Search Results (210)

To balance the quantity of heat generated and consumed, thermal energy storage systems are crucial for power plants and district heating systems. Particularly when phase transitions and pressure variations are not adequately covered in the existing literature, their work frequently takes place under complicated, changing temperature and fluid dynamic settings. The goal of this research is to create a thermodynamic model that incorporates the effects of steam condensation, steam injection, and heating failures to describe the transient behaviour of temperature and pressure in pressure vessels containing single-phase and two-phase fluids. To account for nonlinear, temperature-dependent steam properties, as well as initial and boundary constraints, the study proposes energy balance models for hot water and saturated steam cases. Numerical simulations evaluating sensitivity to parameter changes are presented alongside analytical solutions for isochoric and isobaric systems. The model also includes direct steam injection heating and the use of a heat exchanger. It explains the changes in temperature and pressure that occur in thermal energy storage systems over time, including significant events such as steam cushion collapse and condensate drainage. According to the sensitivity analysis, the main factors influencing the system’s safety limitations and transient dynamic phenomena are thermal power, heat exchanger capacity, and thermal insulation efficiency. The proposed thermodynamic model closes a major gap in the literature by providing reliable predictions of the transient behavior needed for the safe design and reliable operation of pressure vessels utilized for heat storage in district heating networks. This model can be used by engineers and researchers to optimize system design and steer clear of risky operational situations. Full article

In the context of carbon neutrality, the large-scale integration of renewable energy sources has led to frequent load changes in coal-fired boilers. These fluctuations cause key operational parameters to deviate significantly from their design values, undermining combustion stability and reducing operational efficiency. To address this issue, we introduce a novel predictive control method to enhance the control precision of key parameters under complex variable-load conditions, which integrates a coupled predictive model and real-time optimization. The predictive model is based on a coupled Transformer-gated recurrent unit (GRU) architecture, which demonstrates strong adaptability to load fluctuations and achieves high prediction accuracy, with a mean absolute error of 0.095% and a coefficient of determination of 0.966 for oxygen content (OC); 0.0163 kPa and 0.987 for bed pressure (BP); and 0.300 °C and 0.927 for main steam temperature (MST). These results represent substantial improvements over lone implementations of GRU, LSTM, and Transformer models. Based on these multi-step predictions, a WOA-based real-time optimization strategy determines coordinated adjustments of secondary fan frequency, slag discharger frequency, and desuperheating water valves before deviations occur. Field validation on a 300 t/h boiler over a representative 24 h load cycle shows that the method reduces fluctuations in OC, BP, and MST by 62.07%, 50.95%, and 40.43%, respectively, relative to the original control method. By suppressing parameter variability and maintaining key parameters near operational targets, the method enhances boiler thermal efficiency and steam quality. Based on the performance gain measured during the typical operating day, the corresponding annual gain is estimated at ~1.77%, with an associated CO₂ reduction exceeding 6846 t. Full article

Biomass gasification serves as a key carbon-neutral technology. To effectively address the challenge of tar treatment during biomass gasification, the National Institute of Clean and low-carbon Energy developed a fluidized bed coupled with an entrained-flow bed. A steady-state Aspen Plus V12 model was designed to assess the compatibility between the two beds and optimize operating parameters. The model divides the process into three main zones: fluidized bed gasification, entrained-flow bed gasification, and bottom slag treatment, employing a reaction-restricted equilibrium assumption. Simulation results indicate that an increase in pressure leads to a reduction in the concentration of syngas components (CO and H₂), an insignificant rise in gas low heating value (LHV), and a notable decline in cold gas efficiency (η). A higher equivalence ratio (ER) results in decreased syngas components, along with a significant reduction in both LHV and η. The introduction of carbon dioxide reduces syngas components and lowers LHV. Similarly, the addition of steam reduces the CO content of the syngas and decreases its LHV. When the fluidized bed temperature exceeds 900 °C, changes in LHV and gas yield become negligible, while variations remain minimal when the entrained-flow bed temperature exceeds 1200 °C. Full article

Transient safety analysis is a critical aspect of ensuring the safe design of Liquid Metal-cooled Fast Reactors (LMRs), relying heavily on advanced system analysis programs. To this end, the China Institute of Atomic Energy (CIAE) independently developed the Fast Reactor Transient Analysis Code (FRTAC) system analysis code for LMRs, which has been applied to the safety analysis of several reactor types. However, long-term use has revealed certain limitations, such as complex control system modeling and numerical dissipation from the first-order numerical scheme. This study analyzes the current limitations of the code and carries out systematic improvements and validation. The main improvements include enhancing the system compilation architecture and refactoring functional modules to improve computational efficiency, scalability, and usability; introducing a second-order accurate numerical scheme based on a limiter to reduce numerical dissipation in the convection term while ensuring computational stability; and optimizing the solution procedure to accommodate the new architecture and algorithms. The improved code’s computational stability and accuracy were validated using the Edwards blowdown experiment and the Energy Technology Engineering Center (ETEC) once-through steam generator steady-state test, respectively. The validation results show that the improved code maintains excellent numerical stability in problems with rapid transient pressure changes. In steady-state convective heat transfer problems, the computational accuracy and grid convergence are significantly improved, with the relative deviation of the water-side outlet temperature reduced from −3.56% to −0.59%. Under the same computational conditions, the computational efficiency was increased by up to 36.1%. The results of this study will provide a more accurate and efficient system analysis code for the transient safety analysis of LMRs. Full article

Steam flow-induced vibration (FIV) of cooling tubes poses critical failure risks in nuclear power plant condensers. However, accurate FIV prediction remains challenging due to the complex three-dimensional flow structures in full-scale condensers, which are often oversimplified in existing models. To address this gap, this study develops a novel full-scale Computational Fluid Dynamics (CFD) model that uniquely integrates the low-pressure exhaust cylinder, condenser throat, and tube bundles. This approach enables a comprehensive evaluation of shell-side flow characteristics and FIV phenomena under both Valve Wide Open (VWO) and partial-load conditions (with either Modules A/C or B/D active). The results quantitatively identify peak FIV risk coefficients in specific zones—particularly at branch-shaped channel inlets and certain tube bundle corners where steam impingement is most intense—with values reaching 0.7 under VWO, 0.67 with Modules A/C active, and 0.74 with Modules B/D active. Notably, the peak FIV risk under B/D active condition is approximately 10.4% higher than under A/C active condition, indicating that partial-load operation with Modules B/D active presents the highest FIV risk among investigated scenarios. These findings provide novel insights into FIV mechanisms and establish a critical theoretical foundation for optimizing condenser design and enhancing operational safety protocols. Full article

The transition to low-carbon energy systems necessitates innovative design strategies for decarbonizing hydrogen production, particularly in industrial-scale applications where steam methane reforming (SMR) remains predominant. This study proposes a novel, integrated process design for blue hydrogen production that addresses both energy and environmental sustainability through process intensification and resource valorization. A hybrid system was developed that combines solar thermal energy input with the catalytic potential of industrial waste, specifically, red mud, a byproduct of alumina refining. A solar parabolic dish (SPD) was engineered to contribute 10% of the heat demand, generating superheated steam at 477 °C. This work serves as a proof-of-concept, demonstrating the technical viability of integration at a bench scale. In parallel, red mud was characterized, thermochemically activated, and formulated into a low-cost catalyst for the SMR process. The integrated system includes solar-assisted steam generation, red mud-based catalytic reforming, CO₂ capture using methyl diethanolamine (MDEA), and hydrogen purification via pressure swing adsorption (PSA). The full process was modeled and optimized using ASPEN Plus, ASPEN Adsorption, and COMSOL Multiphysics^® Under optimal conditions (900 °C, 25 bar, steam-to-carbon ratio of 3), the system produced 1070 kg/h of hydrogen, achieving 95% CO₂ capture efficiency and 99.99% hydrogen purity. Techno-economic analysis revealed the red mud-derived catalyst costs 3.89 SAR/g (1.04 USD/g), a 77% cost reduction compared to conventional Ni-based catalysts. The integration of solar thermal energy, while offering modest direct economic savings of approximately 9500 SAR (2530 USD) annually, primarily demonstrates the technical feasibility of renewable heat integration for reducing the carbon intensity of hydrogen production. Full article

Emissions reduction and energy saving at thermal power plants are crucial for energy development. This paper presents the results of thermodynamic analysis and optimization of thermal circuits of combined-cycle power plants incorporating an organic Rankine cycle and supplementary burners. It is established that at a power unit with GTE-170, the transition from a binary cycle with a double-circuit waste heat boiler to a trinary one leads to an increase in net efficiency by 0.79%. It is established that in the trinary cycle, fuel afterburning in the exhaust-gas environment leads to an increase in the net capacity of the power plant: the increase is up to 4.1% with an increase in the degree of afterburning by 0.1 at a steam temperature of 515 °C. It was revealed that the introduction of intermediate superheat provides an increase in the efficiency of the binary cycle by an average of 0.2–3%, and of the trinary cycle by 2–4%, with a change in the degree of afterburning from 0 to 0.5 at an initial steam temperature of 515 °C. The use of supplementary combustion and the organic Rankine cycle make it possible to reduce carbon dioxide emissions in combined-cycle power plants. Compared to a single-pressure combined cycle, the ORC-integrated configuration reduces specific CO₂ emissions by more than 7.5%, while supplementary fuel combustion with an increased steam inlet temperature results in a reduction of up to 10%. Full article

A full-scale CFD model of a steam turbine, including the regulating and multiple pressure stages, was developed to quantify the axial thrust—a critical parameter for operational safety. The results under various loads reveal two key findings: (1) The blade root hub is the primary source of the total axial thrust, exhibiting a near-linear relationship with mass flow rate under partial loads—a crucial insight for precise thrust forecasting. (2) Significant circumferential pressure non-uniformity was identified as a primary characteristic of partial-load operation. Furthermore, an optimized mixing chamber geometry is proposed, which reduces regulating stage loss by 0.59% and 0.31% under Valve Wide Open (VWO) and Turbine Heat Acceptance (THA) conditions, respectively. This study provides a concrete strategy for enhancing turbine design and safety. Full article

In China, crude phenols, mixtures commonly produced in the coal industry, are inexpensive and abundant in supply, but their valorization is hindered by high energy consumption in the separation process. It is of great academic and commercial significance to improve the separation process of crude phenols to achieve energy efficiency and cost reduction. In this study, a heat pump-assisted distillation (HPD) system for crude phenol separation was developed. External vapor recompression was adopted due to the strong corrosiveness, high toxicity, heat sensitivity, and easy polymerization of crude phenols. Compared with conventional distillation (CD), HPD showed clear advantages in lowering operating costs. The effects of design variables including pressure, the number of theoretical plates and temperature differences between the condenser and reboiler on reflux ratios, kettle temperature, equipment costs, operating costs, and total annual cost (TAC) were investigated and optimized in detail. The effect of steam prices on process economic feasibility was also studied. It was found that HPD reduced at least 55% of the operational cost compared to CD when the steam price was higher than 10.8 USD/GJ. Carbon emission evaluation indicated that CO₂ generated by the HPD process was 56.3% lower than CD. Full article

This study investigates the primary frequency regulation dynamic characteristics of industrial steam extraction turbine units under deep peak regulation conditions. A high-fidelity integrated dynamic model was established, incorporating the governor system, steam turbine with extraction modules, and interconnected pipeline dynamics. Through comparative simulations and experimental validation, the model demonstrates high accuracy in replicating real-unit responses to frequency disturbances. For the power grid system in this study, the frequency disturbance mainly comes from three aspects: first, the power imbalance formed by the random mutation of the load side and the intermittence of new energy power generation; second, transformation of the energy structure directly reduces the available frequency modulation resources; third, the system-equivalent inertia collapse effect caused by the integration of high permeability new energy; the rotational inertia provided by the traditional synchronous unit is significantly reduced. In the cogeneration unit and its control system in Guangxi involved in this article, key findings reveal that increased peak regulation depth (30~50% rated power) exacerbates nonlinear fluctuations. This is due to boiler combustion stability thresholds and steam pressure variations. Key parameters—dead band, power limit, and droop coefficient—have coupled effects on performance. Specifically, too much dead band (>0.10 Hz) reduces sensitivity; likewise, too high a power limit (>4.44%) leads to overshoot and slow recovery. The robustness of parameter configurations is further validated under source-load random-intermittent coupling disturbances, highlighting enhanced anti-interference capability. By constructing a coordinated control model of primary frequency modulation, the regulation strategy of boiler and steam turbine linkage is studied, and the optimization interval of frequency modulation dead zone, adjustment coefficient, and frequency modulation limit parameters are quantified. Based on the sensitivity theory, the dynamic influence mechanism of the key control parameters in the main module is analyzed, and the degree of influence of each parameter on the frequency modulation performance is clarified. This research provides theoretical guidance for optimizing frequency regulation strategies in coal-fired units integrated with renewable energy systems. Full article

Methane steam reforming is the most widely adopted hydrogen production technology. To address the challenges associated with the large radial thermal resistance and low mass transfer rates inherent in the tubular packed bed reactors during the MSR process, this study proposes a structural design optimization that integrates annular metal foam gas channels along the inner wall of the reforming tubes. Utilizing multi-physics simulation methods and taking the conventional tubular reactor as a baseline, a comparative analysis was performed on physical parameters that characterize flow behavior, heat transfer, and reaction in the reforming process. The integration of the annular channels induces a radially non-uniform distribution of flow resistance in the tubes. Since the metal foam exhibits lower resistance, the fluid preferentially flows through the annular channels, leading to a diversion effect that enhances both convective heat transfer and mass transfer. The diversion effect redirects the central flow toward the near-wall region, where the higher reactant concentration promotes the reaction. Additionally, the higher thermal conductivity of the metal foam strengthens radial heat transfer, further accelerating the reaction. The effects of operating parameters on performance were also investigated. While a higher inlet velocity tends to hinder the reaction, in tubes integrated with annular channels, it enhances the diversion effect and convective heat transfer. This offsets the adverse impact, maintaining high methane conversion with lower pressure drop and thermal resistance than the conventional tubular reactor does. Full article

Addressing the insufficient research on the aerodynamic performance of the coupled last stage and exhaust hood structure in compact marine steam turbines under off-design conditions, this paper establishes for the first time a fully three-dimensional coupled model. It systematically analyzes the influence of the last-stage moving blade shrouds and exhaust hood stiffeners on steam flow loss, static pressure recovery, and vibrational excitation. The research methodology includes the following: employing a hybrid structured-unstructured meshing technique, conducting numerical simulations based on the Shear Stress Transport (SST) turbulence model, and utilizing the static pressure recovery coefficient, total pressure loss coefficient, and cross-sectional flow velocity non-uniformity as performance evaluation metrics. The principal findings are as follows: (1) After installing self-locking shrouds on the moving blades, steam flow loss is reduced by 4.7%, and the outlet pressure non-uniformity decreases by 12.3%. (2) Although the addition of cruciform stiffeners in the diffuser section of the exhaust hood enhances structural rigidity, it results in an 8.4% decrease in the static pressure recovery coefficient, necessitating further optimization of geometric parameters. (3) The coupled model exhibits optimal aerodynamic performance at a 50% design flow rate and 100% design exhaust pressure. The results provide a theoretical basis for the structural optimization of low-noise compact steam turbines. Full article

Efficient drying is crucial for the preservation and high-value utilization of tricholoma matsutake (TM). Traditional hot-air drying is inefficient, energy-intensive, and prone to quality degradation. This study investigates the application of microwave drying for TM, systematically analyzing its dielectric properties and moisture states, and elucidating the dielectric response mechanisms during drying. Response surface methodology (RSM) was employed to optimize key process parameters, including microwave power, drying time, and sample mass, and to validate the feasibility of the optimized process for industrial applications. Results revealed that the dehydration process of TM comprises three distinct stages, with free water evaporation contributing 69.8% of the total weight loss. Dielectric properties correlated strongly with apparent density and temperature, with the loss tangent ($\mathit{tan}\delta$) increasing by 213.0% at higher temperatures, confirming dipole loss as the primary heating mechanism. Under optimized drying conditions (power: 620.00 W, time: 2.70 min, mass: 13.2 g), a dehydration rate (DR) of 85.41% was achieved, with a 1.50% deviation from the model-predicted values. The optimized process effectively maintained the relative integrity of the microstructure of TM, with the C/O ratio increasing from 1.03 to 1.31. Steam pressure-driven moisture migration was identified as the primary mechanism facilitating microwave-enhanced dehydration. Pilot-scale experiments scaled up the processing capacity to 15 kg/h and confirmed that the new process reduced total costs by 38% compared to traditional hot-air drying. The study developed an efficient and reliable microwave drying model, supporting industrial-scale TM processing. Full article

Geothermal power generation offers a high availability factor and independence from weather conditions, yet steam production in geothermal wells often declines over time due to factors such as pressure depletion and scale deposition. To enable early detection of production anomalies and optimize maintenance, this paper proposes an anomaly detection framework based on Singular Spectrum Analysis (SSA). First, a Butterworth low-pass filter reduces high-frequency noise; then, SSA decomposes the time series, focusing on the largest singular value’s corresponding vectors. An anomaly score measures the deviation between current and historical singular vectors, and Non-Maximum Suppression (NMS) aggregates consecutive peaks to reduce false positives. We apply this method to 14 years of data from nine geothermal wells, comparing two threshold strategies: a unified threshold and well-specific thresholds. Results show that while a unified threshold simplifies deployment, individual thresholds can improve detection in certain wells, underscoring the impact of well characteristics and class imbalance. Our findings demonstrate that SSA-based anomaly detection, combined with NMS and threshold optimization, can effectively support maintenance decisions in geothermal power plants. Full article

The urgent need to address the climate crisis demands a swift transition from fossil fuels to renewable energy. Clean hydrogen, produced through ethanol steam reforming (ESR), offers a viable solution. Traditional ESR operates at atmospheric pressure, requiring costly separation and compression of hydrogen. High-pressure ESR, however, improves hydrogen purification, streamlines processes like pressure swing adsorption, and reduces operational costs while enhancing energy efficiency. High-pressure ESR also enables compact reactor designs, minimizing equipment size and land use by compressing reactants into smaller volumes. This study evaluates two nickel-based commercial catalysts, AR-401 and NGPR-2, under high-pressure ESR conditions. Key parameters, including reaction temperature, steam-to-ethanol ratio, and weight hourly space velocity, were optimized. At 30 bars, 700 °C, and a steam-to-ethanol ratio of 9, both catalysts demonstrated complete ethanol conversion, with hydrogen selectivity of 65–70% and yields of 4–4.5 moles of H₂ per mole of ethanol. Raising the temperature to 850 °C improved hydrogen selectivity to 74% and yielded 5.2 moles of H₂ per mole. High-pressure ESR using renewable ethanol provides a scalable, efficient pathway for hydrogen production, supporting sustainable energy solutions. Full article