Cogeneration Operation Model for Gas Turbine and Steam Cost Optimization
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Solution Overview
Problem
Optimizing the operating parameters of cogen facilities associated with crude processing facilities is complex due to numerous interacting parameters, making intuitive solutions difficult or impossible.
Innovation Solution
A method is developed to create a model that optimizes operations for cogen facilities by collecting data and creating an objective function to minimize total operating costs, based on fuel and net power costs, which is used to control gas turbines and steam generation rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If optimization of cogen facility operations is attempted through intuitive methods, then the process is simple, but the solution is difficult or impossible to achieve due to complex parameter interactions
Solution Approach 1:
The patent replaces intuitive manual optimization methods with a computational modeling approach. An objective function is created that mathematically represents total operating costs, and optimization software automatically determines optimal operating parameters by processing facility data through the model, eliminating the need for complex manual analysis while achieving precise results
Solution Approach 2:
The patent introduces an intermediate optimization model that acts as a mediator between facility operations and decision-making. The model processes operational data, applies optimization algorithms, and generates recommended operating parameters, serving as an intermediary layer that simplifies the complex relationship between multiple interacting parameters and optimal solutions
2Productivity
If cogeneration is implemented to improve efficiency, then power and steam production efficiency increases, but system complexity increases due to multiple interacting parameters
Solution Approach 1:
The patent creates a universal optimization model that can handle multiple cogen facility configurations and operating scenarios through a single framework. The objective function and constraint model are designed to accommodate different gas turbine arrangements, steam generation rates, and operational conditions, providing a multi-functional solution that manages system complexity while maintaining efficiency
Solution Approach 2:
The patent systematically manages system complexity by identifying and optimizing key parameters such as gas turbine operating points, steam generation rates, and fuel consumption. The optimization model adjusts these parameters within defined constraints to achieve efficient operation without requiring complex manual coordination of all system variables
3Power
If more gas turbines and boilers are operated to meet demand, then power and steam supply increases, but total operating cost increases
Solution Approach 1:
The patent implements dynamic optimization that adjusts gas turbine and boiler operating levels based on real-time or scenario-specific demands. The model determines the optimal mix and operating points of multiple gas turbines and steam generation facilities, dynamically balancing power supply requirements against fuel consumption and operating costs rather than operating all units at fixed levels
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The model effectively reduces operating costs and improves energy intensity by determining the optimal number of gas turbines and boilers to run, achieving an energy intensity improvement of 1-2% without incurring capital costs.
Implementation Method 1
They are often located in industrial areas, such as near refineries and chemical plants, for which they can provide both electrical power and steam. Cogen facilities increase the efficiency of power generation and steam production as the production of each can be made from the same fuel source, which is converted to power, for example, in a gas turbine.
Implementation Method 2
The waste heat from this power conversion is then used to generate steam.
Data Source
AI summary
A method for developing a model to optimize operations for a cogen facility is provided. The method includes collecting data on the operation of the cogen facility and creating an objective function to minimize total operating cost of the cogen facility, wherein the objective function is based, at least in part, on a fuel cost and a net power cost. An output is provided from the objective function, wherein the output is used to control a mixture of gas turbines used in the cogen facility and steam generation rates.