Integrated gasification combined cycle (IGCC) plants are an attractive technology option for power generation, especially in a carbon-constrained environment. IGCC power plants use gasifiers to produce a synthesis gas, primarily a mixture of hydrogen and carbon monoxide, which is cleaned and then fired in a combined cycle system to generate electricity using gas and steam turbines. The advantages of gasification-based technology include environmental benefits, potential for carbon dioxide (CO₂) capture, the ability to use a variety of feedstocks (e.g., coal, biomass, pet coke), and its high efficiency relative to other power generation technologies.
NETL’s AVESTAR™ team has developed, tested, and deployed a unique high-fidelity, real-time IGCC dynamic simulator as part of its operator training system (OTS), in collaboration with WVU, Fossil Consulting Services, Invensys Operations Management, Enginomix, and the Electric Power Research Institute. The 520 MW(net) reference IGCC plant for the OTS is designed with two trains, each consisting of slurry-fed, entrained-flow gasifiers with radiant syngas coolers and two-stage water-gas shift reactors for H2S and CO₂ capture. The combined cycle uses two advanced gas turbines, a triple pressure-level heat recovery steam generator, and steam cycle.

Virtual reality technology makes the OTS more realistic by providing a 3D plant walk-through environment. The user can navigate an avatar (field operator) through the 3D virtual plant using a gamepad, a handheld device that most video games enthusiasts are very familiar with. This allows ITS users to interact with plant equipment (e.g., a gasifier), activate transparent views (e.g., liquid level in a tank), display pop-up trends (e.g., gas turbine combustor temperature over time), and experience equipment sound effects (e.g., pump engines), malfunctions (e.g., leaks, fires), and visual training scenarios (e.g., CO₂ absorber column operation). Any action that the user carries out in the 3D environment is immediately reflected in the IGCC dynamic simulator and conversely, any value that is updated by the simulation interface is updated in the virtual reality platform.

Immersive training system for IGCC plant with CO2 capture.

The user can move and interact freely within the virtual plant, without being bound to pre-fixed paths or animations. A 3D visor with head tracking is provided for training a single field operator. Stereoscopic projectors are provided for training multiple operators using shutter glasses. To increase the visual realism, all 3D component models make use of textures and shading, derived mainly from high-resolution stereoscopic 3D photographs of commercial-scale plants. Realistic sound effects, such as constant low-intensity background sounds (e.g., distant equipment), random environment sounds (e.g., flock of seagulls), and equipment-specific sounds (e.g., pump engines, sirens), increase the sense of immersion for the user.

The ITS user can select equipment components and activate a transparent view. In the figure below, the shell of a reboiler has been made transparent, so that the student can “see” the boiling liquid and vapor flow. The figure on the right shows a transparent view of a distillation column in which the animated vapor and liquid flow up and down the column, tied to real-time process variables. For all of the transparent equipment items, the visual representations are interactive and depend on process conditions, as generated by the dynamic simulator in real time.

Transparent view of reboiler with fill level visible (left) and distillation column with animation of liquid and vapor flows (right).

The virtual plant can be used to practice training routines for malfunctions and emergencies that could not be attempted in the real plant (e.g., leaks, fires).

The next figure shows a gas pipe leaking in the Claus plant area. In another malfunction example, the pure oxygen piping at the outlet of the oxygen compressor in the air separation unit ruptures. The situation progresses to light smoke, then heavy smoke, followed by a large fire that requires isolating the oxygen compressor by closing the appropriate valve, shutting down the compressor, and switching over to an oxygen supply from the oxygen storage tank. Gasifier operations will be affected appropriately, based on the severity of the rupture and reduction in oxygen supply to the gasifier.

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AVESTAR™ Center Seeks Collaborative R&D Opportunities

NETL and its Regional University Alliance partners are pursuing an innovative and collaborative R&D program in the areas of high-fidelity dynamic equipment and process modeling, dynamic reduced order modeling, advanced process control, sensor placement, and 3D virtual plant simulation. The AVESTAR team wants to work with leading experts in the operation and control of clean energy systems. The goal is to operate power generation systems safely and effectively with optimal efficiency, while protecting the environment.

Cooperative Research and Development Agreements (CRADAs) allow our laboratory to collaborate with the private sector, academia, and other government entities. This benefits all partners by:

• Collaborating with energy experts and research leaders in dynamics and control,
• Access to real-time, high-fidelity dynamic simulators and immersive training systems, and
• Leveraging world-class training and research facilities.

For more information pursing a CRADA with the AVESTAR team, please contact NETL's Technology Transfer Office.