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BUILDING OPERATION WINDOWS.<br />

AN EFFECTIVE TOOL FOR IMPROVING GASIFIER<br />

OPERATION IN IGCC POWER PLANTS<br />

Sergio Usón * , Antonio Valero <strong>an</strong>d Víctor R<strong>an</strong>gel (TDG Group + )<br />

Centre <strong>for</strong> Research of Energy Resources <strong>an</strong>d Consumptions (CIRCE)<br />

University of Zaragoza<br />

María de Luna 3, 50018 Zaragoza<br />

Spain<br />

ABSTRACT<br />

IGCC technology has demonstrated its feasibility but efficiency <strong>an</strong>d reliability c<strong>an</strong> be improved.<br />

So that, <strong>an</strong> <strong>operation</strong> window is presented as a <strong>tool</strong> <strong>for</strong> optimising gasifier <strong>operation</strong>.<br />

Two models of entrained flow gasifiers (one simple <strong>an</strong>d the other more complex) are validated<br />

with a large set of actual pl<strong>an</strong>t <strong>operation</strong> periods. The two models are used to build <strong>operation</strong><br />

<strong>windows</strong>, which are graphs where the main gasification parameters are related to the degrees of<br />

freedom that the operator has. Comparison of the two <strong>windows</strong> allows to see limitations of the<br />

simple model <strong>an</strong>d to underst<strong>an</strong>d the gasifier <strong>operation</strong>.<br />

A general method <strong>for</strong> <strong>building</strong> experimental <strong>operation</strong> <strong>windows</strong> only from pl<strong>an</strong>t data has been<br />

developed. When the method is applied to the gasifier, tendencies of the <strong>windows</strong> are the same of<br />

those of the model-made <strong>windows</strong>.<br />

In conclusion, <strong>operation</strong> <strong>windows</strong> are practical <strong>tool</strong>s that help to operate <strong>an</strong>d diagnose a system<br />

(e.g. a gasifier). They allow to underst<strong>an</strong>d how it works, to optimise its <strong>operation</strong> <strong>an</strong>d to avoid<br />

wrong <strong>operation</strong> that may cause pl<strong>an</strong>t shut off.<br />

Keywords: Gasification, IGCC, Operation, Optimisation<br />

NOMENCLATURE<br />

C Carbon content in fuel<br />

CGE Cold gas efficiency [%]<br />

d Dist<strong>an</strong>ce<br />

daf Dry <strong>an</strong>d ash free<br />

i Real <strong>operation</strong> point<br />

j Point in a iso-line<br />

k Point in four-point group<br />

LHV Low heating value [kJ/kg]<br />

max Maximum<br />

min Minimum<br />

p Parameter<br />

rel Relative<br />

x Independent variable<br />

y Independent variable<br />

z Dependent variable<br />

* Corresponding author: Phone: +34 976 76 25 82 Fax: +34 976 73 20 78 E-mail: suson@unizar.es<br />

+ Thermoeconomic Diagnosis Group.<br />

0 Coordenate of point in a iso-line<br />

δ Increment<br />

INTRODUCTION<br />

Coal gasification is <strong>an</strong> efficient <strong>an</strong>d<br />

environmentally friendly way to use coal not only<br />

to generate electricity in Integrated Gasification<br />

Combined Cycle (IGCC) power pl<strong>an</strong>ts, but also to<br />

produce hydrogen <strong>an</strong>d syngas <strong>for</strong> the chemical<br />

industry [1-5]. However, right <strong>operation</strong> of a<br />

gasifier is very complex <strong>for</strong> two reasons.<br />

First, actual operating conditions usually differ<br />

from design conditions because experience in<br />

gasifiers <strong>operation</strong> is very small compared to<br />

expertise on conventional equipment such as


oilers. Besides, design fuel is sometimes modified<br />

by adding coke, biomass... So that, gasifier<br />

working should be revised by using experience.<br />

Second, proper gasifier <strong>operation</strong> is more critical<br />

th<strong>an</strong> boiler <strong>operation</strong>, because it does not consist in<br />

just maximising efficiency but other issues, that in<br />

turn requires keeping several output variables (gas<br />

composition <strong>an</strong>d gasification temperature) in<br />

correct r<strong>an</strong>ges <strong>an</strong>d maximising fuel/gas conversion<br />

by adjusting two input variables (oxygen <strong>an</strong>d<br />

steam that are introduced in the gasifier).<br />

Gasification temperature is a variable that c<strong>an</strong>not<br />

be measured but has to be kept in a right r<strong>an</strong>ge<br />

because it determines not only efficiency but also<br />

safe <strong>operation</strong>. In oxygen-blown slagging gasifiers<br />

<strong>an</strong> error in oxygen measurement could cause either<br />

very high temperatures that c<strong>an</strong> damage the<br />

equipment or temperatures under slagging point<br />

that c<strong>an</strong> stop slag flow <strong>an</strong>d blocking. Besides,<br />

although output variables could be considered<br />

separately, a modification in <strong>an</strong> input variable<br />

implies ch<strong>an</strong>ges in all output variables, so that all<br />

dependencies should be understood <strong>an</strong>d integrated.<br />

In conclusion, to operate the gasifier it is necessary<br />

to use criteria corresponding to the gasifier<br />

working not only in tendencies but also in absolute<br />

values.<br />

Elcogas IGCC Power Pl<strong>an</strong>t in Puertoll<strong>an</strong>o (Spain)<br />

is a demonstration project where several Europe<strong>an</strong><br />

comp<strong>an</strong>ies work together. CIRCE has collaborated<br />

with Elcogas <strong>for</strong> several years in <strong>operation</strong> pl<strong>an</strong>t<br />

optimisation <strong>an</strong>d diagnosis. The main achievement<br />

of CIRCE work is the development of the TDG<br />

system [6,7]. TDG is <strong>an</strong> acronym of<br />

Thermoeconomic Diagnosis, which consists in<br />

comparing two pl<strong>an</strong>t real stable <strong>operation</strong> periods,<br />

determining the causes why efficiency varies <strong>an</strong>d<br />

qu<strong>an</strong>tifying the influence of each cause in<br />

efficiency deviation. This in<strong>for</strong>mation allows to<br />

optimise the pl<strong>an</strong>t by comparing the influence of<br />

malfunctions in pl<strong>an</strong>t efficiency to the cost of<br />

solving these malfunctions.<br />

A gasifier is not isolated; not only gas production<br />

have <strong>an</strong> influence on the gas cle<strong>an</strong>ing section <strong>an</strong>d<br />

on the combined cycle but also the combined cycle<br />

<strong>an</strong>d the air separation unit influence the gasifier<br />

<strong>operation</strong>. TDG takes these interactions into<br />

account but the relationship between gasifier<br />

<strong>operation</strong> <strong>an</strong>d gasifier working should be deeply<br />

investigated.<br />

The aim of this work is to tr<strong>an</strong>s<strong>for</strong>m a hard subject<br />

that comprise several related variables into<br />

something that c<strong>an</strong> be used <strong>an</strong>d applied by<br />

operators <strong>an</strong>d that could be implemented in the<br />

pl<strong>an</strong>t control system. Operators need a practical<br />

<strong>tool</strong> which help them to adjust gasifier <strong>operation</strong> in<br />

few minutes (perhaps seconds), taking into account<br />

several variables at the same time; so that, a<br />

graphic <strong>tool</strong> is proposed.<br />

The concept of <strong>operation</strong> window is applied to a<br />

two dimensional graph which axes corresponds to<br />

the input variables (oxygen/fuel ratio in x <strong>an</strong>d<br />

steam/fuel ratio in y) where the main output<br />

variables evolution (temperature, efficiency <strong>an</strong>d<br />

concentration of the main components of the gas)<br />

is plotted by using const<strong>an</strong>t value lines.<br />

Maximum <strong>an</strong>d minimum values of the output<br />

variables determine the region or the window<br />

where the gasifier should be operated. Since there<br />

are two degrees of freedom, there are several ways<br />

to modify the value of <strong>an</strong> output variable <strong>an</strong>d the<br />

choice of the best one depends of the other output<br />

variables. So that, a graph which shows all<br />

import<strong>an</strong>t variables is very useful to operate the<br />

gasifier in a safe <strong>an</strong>d efficient way.<br />

In this paper, two models are validated with a large<br />

set of pl<strong>an</strong>t data <strong>an</strong>d used to build <strong>operation</strong><br />

<strong>windows</strong>. These <strong>windows</strong> c<strong>an</strong> be very useful to<br />

explore new <strong>operation</strong> zones. However, to <strong>an</strong>alyse<br />

<strong>an</strong>d improve actual <strong>operation</strong> it is better to take<br />

adv<strong>an</strong>tage of expertise by <strong>building</strong> <strong>operation</strong><br />

<strong>windows</strong> from pl<strong>an</strong>t data without a model <strong>an</strong>d to<br />

use model-built <strong>windows</strong> as reference to provide<br />

theoretical support. Since, un<strong>for</strong>tunately, there<br />

were no methodologies to build <strong>operation</strong> <strong>windows</strong><br />

from pl<strong>an</strong>t data, a new general method has been<br />

developed <strong>an</strong>d applied to the case of study.<br />

As a result, <strong>windows</strong> built by using a large amount<br />

of pl<strong>an</strong>t data <strong>an</strong>d supported by theoretical models<br />

are obtained. These <strong>windows</strong> are very useful not<br />

only to improve future <strong>operation</strong> but also to<br />

<strong>an</strong>alyse past <strong>operation</strong>, which is also a type of<br />

diagnosis because it allows comparing differences<br />

in gas composition <strong>an</strong>d gasification temperature<br />

<strong>an</strong>d efficiency of several <strong>operation</strong> strategies.<br />

Results show that, depending on <strong>operation</strong> mode,<br />

gasifier efficiency may vary 3 percent, which<br />

me<strong>an</strong>s about 5 MWe.<br />

CHOICE OF THE SUPPORTING GASIFIER<br />

MODEL<br />

The PRENFLO (Pressurized ENtrained FLOw)<br />

gasifier is fed with fuel (a mixture of coal <strong>an</strong>d<br />

petroleum coke), oxygen, steam <strong>an</strong>d nitrogen,<br />

which react at a high temperature becoming a


combustible gas (synthesis gas). This kind of<br />

gasifier achieves very high carbon conversion in a<br />

short reaction time. When the gas leaves the<br />

reaction chamber, it is quickly cooled by a flow of<br />

cold gas in order to lock gas phase equilibrium <strong>an</strong>d<br />

solidify the ash carried by the gas (most of ash<br />

leaves the gasifier as slag that flows to the bottom).<br />

Then, the gas is further cooled to get the right<br />

temperature to be cle<strong>an</strong>ed. Sensible heat of the gas<br />

is used to generate steam, which is exported to the<br />

steam cycle.<br />

Boiling<br />

Water<br />

1<br />

Pirolisis <strong>an</strong>d volatiles<br />

combustion<br />

T ~ 2000ºC<br />

Raw Gas + Fly Ash<br />

Slag<br />

1750 ºC<br />

25 bar<br />

Figure 1: Reaction chamber<br />

Since the amount of fuel is determined by the gas<br />

dem<strong>an</strong>d of the turbine <strong>an</strong>d nitrogen is mainly used<br />

to carry the fuel, the only degrees of freedom that<br />

the operator has to control gasification reactions<br />

are the amounts of oxygen <strong>an</strong>d steam. These flows<br />

are controlled by the oxygen/fuel <strong>an</strong>d steam/fuel<br />

ratios.<br />

Two models of the reaction chamber were<br />

available. The first one (const<strong>an</strong>t fuel conversion)<br />

is proposed by V<strong>an</strong> der Burgt [8,9] <strong>an</strong>d was used to<br />

the fine-tuning of the control system during<br />

commisioning. This model considers const<strong>an</strong>t fuel<br />

conversion ratio, so that it avoids gasification<br />

process simulation <strong>an</strong>d only takes into account<br />

matter <strong>an</strong>d energy bal<strong>an</strong>ces <strong>an</strong>d gas phase<br />

equilibrium.<br />

The second one (variable fuel conversion) was<br />

proposed by Martínez [10] to be used as the offdesign<br />

simulator of the gasifier in the TDG system.<br />

It divides gasification process into several stages,<br />

studies gas-particle interaction <strong>an</strong>d simulates gas<br />

phase equilibrium. So that, this complex model<br />

takes into account fuel conversion variation due to<br />

gasification conditions modifications.<br />

To adjust the two models, in<strong>for</strong>mation provided by<br />

the TDG System is used [6,7]. This system<br />

connects to the pl<strong>an</strong>t in<strong>for</strong>mation system <strong>an</strong>d<br />

4<br />

3<br />

Burner<br />

2<br />

Meth<strong>an</strong>e <strong>for</strong>mation<br />

Gasification<br />

Burners<br />

N2<br />

O2 + H2O Secondary<br />

Fuel<br />

O2 + H2O Primary<br />

Flame detector<br />

Formation <strong>an</strong>d<br />

combustion of part of<br />

the char.<br />

identifies stable working periods. For each period,<br />

TDG stores <strong>an</strong>d validates in<strong>for</strong>mation <strong>an</strong>d, by<br />

using data reconciliation <strong>an</strong>d closing energy <strong>an</strong>d<br />

matter bal<strong>an</strong>ces, determines the thermodynamic<br />

state of the pl<strong>an</strong>t.<br />

The in<strong>for</strong>mation of 2,874 real <strong>operation</strong> periods<br />

(which me<strong>an</strong>s 4,812 hours) filtered <strong>an</strong>d processed<br />

by this system is used to tune the models: in the<br />

model proposed by V<strong>an</strong> der Burgt the fuel<br />

conversion ratio is adjusted <strong>an</strong>d in the Martínez<br />

model the values of this ratio are used to adjust the<br />

particle residence time.<br />

To validate the models, relative average<br />

experimental discrep<strong>an</strong>cy (taking into account this<br />

historical data) is calculated <strong>for</strong> gasification<br />

temperature, main gas composition <strong>an</strong>d CGE (Cold<br />

Gas Efficiency, or a ratio between chemical energy<br />

of the gas <strong>an</strong>d chemical energy of the fuel). Results<br />

are shown in Table 1.<br />

Const<strong>an</strong>t fuel Variable fuel<br />

conversion conversion<br />

Temperature 2.1% 2.4%<br />

CGE 0.26% 0.8%<br />

CO 0.20% 0.56%<br />

H2 0.62% 0.43%<br />

CO2 1.6% 4.9%<br />

H2O 1.9% 5.3%<br />

H2S 7.7% 7.9%<br />

COS 8.25% 8.5%<br />

Table 1: Relative average errors of the two models.<br />

As c<strong>an</strong> be seen, errors of CGE <strong>an</strong>d the most<br />

abund<strong>an</strong>t species (CO, H2) are very small.<br />

However, relative errors increase <strong>for</strong> the less<br />

concentrated species. One remarkable result is that<br />

errors of the const<strong>an</strong>t conversion ratio model in<br />

CGE, CO2 <strong>an</strong>d H2O are lower th<strong>an</strong> errors of the<br />

variable conversion ratio model. This is due to the<br />

limitations of working with actual pl<strong>an</strong>t data.<br />

These difficulties increase when a more complex<br />

model is used. However, errors of both models are<br />

low <strong>an</strong>d differences will be seen in next section by<br />

comparing simulations in a zone wider th<strong>an</strong> usual<br />

<strong>operation</strong> region.<br />

MODEL-BUILT OPERATION WINDOWS<br />

Once the models have been presented <strong>an</strong>d<br />

validated, they are used to build reference<br />

<strong>operation</strong> <strong>windows</strong>. In Figure 2, <strong>an</strong> <strong>operation</strong><br />

window built from the const<strong>an</strong>t conversion model


is shown. This window has been plotted by using<br />

in<strong>for</strong>mation from a real <strong>operation</strong> period <strong>an</strong>d by<br />

modifying oxygen <strong>an</strong>d steam ratios. As c<strong>an</strong> be<br />

seen, when oxygen or steam increases, CO2<br />

increases <strong>an</strong>d CO decreases. When oxygen<br />

increases or steam decreases, temperature increases<br />

<strong>an</strong>d H2 decreases. Finally, CGE decreases when<br />

oxygen increases <strong>an</strong>d decreases slightly if steam<br />

increases.<br />

Steam ratio (kg steam/kg fuel daf)<br />

Operation window. Const<strong>an</strong>t conversion model.<br />

0,18<br />

CGE = 74%<br />

CGE = 75%<br />

CGE = 76%<br />

CGE = 77%<br />

0,16<br />

CGE = 78%<br />

T = 1600 ºC<br />

T = 1700 ºC<br />

T = 1800 ºC<br />

0,14<br />

T = 1900 ºC<br />

58% CO<br />

60% CO<br />

0,12<br />

62% CO<br />

64% CO<br />

20% H2<br />

21% H2<br />

0,1<br />

22% H2<br />

23% H2<br />

1% CO2<br />

0,08<br />

0,69 0,71 0,73 0,75<br />

2% CO2<br />

3% CO2<br />

4%CO2<br />

Oxygen ratio (Nm3 pure O2/kg fuel daf)<br />

5% CO2<br />

Figure 2: Const<strong>an</strong>t conversion <strong>operation</strong> window.<br />

In Figure 3, <strong>an</strong> equivalent <strong>operation</strong> window using<br />

the variable conversion model is shown. In this<br />

model, when temperature decreases, fuel<br />

conversion decreases. As a result, CGE reaches a<br />

maximum <strong>an</strong>d, as long as oxygen decreases fuel<br />

conversion decreases, CO <strong>an</strong>d CO2 variations are<br />

lower. As c<strong>an</strong> be seen, when oxygen ratio is high<br />

<strong>an</strong>d conversion increases to 100 percent (right side<br />

of the window) the const<strong>an</strong>t conversion window<br />

becomes similar to variable conversion window<br />

but values are displaced. This displacement is due<br />

to that fuel conversion in const<strong>an</strong>t conversion<br />

model has been adjusted to 98.5 percent.<br />

Steam ratio (kg steam/kg fuel daf)<br />

0,18<br />

0,16<br />

0,14<br />

0,12<br />

0,1<br />

Operation window. Variable conversion model.<br />

0,08<br />

0,69 0,71 0,73 0,75<br />

Oxygen ratio (Nm3 pure O2/kg fuel daf)<br />

CGE = 75,5%<br />

CGE = 76%<br />

CGE = 76,5%<br />

CGE = 77%<br />

CGE = 77,5%<br />

T = 1700 ºC<br />

T = 1800 ºC<br />

T = 1900 ºC<br />

58% CO<br />

60% CO<br />

62% CO<br />

20% H2<br />

21% H2<br />

22% H2<br />

23% H2<br />

2% CO2<br />

3% CO2<br />

4%CO2<br />

5% CO2<br />

Figure 3: Variable conversion <strong>operation</strong> window.<br />

The <strong>windows</strong> built by using two models c<strong>an</strong> help<br />

to compare the models: although both c<strong>an</strong> fit pl<strong>an</strong>t<br />

data quite accurately, when the <strong>operation</strong> zone is<br />

exp<strong>an</strong>ded they show differences. Besides, they are<br />

<strong>an</strong> example of how <strong>operation</strong> <strong>windows</strong> c<strong>an</strong> be very<br />

useful to plot in<strong>for</strong>mation in order to underst<strong>an</strong>d<br />

the gasifier working <strong>an</strong>d to optimise its <strong>operation</strong>.<br />

The const<strong>an</strong>t conversion model was very useful to<br />

tune the control system in a small <strong>operation</strong> zone<br />

but it does not provide good results when this zone<br />

is exp<strong>an</strong>ded. To do so, a variable conversion model<br />

should be used. However, it might be difficult to<br />

tune this complex model with pl<strong>an</strong>t data<br />

corresponding to a reduced <strong>operation</strong> zone, as<br />

could be seen when both models were validated. In<br />

conclusion, it is better to build pl<strong>an</strong>t <strong>operation</strong><br />

<strong>windows</strong> directly from pl<strong>an</strong>t data <strong>an</strong>d to use the<br />

models to give theoretical support to the pl<strong>an</strong>t<br />

results. So that, a new method to build <strong>operation</strong><br />

<strong>windows</strong> from pl<strong>an</strong>t data is presented <strong>an</strong>d applied.<br />

METHODOLOGY FOR BUILDING<br />

OPERATION WINDOWS FROM PLANT<br />

DATA<br />

A method to get a family of points that<br />

corresponds to <strong>an</strong> iso-line (line of const<strong>an</strong>t value of<br />

a dependent variable) in a window (const<strong>an</strong>t value<br />

of a parameter) is explained. This process c<strong>an</strong> be<br />

repeated <strong>for</strong> the other iso-lines, <strong>for</strong> the other values<br />

of the parameter <strong>an</strong>d <strong>for</strong> the other dependent<br />

variables until getting all the <strong>windows</strong> built.<br />

A dependent variable z that depends on two<br />

independent variables (x <strong>an</strong>d y) <strong>an</strong>d a parameter (p)<br />

is considered:<br />

z = z(<br />

x,<br />

y,<br />

p)<br />

(1)<br />

In the example of the gasifier, x is the oxygen ratio,<br />

y the steam ratio <strong>an</strong>d p the load. The dependent<br />

variable z c<strong>an</strong> be temperature, CGE or one<br />

concentration. Graphically, the iso-line is the<br />

intersection of the surface p = p0 <strong>an</strong>d the pl<strong>an</strong>e z =<br />

z0 (Figure 4).<br />

A group of <strong>operation</strong> points characterised by the<br />

values of the four variables (x, y, p, z)i is available<br />

(the 2,874 actual <strong>operation</strong> points used to tune the<br />

models) <strong>an</strong>d we w<strong>an</strong>t to tr<strong>an</strong>s<strong>for</strong>m it into <strong>an</strong>other<br />

group of points (x0, y0, p0, z0)j where p0 <strong>an</strong>d z0 are<br />

given by the window <strong>an</strong>d the iso-line respectively,<br />

<strong>an</strong>d x0 <strong>an</strong>d y0 are the unknown qu<strong>an</strong>tities. The<br />

procedure <strong>for</strong> doing this tr<strong>an</strong>s<strong>for</strong>mation consists of<br />

<strong>building</strong> groups of four points <strong>an</strong>d, by considering<br />

that the z function is linear in small zones,<br />

obtaining one new point from each group.


X<br />

Figure 4: Methodology scheme<br />

The first step is to make four-point groups. To<br />

select them, the following conditions are imposed:<br />

i) Their p <strong>an</strong>d z values should be near to p0 <strong>an</strong>d z0:<br />

p δ ≤ p ≤ p + δ k = 1..<br />

(2)<br />

0 − P k 0 P 4<br />

z0 − δ z ≤ zk<br />

≤ z0<br />

+ δ z = 1..<br />

4<br />

k (3)<br />

ii) Once a point 1 that accomplish the previous<br />

conditions has been selected, the other three points<br />

are chosen according to the following criteria:<br />

p − p ⋅ p − p ><br />

(4)<br />

( 1 0 ) ( 2 0 ) 0<br />

( 1 − z0<br />

) ⋅ ( z2<br />

− z0<br />

) < 0<br />

( 1 − p0<br />

) ⋅ ( p3<br />

− p0<br />

) < 0<br />

( 1 − z0<br />

) ⋅ ( z3<br />

− z0<br />

) > 0<br />

( 1 − p0<br />

) ⋅ ( p4<br />

− p0<br />

) < 0<br />

( − z ) ⋅ ( z − z ) < 0<br />

z (5)<br />

p (6)<br />

z (7)<br />

p (8)<br />

z 1 0 4 0<br />

(9)<br />

iii) If <strong>for</strong> each point 1 (<strong>for</strong> each group) there are<br />

various possible points 2, 3 or 4, the points that<br />

minimise the following expression are chosen:<br />

2<br />

d k =<br />

2 ( xk<br />

− x1<br />

)<br />

2<br />

x − x<br />

+<br />

2 ( yk<br />

− y1<br />

)<br />

2<br />

y − y<br />

(10)<br />

( ) ( ) +<br />

max min<br />

max min<br />

( )<br />

( ) 2<br />

2<br />

pk − p1<br />

+ k = 2..<br />

4<br />

p − p<br />

max<br />

Z<br />

P1<br />

min<br />

P = P0<br />

Z = Z0<br />

Where dist<strong>an</strong>ces are divided into the maximum<br />

dist<strong>an</strong>ce in order to avoid scale effect. A maximum<br />

dk is also imposed.<br />

The first condition is only a filter to select the<br />

points nearer to the iso-line. By using only this<br />

condition <strong>an</strong> <strong>operation</strong> window could be built, but<br />

if δ values were small the window would have very<br />

few points <strong>an</strong>d if δ values were high the window<br />

P3<br />

P0<br />

P2<br />

P4<br />

ISO-LINE<br />

Y<br />

clarity would decrease. Hence, a more elaborated<br />

method is proposed.<br />

The second <strong>an</strong>d third conditions are used to build<br />

the four-point groups from the points that have<br />

passed the first condition filter. The second<br />

condition is proposed to ensure a good distribution<br />

of the four points around the unknown point. Since<br />

the surface p = p0 <strong>an</strong>d the pl<strong>an</strong>e z = z0 determine<br />

four regions in the space, each point of the group<br />

should be in a different region. Due to the third<br />

condition the four points are in a small region, in<br />

which the z function c<strong>an</strong> be considered as linear<br />

(Figure 4).<br />

Once the four-point groups have been built, the<br />

pairs (x0, y0) are generated (one pair from each<br />

group). To obtain these pairs, the dependent<br />

variable is expressed in each one of the four points<br />

with a first order Taylor series around the point (x0,<br />

y0, p0).<br />

zk = z0<br />

+ z x ⋅ ( xk<br />

− x0<br />

) + z y ⋅ ( yk<br />

− y0<br />

)+ (11)<br />

+ z p ⋅ ( pk<br />

− p0<br />

) k = 1..<br />

4<br />

As there are four equations <strong>an</strong>d five unknown<br />

qu<strong>an</strong>tities (zx, zy, zp, x0 <strong>an</strong>d y0) <strong>an</strong> additional<br />

condition should be added. This condition is that<br />

the following expression (dist<strong>an</strong>ce from the new<br />

point to the old ones) should be minimum:<br />

4<br />

2<br />

2<br />

⎛ ( ) ( ) ⎞<br />

2 x<br />

∑ ⎜ k − x0<br />

yk<br />

− y0<br />

d =<br />

⎟<br />

⎜<br />

+<br />

(12)<br />

2<br />

2<br />

= ( ) ( ) ⎟<br />

k 1 ⎝ xmax<br />

− xmin<br />

ymax<br />

− ymin<br />

⎠<br />

By solving the system <strong>for</strong> each four-point group, a<br />

family of points is obtained. These points, when<br />

plotted, <strong>for</strong>m the iso-line. Since this linear system<br />

is solved <strong>for</strong> each four-point group, this<br />

methodology c<strong>an</strong> be used <strong>for</strong> <strong>an</strong>y curve shape<br />

although it is based on first order Taylor series.<br />

GASIFIER OPERATION WINDOW FROM<br />

PLANT DATA<br />

The methodology described above has been<br />

applied to build <strong>an</strong> <strong>operation</strong> window of the<br />

gasifier <strong>for</strong> a 90% load (p=90). Pl<strong>an</strong>t data are the<br />

same that were used to validate the models. Since<br />

the iso-lines are now groups of points, it is more<br />

convenient to use one graph <strong>for</strong> each dependent<br />

variable. The graph that c<strong>an</strong> be seen more clearly is<br />

the concentration of CO2 (Figure 5).<br />

Operation <strong>windows</strong> show the same tendency as<br />

model-built <strong>windows</strong> but they are limited to a more<br />

reduced zone. In this zone, both models give<br />

similar values, which explain why errors are<br />

reduced. The graphs of the other dependent


variables are not as clear as the graph of CO2 but,<br />

except the graph of H2, the tendency c<strong>an</strong> be<br />

appreciated. All <strong>windows</strong> c<strong>an</strong> be seen in [11].<br />

Steam ratio (kg/kg fuel daf)<br />

Steam ratio (kg/kg fuel daf)<br />

Steam ratio (kg/kg fuel daf)<br />

0,18<br />

0,16<br />

0,14<br />

0,12<br />

0,1<br />

CO2<br />

0,08<br />

0,69 0,71 0,73 0,75<br />

O2 ratio (Nm3 pure O2/kg fuel daf)<br />

0,18<br />

0,16<br />

0,14<br />

0,12<br />

0,1<br />

Figure 5: CO2 <strong>operation</strong> window<br />

CO2<br />

0,08<br />

0,69 0,71 0,73 0,75<br />

O2 ratio (Nm3 pure O2/kg fuel daf)<br />

CO2 = 2,75%<br />

CO2 = 3%<br />

CO2 = 3,25%<br />

CO2 = 3,5%<br />

CO2 = 3,75%<br />

CO2 = 4%<br />

CO2 = 4,25%<br />

CO2 = 2,75%<br />

CO2 = 3%<br />

CO2 = 3,25%<br />

CO2 = 3,5%<br />

CO2 = 3,75%<br />

CO2 = 4%<br />

CO2 = 4,25%<br />

Figure 6: CO2 <strong>operation</strong> window, using ratio<br />

tr<strong>an</strong>s<strong>for</strong>mation <strong>an</strong>d average fuel composition<br />

0,18<br />

0,16<br />

0,14<br />

0,12<br />

0,1<br />

H2<br />

0,08<br />

0,69 0,71 0,73 0,75<br />

O2 ratio (Nm3 pure O2/kg fuel daf)<br />

H2 = 20,5%<br />

H2 = 21%<br />

H2 = 21,5%<br />

H2 = 22%<br />

H2 = 22,5%<br />

H2 = 23%<br />

Figure 7: H2 <strong>operation</strong> window, using ratio<br />

tr<strong>an</strong>s<strong>for</strong>mation <strong>an</strong>d average fuel composition<br />

To improve the resolution of the graphs of<br />

compositions, in<strong>for</strong>mation about the fuel<br />

composition should be included. One way to do<br />

this is by applying the method to build the<br />

<strong>windows</strong> not to the oxygen <strong>an</strong>d steam ratios but to<br />

a ratios O/C <strong>an</strong>d H/O that are calculated by<br />

dividing the total amount of carbon, hydrogen <strong>an</strong>d<br />

oxygen (taking into account the carbon, oxygen<br />

<strong>an</strong>d hydrogen contained in fuel, the steam <strong>an</strong>d the<br />

oxygen). Then, the pairs (x0, y0) should be<br />

tr<strong>an</strong>s<strong>for</strong>med from O/C <strong>an</strong>d H/O to oxygen/fuel <strong>an</strong>d<br />

steam/fuel ratios by using <strong>an</strong> average fuel<br />

composition. This idea is based on the fact that,<br />

since the fuel conversion <strong>an</strong>d final equilibrium<br />

const<strong>an</strong>ts are roughly const<strong>an</strong>t <strong>an</strong>d the influence of<br />

nitrogen <strong>an</strong>d sulphur c<strong>an</strong> be neglected, the final gas<br />

composition only depends on the relations between<br />

carbon, oxygen <strong>an</strong>d hydrogen. As c<strong>an</strong> be seen in<br />

Figures 7 <strong>an</strong>d 8, the graph of CO2 becomes clearer<br />

<strong>an</strong>d the graph of H2 shows a tendency (while the<br />

steam <strong>an</strong>d oxygen ratios were used directly no<br />

tendency was seen). The improvement obtained in<br />

the H2 is due to the small molecular mass of this<br />

element, which made that a small ch<strong>an</strong>ge in the<br />

fuel composition causes <strong>an</strong> import<strong>an</strong>t dispersion in<br />

the gas composition.<br />

Although the use of O/C <strong>an</strong>d H/O ratios improves<br />

the clarity of composition <strong>windows</strong>, this<br />

tr<strong>an</strong>s<strong>for</strong>mation is not suitable <strong>for</strong> energy related<br />

variables (temperature <strong>an</strong>d CGE) because it mixes<br />

all sources of carbon, oxygen <strong>an</strong>d hydrogen<br />

without taking into account the variation of LHV<br />

that a modification of fuel composition implies.<br />

One way to introduce fuel LHV <strong>an</strong>d to use O/C<br />

<strong>an</strong>d H/O ratios in the CGE window is by<br />

representing not CGE but a relative CGE [11].<br />

This variable is calculated by introducing a<br />

correction factor fCGE that allows to take into<br />

account variations in the relation of fuel LHV <strong>an</strong>d<br />

carbon content in the fuel:<br />

CGE = CGE ⋅ f (13)<br />

f<br />

CGE<br />

rel<br />

CGE<br />

38,<br />

500<br />

= (14)<br />

⎛ LHV fuel ⎞<br />

⎜ ⎟<br />

⎜ C ⎟<br />

⎝ fuel ⎠<br />

( kJ / kg )<br />

For the <strong>an</strong>alysed periods, this factor varies from<br />

0.982 to 1.015. In figure 6 <strong>an</strong> <strong>operation</strong> window of<br />

CGErel built by using O/C <strong>an</strong>d H/O ratios is shown.<br />

The iso-lines show that the gasifier is operated in<br />

the high fuel conversion zone, by using oxygen<br />

ratios above the maximum CGE point.


Figure 8: Relative CGE <strong>operation</strong> window, using<br />

ratio tr<strong>an</strong>s<strong>for</strong>mation <strong>an</strong>d average fuel composition<br />

Pl<strong>an</strong>t data <strong>operation</strong> <strong>windows</strong> presented in this<br />

section shows the same tendencies as model-built<br />

<strong>operation</strong> <strong>windows</strong> but the iso-lines are slightly<br />

displaced. For example, the maximum CGE point<br />

would be displaced towards the left side of the<br />

pl<strong>an</strong>t data <strong>operation</strong> <strong>windows</strong>, while in the<br />

variable-conversion model <strong>operation</strong> window this<br />

point is near the centre. This aspect demonstrates<br />

that it has been very useful to build these <strong>windows</strong><br />

from pl<strong>an</strong>t data.<br />

However, if these <strong>windows</strong> are going to be used by<br />

pl<strong>an</strong>t operators, point families should be<br />

tr<strong>an</strong>s<strong>for</strong>med into lines <strong>an</strong>d all variables should be<br />

plotted in the same graph (Figure 9).<br />

Steam ratio (kg/kg fuel daf)<br />

Steam ratio (kg/kg fuel daf)<br />

0,18<br />

0,16<br />

0,14<br />

0,12<br />

0,1<br />

0,18<br />

0,16<br />

0,14<br />

0,12<br />

0,1<br />

Figure 9: Operation window <strong>for</strong> operators use<br />

CONCLUSIONS<br />

CGE rel<br />

0,08<br />

0,69 0,71 0,73 0,75<br />

O2 ratio (Nm3 pure O2/kg fuel daf)<br />

Operation window 90% load.<br />

0,08<br />

0,69 0,71 0,73 0,75<br />

O2 ratio (Nm3 pure O2/kg fuel daf)<br />

CGE = 75%<br />

CGE = 75,5%<br />

CGE = 76%<br />

CGE = 76,5%<br />

CGE = 77%<br />

CGE = 77,5%<br />

CGE = 78%<br />

CGE = 73%<br />

CGE = 74%<br />

CGE = 75%<br />

CGE = 76%<br />

T = 1700 ºC<br />

T = 1750 ºC<br />

T = 1800 ºC<br />

T = 1850 ºC<br />

T = 1900 ºC<br />

CO = 59%<br />

CO = 60%<br />

CO = 61%<br />

CO = 62%<br />

CO = 63%<br />

H2 = 21 %<br />

H2 = 21,5 %<br />

H2 = 22 %<br />

H2 = 22,5 %<br />

H2 = 23 %<br />

H2 = 23,5 %<br />

CO2 = 2%<br />

CO2 = 2,5%<br />

CO2 = 3%<br />

CO2 = 3,5%<br />

Since the gasifier runs with a high <strong>an</strong>d const<strong>an</strong>t<br />

fuel conversion ratio <strong>an</strong>d variations of this<br />

parameters c<strong>an</strong> not be detected, a simple model<br />

like the one proposed by V<strong>an</strong> der Burgt is enough<br />

to reconcile pl<strong>an</strong>t data. However, if a wider<br />

<strong>operation</strong> r<strong>an</strong>ge is explored, a more sophisticated<br />

model with variable fuel conversion ratio is<br />

needed.<br />

An <strong>operation</strong> window is a practical <strong>tool</strong>, which c<strong>an</strong><br />

help to underst<strong>an</strong>d how the gasifier works <strong>an</strong>d to<br />

operate it in <strong>an</strong> efficient way. By comparing the<br />

two model-built <strong>windows</strong>, const<strong>an</strong>t conversion<br />

model limitation c<strong>an</strong> be seen.<br />

Although the models are useful to tune control<br />

system <strong>an</strong>d to <strong>an</strong>alyse new <strong>operation</strong> zones, to<br />

study actual gasifier <strong>operation</strong> it is better to build<br />

<strong>windows</strong> from pl<strong>an</strong>t data. Hence a new method is<br />

proposed. It is a general methodology that has<br />

three adv<strong>an</strong>tages: 1) it allows to introduce more<br />

th<strong>an</strong> one independent variable, 2) it does not<br />

impose <strong>an</strong>y type of graph (linear, polynomial) <strong>an</strong>d<br />

3) it c<strong>an</strong> be applied to real <strong>operation</strong> periods<br />

because it does not need even distributed data.<br />

Thus, it c<strong>an</strong> be very useful <strong>for</strong> studying <strong>an</strong>y<br />

system.<br />

Operation <strong>windows</strong> shown in this paper are<br />

currently being used in Puertoll<strong>an</strong>o power pl<strong>an</strong>t<br />

daily <strong>operation</strong>. Th<strong>an</strong>ks to this work, operators<br />

have a graph in which the consequences of their<br />

actions are clearly plotted, which c<strong>an</strong> avoid errors<br />

<strong>an</strong>d pl<strong>an</strong>t failures. Since pl<strong>an</strong>t data <strong>windows</strong> shows<br />

that in usual <strong>operation</strong> CGE c<strong>an</strong> vary about 3<br />

points, which me<strong>an</strong>s about 5 MW, the use of the<br />

<strong>windows</strong> c<strong>an</strong> improve pl<strong>an</strong>t efficiency<br />

signific<strong>an</strong>tly.<br />

SUMMARY OF THE METHODOLOGY<br />

If coal is going to play <strong>an</strong> import<strong>an</strong>t role as<br />

abund<strong>an</strong>t <strong>an</strong>d even distributed energy source in the<br />

XXI century, cle<strong>an</strong> <strong>an</strong>d efficient technologies<br />

should be used. Perhaps, the most promising<br />

technique is gasification, because it allows going<br />

into the hydrogen society <strong>an</strong>d also facilitates the<br />

CO2 capture <strong>an</strong>d disposal of. But gasification is not<br />

combustion. The optimum working condition of a<br />

gasifier is only obtained through the control of the<br />

reactive agents taking place in the reaction<br />

chamber (concentration, pressure <strong>an</strong>d temperature),<br />

in opposition to combustion, which is a reaction<br />

totally developed.<br />

Accordingly, the problem of obtaining <strong>operation</strong><br />

<strong>windows</strong> is <strong>an</strong> universal problem that every<br />

existing or pl<strong>an</strong>ned gasification pl<strong>an</strong>t will have to<br />

face to. This problem c<strong>an</strong>not be solved by using<br />

only a pure theoretical <strong>an</strong>alysis but <strong>an</strong> empirical<br />

feedback helping to solve the fine-tuning of a<br />

gasifier is also needed. As already said, this could<br />

suppose a lost in gasifier efficiency of as much as 3


percent. There<strong>for</strong>e, the methodology developed in<br />

this paper c<strong>an</strong> be of use <strong>for</strong> new IGCC pl<strong>an</strong>ts<br />

provided that the experience gained from <strong>an</strong><br />

already existing pl<strong>an</strong>t is considered.<br />

So, the methodology presented in this paper c<strong>an</strong> be<br />

summarised as follows:<br />

i) Previously, it should be necessary to have<br />

<strong>an</strong> on-line system that provides in<strong>for</strong>mation<br />

about gasifier efficiency, pressures,<br />

temperatures <strong>an</strong>d so on, which is nowadays a<br />

common <strong>tool</strong> technique.<br />

ii) A theoretical <strong>an</strong>alysis should be carried out<br />

by using a model in order to obtain tendencies.<br />

The model should have been tuned by using<br />

pl<strong>an</strong>t data. Steam <strong>an</strong>d oxygen ratios should be<br />

considered as independent variables <strong>an</strong>d<br />

temperature, main gas components <strong>an</strong>d<br />

efficiency as dependent variables. An<br />

<strong>operation</strong> window should be used to plot all<br />

dependencies in one graph.<br />

iii) Operation <strong>windows</strong> from pl<strong>an</strong>t data should<br />

be built by using the method proposed in this<br />

paper. If these <strong>windows</strong> did not show the same<br />

tendencies as the model-built ones, hypothesis<br />

assumed in the model should be revised.<br />

iv) Finally, conclusions about how to modify<br />

<strong>operation</strong> to increase efficiency should be<br />

obtained <strong>an</strong>d a clearer version of the <strong>windows</strong><br />

(substituting the points to lines) should be<br />

provided to operators.<br />

ACKNOWLEDGMENTS<br />

The authors would like to acknowledge the<br />

m<strong>an</strong>agement of Elcogas power pl<strong>an</strong>t <strong>for</strong> their<br />

faithful collaboration at every moment, specially to<br />

Ing. Fr<strong>an</strong>cisco García-Peña, Engineering &<br />

Mainten<strong>an</strong>ce m<strong>an</strong>ager, Ing. Alej<strong>an</strong>dro Muñoz,<br />

head of technology, Ing. Silvia Burgos, head of the<br />

R&D group, Ing. Fr<strong>an</strong>cisco Puente <strong>an</strong>d Ing. Pedro<br />

Casero, <strong>for</strong> their const<strong>an</strong>t <strong>an</strong>d active support to this<br />

idea.<br />

REFERENCES<br />

[1] Pisa J. Análisis Termoeconómico aplicado al<br />

diseño de pl<strong>an</strong>tas IGCC. PhD Thesis.<br />

Department of Mech<strong>an</strong>ical Engineering,<br />

University of Zaragoza. 1996.<br />

[2] Stiegel GJ, Maxwell RC. Gasification<br />

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Technology 2001;71:1-3:79-97.<br />

[3] Europe<strong>an</strong> Commission, Directorate-General<br />

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Gasification.<br />

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pl<strong>an</strong>ts. Private communication. 1998.<br />

[9] Ayerbe E. Elaboración, estudio y validación<br />

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Thesis. Department of Mech<strong>an</strong>ical<br />

Engineering, University of Zaragoza. 2002.<br />

[10] Usón S, Martínez A, Valero A, Correas L.<br />

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University of Zaragoza.2002.

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