol/s
m.fs.unit.side_1_inlet.enth_mol[0].fix(h) # J/mol
m.fs.unit.side_1_inlet.pressure[0].fix(2.5449e7) # Pascals
# FLUE GAS Inlet from Primary Superheater
FGrate = 28.3876e3 * 0.18 # mol/s equivalent of ~1930.08 klb/hr
# Use FG molar composition to set component flow rates (baseline report)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "H2O"].fix(FGrate * 8.69 / 100)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "CO2"].fix(FGrate * 14.49 / 100)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "N2"].fix(FGrate * 74.34 / 100)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "O2"].fix(FGrate * 2.47 / 100)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "NO"].fix(FGrate * 0.0006)
m.fs.unit.side_2_inlet.flow_mol_comp[0, "SO2"].fix(FGrate * 0.002)
m.fs.unit.side_2_inlet.temperature[0].fix(1102.335)
m.fs.unit.side_2_inlet.pressure[0].fix(100145)
# Primary Superheater
ITM = 0.0254 # inch to meter conversion
m.fs.unit.tube_di.fix((2.5 - 2 * 0.165) * ITM)
m.fs.unit.tube_thickness.fix(0.165 * ITM)
m.fs.unit.pitch_x.fix(3 * ITM)
# gas path transverse width 54.78 ft / number of columns
m.fs.unit.pitch_y.fix(54.78 / 108 * 12 * ITM)
m.fs.unit.tube_length.fix(53.13 * 12 * ITM)
m.fs.unit.tube_nrow.fix(20 * 2)
m.fs.unit.tube_ncol.fix(108)
m.fs.unit.nrow_inlet.fix(4)
m.fs.unit.delta_elevation.fix(50)
m.fs.unit.tube_r_fouling = 0.000176 # (0.001 h-ft^2-F/BTU)
m.fs.unit.tube_r_fouling = 0.003131 # (0.03131 - 0.1779 h-ft^2-F/BTU)
if m.fs.unit.config.has_radiation is True:
m.fs.unit.emissivity_wall.fix(0.7) # wall emissivity
# correction factor for overall heat transfer coefficient
m.fs.unit.fcorrection_htc.fix(1.5)
# correction factor for pressure drop calc tube side
m.fs.unit.fcorrection_dp_tube.fix(1.0)
# correction factor for pressure drop calc shell side
m.fs.unit.fcorrection_dp_shell.fix(1.0)
assert degrees_of_freedom(m) == 0
iscale.calculate_scaling_factors(m)
m.fs.unit.initialize()
results = solver.solve(m)
# Check for optimal solution
assert check_optimal_termination(results)
assert value(
m.fs.unit.side_1.properties_out[0].temperature) == pytest.approx(
tout_1, abs=0.5)
assert value(
m.fs.unit.side_2.properties_out[0].temperature) == pytest.approx(
tout_2, abs=0.5)
def get_model(dynamic=True, load_state=None, save_state=None, time_set=None, nstep=None):
if load_state is not None and not os.path.exists(load_state):
# Want to load state but file doesn't exist, so warn and reinitialize
_log.warning(f"Warning cannot load saved state {load_state}")
load_state = None
m = pyo.ConcreteModel()
m.dynamic = dynamic
m.init_dyn = False
if time_set is None:
time_set = [0,20,200]
if nstep is None:
nstep = 5
if m.dynamic:
m.fs_main = FlowsheetBlock(default={"dynamic": True, "time_set": time_set})
else:
m.fs_main = FlowsheetBlock(default={"dynamic": False})
# Add property packages to flowsheet library
m.fs_main.prop_water = iapws95.Iapws95ParameterBlock()
m.fs_main.prop_gas = FlueGasParameterBlock()
m.fs_main.fs_blr = FlowsheetBlock()
m.fs_main.fs_stc = FlowsheetBlock()
m = blr.add_unit_models(m)
m = stc.add_unit_models(m)
if m.dynamic:
# extra variables required by controllers
# master level control output, desired feed water flow rate at bfp outlet
m.fs_main.flow_level_ctrl_output = pyo.Var(
m.fs_main.config.time,
initialize=10000,
doc="mole flow rate of feed water demand from drum level master controller"
)
# boiler master pv main steam pressure in MPa
m.fs_main.main_steam_pressure = pyo.Var(
m.fs_main.config.time,
initialize=13,
doc="main steam pressure in MPa for boiler master controller"
)
# PID controllers
# master of cascading level controller
m.fs_main.drum_master_ctrl = PIDController(default={"pv":m.fs_main.fs_blr.aDrum.level,
"mv":m.fs_main.flow_level_ctrl_output,
"type": 'PI'})
# slave of cascading level controller
m.fs_main.drum_slave_ctrl = PIDController(default={"pv":m.fs_main.fs_stc.bfp.outlet.flow_mol,
"mv":m.fs_main.fs_stc.bfp_turb_valve.valve_opening,
"type": 'PI',
"bounded_output": False})
# turbine master PID controller to control power output in MW by manipulating throttling valve
m.fs_main.turbine_master_ctrl = PIDController(default={"pv":m.fs_main.fs_stc.power_output,
"mv":m.fs_main.fs_stc.turb.throttle_valve[1].valve_opening,
"type": 'PI'})
# boiler master PID controller to control main steam pressure in MPa by manipulating coal feed rate
m.fs_main.boiler_master_ctrl = PIDController(default={"pv":m.fs_main.main_steam_pressure,
"mv":m.fs_main.fs_blr.aBoiler.flowrate_coal_raw,
"type": 'PI'})
m.discretizer = pyo.TransformationFactory('dae.finite_difference')
m.discretizer.apply_to(m,
nfe=nstep,
wrt=m.fs_main.config.time,
scheme="BACKWARD")
# desired sliding pressure in MPa as a function of power demand in MW
@m.fs_main.Expression(m.fs_main.config.time, doc="Sliding pressure as a function of power output")
def sliding_pressure(b, t):
return 12.511952+(12.511952-9.396)/(249.234-96.8)*(b.turbine_master_ctrl.setpoint[t]-249.234)
# main steam pressure in MPa
@m.fs_main.Constraint(m.fs_main.config.time, doc="main steam pressure in MPa")
def main_steam_pressure_eqn(b, t):
return b.main_steam_pressure[t] == 1e-6*b.fs_blr.aPlaten.outlet.pressure[t]
# Constraint for setpoint of the slave controller of the three-element drum level controller
@m.fs_main.Constraint(m.fs_main.config.time, doc="Set point of drum level slave control")
def drum_level_control_setpoint_eqn(b, t):
return b.drum_slave_ctrl.setpoint[t] == b.flow_level_ctrl_output[t] + \
b.fs_blr.aPlaten.outlet.flow_mol[t] + \
b.fs_blr.blowdown_split.FW_Blowdown.flow_mol[t] #revised to add steam flow only
# Constraint for setpoint of boiler master
@m.fs_main.Constraint(m.fs_main.config.time, doc="Set point of boiler master")
def boiler_master_setpoint_eqn(b, t):
return b.boiler_master_ctrl.setpoint[t] == 0.02*(b.turbine_master_ctrl.setpoint[t] - b.fs_stc.power_output[t]) + b.sliding_pressure[t]
# Constraint for setpoint of boiler master
@m.fs_main.Constraint(m.fs_main.config.time, doc="dry O2 in flue gas in dynamic mode")
def dry_o2_in_flue_gas_dyn_eqn(b, t):
return b.fs_blr.aBoiler.fluegas_o2_pct_dry[t] == 0.05*(b.fs_stc.spray_ctrl.setpoint[t] - b.fs_stc.temperature_main_steam[t]) - \
0.0007652*b.fs_blr.aBoiler.flowrate_coal_raw[t]**3 + \
0.06744*b.fs_blr.aBoiler.flowrate_coal_raw[t]**2 - 1.9815*b.fs_blr.aBoiler.flowrate_coal_raw[t] + 22.275
# controller inputs
# for master level controller
m.fs_main.drum_master_ctrl.gain_p.fix(40000) #increased from 5000
m.fs_main.drum_master_ctrl.gain_i.fix(100)
m.fs_main.drum_master_ctrl.setpoint.fix(0.889)
m.fs_main.drum_master_ctrl.mv_ref.fix(0) #revised to 0
# for slave level controller, note the setpoint is defined by the constraint
m.fs_main.drum_slave_ctrl.gain_p.fix(2e-2) # increased from 1e-2
m.fs_main.drum_slave_ctrl.gain_i.fix(2e-4) # increased from 1e-4
m.fs_main.drum_slave_ctrl.mv_ref.fix(0.5)
# for turbine master controller, note the setpoint is the power demand
m.fs_main.turbine_master_ctrl.gain_p.fix(5e-4) #changed from 2e-3
m.fs_main.turbine_master_ctrl.gain_i.fix(5e-4) #changed from 2e-3
m.fs_main.turbine_master_ctrl.mv_ref.fix(0.6)
# for boiler master controller, note the setpoint is specified by the constraint
m.fs_main.boiler_master_ctrl.gain_p.fix(10)
m.fs_main.boiler_master_ctrl.gain_i.fix(0.25)
m.fs_main.boiler_master_ctrl.mv_ref.fix(29.0)
t0 = m.fs_main.config.time.first()
m.fs_main.drum_master_ctrl.integral_of_error[t0].fix(0)
m.fs_main.drum_slave_ctrl.integral_of_error[t0].fix(0)
m.fs_main.turbine_master_ctrl.integral_of_error[t0].fix(0)
m.fs_main.boiler_master_ctrl.integral_of_error[t0].fix(0)
blr.set_arcs_and_constraints(m)
blr.set_inputs(m)
stc.set_arcs_and_constraints(m)
stc.set_inputs(m)
# Now that the mole is discreteized set and calculate scaling factors
set_scaling_factors(m)
add_overall_performance_expressions(m)
# Add performance measures
if load_state is None:
blr.initialize(m)
stc.initialize(m)
optarg={"tol":5e-7,"linear_solver":"ma27","max_iter":50}
solver = pyo.SolverFactory("ipopt")
solver.options = optarg
_log.info("Bring models closer together...")
m.fs_main.fs_blr.flow_mol_steam_rh_eqn.deactivate()
# Hook the boiler to the steam cycle.
m.fs_main.S001 = Arc(
source=m.fs_main.fs_blr.aPlaten.outlet, destination=m.fs_main.fs_stc.turb.inlet_split.inlet
)
m.fs_main.S005 = Arc(
source=m.fs_main.fs_stc.turb.hp_split[14].outlet_1, destination=m.fs_main.fs_blr.aRH1.tube_inlet
)
m.fs_main.S009 = Arc(
source=m.fs_main.fs_blr.aRH2.tube_outlet, destination=m.fs_main.fs_stc.turb.ip_stages[1].inlet
)
m.fs_main.S042 = Arc(
source=m.fs_main.fs_stc.fwh6.desuperheat.outlet_2, destination=m.fs_main.fs_blr.aECON.tube_inlet
)
m.fs_main.B006 = Arc(
source=m.fs_main.fs_stc.spray_valve.outlet, destination=m.fs_main.fs_blr.Attemp.Water_inlet
)
pyo.TransformationFactory('network.expand_arcs').apply_to(m.fs_main)
# unfix all connected streams
m.fs_main.fs_stc.turb.inlet_split.inlet.unfix()
m.fs_main.fs_stc.turb.hp_split[14].outlet_1.unfix()
m.fs_main.fs_blr.aRH1.tube_inlet.unfix()
m.fs_main.fs_stc.turb.ip_stages[1].inlet.unfix()
m.fs_main.fs_blr.aECON.tube_inlet.unfix()
m.fs_main.fs_blr.Attemp.Water_inlet.unfix()
m.fs_main.fs_stc.spray_valve.outlet.unfix() #outlet pressure fixed on steam cycle sub-flowsheet
# deactivate constraints on steam cycle flowsheet
m.fs_main.fs_stc.fw_flow_constraint.deactivate()
m.fs_main.fs_stc.turb.constraint_reheat_flow.deactivate()
m.fs_main.fs_blr.aBoiler.flowrate_coal_raw.unfix() # steam circulation and coal flow are linked
if m.dynamic==False:
if load_state is None:
m.fs_main.fs_stc.spray_valve.valve_opening.unfix()
m.fs_main.fs_stc.temperature_main_steam.fix(810)
_log.info("Solve connected models...")
print("Degrees of freedom = {}".format(degrees_of_freedom(m)))
assert degrees_of_freedom(m) == 0
res = solver.solve(m, tee=True)
_log.info("Solved: {}".format(idaeslog.condition(res)))
# increase load to around 250 MW
_log.info("Increase coal feed rate to 32.5...")
m.fs_main.fs_stc.bfp.outlet.pressure.unfix()
m.fs_main.fs_stc.turb.throttle_valve[1].valve_opening.fix(0.9)
m.fs_main.fs_blr.aBoiler.flowrate_coal_raw.fix(32.5)
res = solver.solve(m, tee=True)
if not load_state is None:
# the fwh heat transfer coefficient correlations are added in the
# initialization, so if we are skipping the init, we have to add
# them here.
stc._add_heat_transfer_correlation(m.fs_main.fs_stc)
ms.from_json(m, fname=load_state)
if save_state is not None:
ms.to_json(m, fname=save_state)
else:
m.fs_main.fs_blr.dry_o2_in_flue_gas_eqn.deactivate()
t0 = m.fs_main.config.time.first()
m.fs_main.fs_stc.fwh2.condense.level[t0].fix()
m.fs_main.fs_stc.fwh3.condense.level[t0].fix()
m.fs_main.fs_stc.fwh5.condense.level[t0].fix()
m.fs_main.fs_stc.fwh6.condense.level[t0].fix()
m.fs_main.fs_stc.hotwell_tank.level[t0].fix()
m.fs_main.fs_stc.da_tank.level[t0].fix()
m.fs_main.fs_stc.temperature_main_steam[t0].unfix()
m.fs_main.fs_stc.spray_valve.valve_opening[t0].fix()
m.fs_main.fs_blr.aDrum.level.unfix()
m.fs_main.fs_blr.aDrum.level[t0].fix()
m.fs_main.flow_level_ctrl_output.unfix()
m.fs_main.flow_level_ctrl_output[t0].fix()
m.fs_main.fs_stc.bfp.outlet.pressure.unfix()
m.fs_main.fs_blr.aBoiler.flowrate_coal_raw.unfix()
m.fs_main.fs_blr.aBoiler.flowrate_coal_raw[t0].fix()
m.fs_main.fs_stc.turb.throttle_valve[1].valve_opening.unfix()
m.fs_main.fs_stc.turb.throttle_valve[1].valve_opening[t0].fix()
m.fs_main.turbine_master_ctrl.setpoint.fix()
return m