SSRN 4528600
SSRN 4528600
a
Department of Engineering Physics, University of Wisconsin-Madison, 1500 Engineering Drive, Madison, Wisconsin,
53706, United States
b
Department of Mechanical Engineering, University of Wisconsin-Madison, 1500 Engineering Drive, Madison,
Wisconsin, 53706, United States
* [email protected]
Abstract
High capacity of renewable generation on energy grids of the future will require improved flexibility of typical base-load
generators such as nuclear power stations. Integrated energy systems are a route to such flexibility with one option
being considered by nuclear reactor vendors being Nuclear-Solar hybrid systems. Integrating solar generated heat from
parabolic troughs into the feedwater line allows the plant to alleviate turbine bled steam and transiently power boost
above nominal power in Rankine cycles. This article presents a parametric study of the design of such a nuclear solar
hybrid thermal system for a nominal small modular reactor cycle and provides a full system dynamic model written in
DYMOLA with the Modelica language to analyse the dispatch in transient load following operation. The control of the
system is presented and the impact on key variables are analysed due to step changes in electricity demand given to
the plant. The parametric study investigates the trade off in design between improved degrees of power boosting and
system nominal efficiency. The work also suggests that higher final feedwater temperatures offer improved
opportunities for power boosting flexibility. The transient analysis of the system allows a simple method for sizing the
concrete storage and parabolic trough arrays under variable demand and solar insolation profiles and provides a viable
route to a digital twin of such a system.
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for exergetic gains in performance, this paper argues that several proposed academic configurations. They define a
only a transient model that includes the nuclear island can separation between configurations of designs that produce
be used to understand in practice what may be achievable steam directly (DSGs) and those that use some closed
in load following operation. This is because the tempo- intermediary to transfer heat (HTFs). Suresh et al. [5]
ral distribution of parabolic trough generated heat and noted that using solar assisted feedwater heating in a coal
consumption of this heat in the balance of plant during Rankine had the greatest exergy efficiency when the HTF
power boost are not synchronous and vary each time step. configuration was employed.
The design uses a concrete storage to allow energy dis- Alotaibi et al. [13] and Zhong et al. [6] specifically
patchability and as such understanding how the concrete looked at using closed feedwater heating with heat pro-
storage’s temperature gradients and ability to dispatch duced from parabolic troughs from both a technical and
heat in complex load follow scenarios requires a transient economic perspective. The former found a significant (56%)
analysis. Beyond this, the variable operation required gives reduction in levelised electricity cost (LEC) over the 25
leads to large thermal transients that restrict aggressive year lifetime of the plant and the latter looked to optimise
load follow. the configuration of this feedwater heating based on min-
Whilst transient fluctuations in feedwater conditions imising this LEC. Zhong et al. [6] found that at high direct
cause issues in traditional fossil fuel driven Rankine cycles, normal insolation (DNI) (>350 W/m2 ) they could use a
they are significantly more of a problem in nuclear [7] due to high thermal integration temperature and achieve a lower
the sensitivity of the core to even small oscillations in input LEC. This corroborates the work by Popov [14] and Alam
conditions. Boosting power output using feedwater heating et al. [10] who showed the added cycle efficiency improve-
in nuclear introduces large changes in input conditions that ment potential of using solar assisted feedwater heating in
accompany the changing operating modes. Therefore, it the later (higher pressure) stages of the feedwater heating
is clear that the proposed system must be analyzed while chain as opposed to at lower temperatures.
accounting for transient effects to ensure conclusions on
their potential dispatch are correct[8]. 2.2. Transient Operation of Solar Assisted Feedwater Heat-
In this article, we discuss the conceptual design and ing
undertake key parametric studies in steady state to eval- As the above studies show, in steady state operation,
uate the design. We then present a transient dynamic the advantage to adding solar-assisted feedwater heating
model for the entire plant written in the Modelica lan- has been demonstrated clearly. However, it is a more
guage for DYMOLA to assess the plants capabilities to complex issue to maintain constant power plant operation
achieve load following. These studies aim to answer the under variable solar insolation over both short-term (min-
following research questions: utes to hours) and intermediate-term (daily) timescales.
Yan et al. [15] look at the impact on plant dynamic
• What is the power-boost capability such a solar as-
response of DNI changes for a solar assisted closed feedwa-
sisted feedwater heating configuration can achieve ter heating configuration without a thermal energy storage
given the required feedwater inlet conditions? system intermediary. They report significant transient
• What timescales are associated with the change in temperature fluctuations at the outlet of the solar-assisted
feedwater heating and their implications for reactor feedwater heater resulting from both step changes in the
safety? DNI profile and typical daily variation of solar insolation.
Pitz-Paal et al. investigate how solar-assisted direct
• What is the correct sizing of concrete storage to main- heating systems in waste recovery boilers are controlled
tain the ability to respond to temperature transients? while undergoing solar transients [16]. They note signifi-
cant technical challenges in controlling outlet temperatures
• What size of parabolic trough is required to maintain during solar transients. Eck and Hirsch use Modelica to
concrete temperatures for a given solar DNI profile?
analyse control of direct steam generation in parabolic
trough systems [17]. They show that short term irradia-
2. Literature Review tion disturbances due to cloud cover can cause large mass
flow rate disturbances in the parabolic troughs even with
2.1. Solar Assisted Feedwater Heating Configurations optimised control.
Solar parabolic troughs are a more mature alternative to Fossil-fuel-fired plants don’t necessarily require elimi-
large concentrating solar power towers [9]. Commercial oil nation of these medium-term transients when using solar-
troughs with molten salt storage operate up to about 390°C assisted feedwater heating. If their steam generators can
which allows these systems to provide heat for conventional structurally handle varying feedwater conditions, thermal
boilers including super-heat and reheat stages. However, input to the boiler can be increased to maintain desired
parabolic trough technology is well-suited for operating at electrical output in the event of reduced feedwater heating.
lower temperatures because of the lower flux concentration Unfortunately this does not apply to nuclear Rankine cycles
ratio and because the heat transfer fluid (whether oil or for which thermal power increases are typically not achiev-
steam) can accommodate lower temperatures than molten able if a reactor is operating at nominal power. Short term
salt can [4]. Hence, combined with traditional assets they electrical power increases above nominal electrical power
have the potential to offer higher efficiencies and offset any from the plant (transient overpower) is however desirable
associated carbon emissions.[10] [11] due to the ability to sell ramp-up capacity to the grid, an
Many studies have been performed on these parabolic auxiliary service, which will only grow more economically
trough solar hybrid configurations. A review by Behar et valuable as renewables play a large role on grids. Nuclear
al. [12] collected information on all existing plants and plants are also sensitive to variations in their feedwater
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inlet conditions [7] and hence require transients in these using the solar with TES to provide steady state power
inlet conditions to be damped as strongly as possible. and efficiency improvements at lower LCOE.
The simplest way to dampen solar thermal power varia- A different configuration is proposed by Zhao et al.
tions and maintain dispatchability is to introduce a thermal [27] who use a solar power tower CSP plant and a SMR
energy storage medium as a buffer that interfaces between to heat directly a packed bed thermocline from which a
the solar collectors and feedwater heaters. Robust control power cycle can be dispatched independently. This allows
must also be implemented to reject thermal and mass flow total decoupling of power produced from both the nuclear
rate disturbances whilst attempting to track power demand reactor cycle and the solar power produced. The challenge
signal commands. of this concept is that it requires a significant size of CSP,
100 MWe, and a large thermal energy storage system, 14.8h,
2.3. Modelling transients in thermal energy storage coupled to operate and due to temperature limits of the TES often
with solar thermal generation requires curtailment of the CSP.
Hybridized fossil fuel plants are able to compensate for These prior works all look to integrate solar heating
solar variations and, consequently, typically favour direct at the higher temperatures found in the reheat stages of
solar coupling instead of incurring the additional cost of the Rankine cycles. The only work that suggests the lower
thermal storage. On the other hand solar-thermal-only temperature feedwater configuration is the Solar Assisted
plants must find a way to decouple their output from the Reactor (SOAR) concept proposed by Benenati and Pow-
fluctuating solar insolation to achieve dispatchability [18] ell [28], which is the the most relevant prior work. They
and most opt to achieve this by introducing thermal energy suggest that solar heat integrated into the feedwater heat-
storage between the receiver and any power cycle. ing system can improve flexibility of operation and reduce
Several informative transient analyses of such CSP the LEC. They are able to show that higher temperature
plants with TES designs exist with some good examples feedwater heating results in better power boosting and
given in the papers [19] [20] [21]. These simulations were total efficiency of the reactor. While exceptionally well-
able to show that use of TES was able to decouple the investigated at steady state, the work by Benenati and
solar transients from power production ensuring the power Powell does not consider in depth how solar transients
plants can be dispatched at all times, including during the interact with the system.
night.
Of particular interest to this work are studies that use 3. The Design Concept
the Modelica language to perform dynamic modelling of
solar hybrids. The transient analysis of a PT power plant From the learning generated in previous works described
with TES by Montanes et al. [22] used a molten salt two above, this paper proposes thermal integration of parabolic
tank energy storage model in modelica along with a simple trough heat into the late stages of the feedwater heating
power block design. They found good agreement of the chain. The aim, as was mentioned in Popov [14] and
dynamic modelica model with published data from the Alam et al. [10], is to benefit from the closer matching of
Andasol power plant. The work by Liu et al [23] focused temperatures between the feedwater line and 30 bar steam
on the control system development of a CSP with two generated in the parabolic troughs.
tank sensible storage using a Modelica plant model and The design is based upon a conventional steam Rankine
MATLAB/SIMULINK to analyse the control of the system. cycle connected to a steam generator from a nuclear island.
The paper suggests a comprehensive control methodology The nuclear island in the transient model is taken to be a
and state machine to control variables within the dynamic small modular pressurised water reactor with the NuScale
model. Li et al [24] similarly used Modelica to perform design taken as the reference cycle [29]. It’s parameters
dynamic simulation of a coupled open-air receiver and TES are summarised in Table 1.
system. They were able to validate their simulation against Table 1: Adopted Design Parameters
experimental data and saw good agreement with simple
use of PI controllers to provide model control. Variable Adopted Value
2.4. Solar Assisted Feedwater in Nuclear Reactor Module Power 160 MWth
Electrical Power 50 MWe
Whilst there is a wealth of literature for solar feedwater
Steam Mass Flow 67 kg/s
heating in Rankine cycles driven by conventional fossil
Turbine Inlet Pressure 35 bar
generation there is an opportunity to extend this research
Feedwater Inlet Temperature 148°C
to it’s application in nuclear energy production. For nuclear
Steam Outlet Temperature 300°C
energy the potential for offsetting carbon emissions and
Net Efficiency 31%
achieving fuel cost reductions by retrofitting solar thermal
Condenser Pressure 0.08 bar
heating is removed. However, the economic benefit from
improved flexibility of the nuclear island is significant.
The study by Popov and Borissova [25] proposed using The traditional steam Rankine cycle is altered with
a PT field and two tank storage to provide superheat the addition of a higher temperature secondary feedwa-
and reheating on the top end of a PWR driven Rankine ter heater such that feedwater can be both heated by
cycle. The two-tank molten salt storage was shown across high temperature steam bled off the turbine or from the
many differing scenarios to allow continuous operation, pressurised steam loop connected to a dual pipe concrete
and electrical conversion efficiency in the superheat cycle storage. This loop is used to boost the temperature of the
achieved high efficiencies of 52%. A similar concept is incoming feedwater up to the desired inlet condition of the
investigated by Wang et al. [26] with a focus again on steam generator in modes of operation where the primary
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feedwater heating is configured to provide less heat to the
feedwater line than is sufficient to achieve this desired tem-
perature. An overall system diagram for understanding is
shown in Figure 1 with control mechanisms labelled for
discussion in section 6.1. A T-S diagram for the secondary
cycle is shown are shown in Figure 2 with the corresponding
state points and values shown in the schematic diagrams
in Figures 3 and 4 for nominal operation and power boost
mode respectively.
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Figure 3: State Diagram of nominal operation
the LPT-BV which connects to the feedwater heaters as found in Section 6.2 and sizing of the parabolic trough
described above. Both feedwater heaters are modelled as array is performed in Section 7.2.
shell and tube heat exchangers with values of NTU = 6
for the primary feedwater heater and NTU = 15 for the
6. Transient Model Operation
secondary feedwater heater. The condenser is modelled as
an ideal condenser at a pressure of 0.08 bar. 6.1. Modelica Control Scheme
To employ the Modelica model in transient scenarios, a
5.3. The Concrete Storage Model control scheme is devised to hold desired variables constant
The concrete storage model is used from the HYBRID whilst switching between operation states. The control
library with the mathematical description of the model scheme acts on multiple components across over the vari-
detailed in the report by Mikkelson and Doster [34]. It is a ous loops but due to the thermal coupling of the integrated
dual-pipe concrete storage, meaning it can be both charged energy system (IES) the various controls must work to-
and discharged simultaneously with separate channels for gether to respond to the variable load demand and solar
hot and cold fluids. In this design, saturated steam is run isolation profile. An overview of all controlled variables
into the hot channel at 30 bar, and subcooled water is and control components for the IES is given in Table 2 with
discharged at 30 bar in the cold channel to the secondary the schematic in Figure 1 above visualising the location of
feedwater heating stage. Detail on the temperature pro- these components.
files in the concrete storage during transient operation is
provided in Section 6.2 below, The size of the concrete 6.1.1. The Nuclear Island
storage is selected to maintain it’s average temperature Mikkelson and Frick [8] perform a detailed description
under typical solar insolation profile and dispatch and is of the control scheme they use for their SMR primary side
discussed in Section 7.6. model reused in this work. The model written for the
analysis in this paper makes use of their Tave program to
5.4. The Parabolic Trough Array control the reactor module with an overview reproduced
The parabolic trough array model is taken from the here.
ThermoCycle Modelica library developed by Quolin et al. The control program is designed to mirror the control
[35]. It comprises a solar field model that takes DNI, wind scheme proposed for the NuScale design described in the
velocity, ambient temperature, and array angle as inputs. report for the NuScale certification application [29]. Re-
It performs a dynamic 1D radial energy balance with the activity control is primarily modelled through the use of
geometry modelled on Schott PTR70 collectors [36]. For control rods to maintain a fixed core average temperature.
simplicity, it was taken that ambient temperature and In our implementation we use a nominal inlet temperature
◦
wind velocity remained constant and the array tracking of 148 C and a desire an outlet temperature of 300◦ C thus
angle was taken from the system advisor model (SAM) setting the controlled temperature to 224◦ C. Reactivity
for a parabolic trough [37]. The parabolic troughs are fed influences from injected boron and excess reactivity are set
with inlet sub-cooled water at 30 bar with saturated steam to nominal values which can be altered to simulate earlier
produced at the outlet for high solar DNI. Once again or later stages in reactor lifetime. Pressure is held constant
further detail on the transient temperature drops can be in the primary at 127.6 bar through proportional control
on the pressuriser models heaters and sprays.
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Figure 4: State Diagram of power boost operation
Figure 5: A Modelica implementation of the model with an exploded view of the balance of plant implementation.
Table 2: Transient Analysis control methods summary. Label numbers correspond to callouts in Figure 1.
6.1.2. The Balance of Plant and Concrete Discharge tation is not optimised, and significant additional work is
The response of balance-of-plant controls are critical proposed by the authors to tune these controllers. Instead,
to smooth operation of the IES in transition from nominal here, the control PI values were chosen to be sufficient to
to overpower. The controls take the form of PI feedback analyse key long term transients in the system and demon-
controllers that act based on the error between a measured strate the effect of control on shorter-term transients.
state and a desired setpoint. This PI control implemen- The state switching is driven by the LPT-BV. This
6
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a quantity refered to as aperture normal irradiation (ANI).
In order to maintain temperatures below safe operation
limits, mass flow is driven for all significant ANI values
with a nominal threshold for pumping set at 2 W/m2 .
This threshold can be raised to account for sensitivity of
detection equipment. The maximum mass flow rate to
the array is set to ensure sufficient steam output quality
at high ANI values. The resulting temperature profiles
in transient operation are discussed below. Pressure in
the charging loop is controlled in a similar fashion to the
discharge loop with a valve connected to an external high
pressure boundary.
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Figure 7: Parabolic Trough and Concrete Thermal Storage Channel Temperature Analysis
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altering this steam flow. Figure 11 shows how the efficiency
of the plant in nominal operation is reduced by increasing
the feedwater inlet temperature primarily due to the high
bleed off pressure reducing the work in the HPT.
The two studies above present a trade-off. We can in-
crease power boost capabilities of the reactor by increasing
feedwater temperature and/or increasing bleed off pressure
between the HPT and LPT in the power plant. However,
these two effects are not independent of each other. Im-
proved power output comes at the cost of reducing the
plants system efficiency at nominal operation.
Many of these design parameters will often be set inde-
pendently from the balance of plant design. Most notable
is the feedwater inlet temperature which is largely a func-
tion of the nuclear islands design, so choice in extraction
pressure will typically follow from this parameter.
Figure 12: Share of total work taken by each turbine with change in
the feedwater inlet temperature
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Figure 13: Parabolic Trough Generated Heat for Transient Test Case Figure 15: Generator Load Following Electrical Power Demand
Figure 14: Concrete Energy Storage Average Temperature for Tran- Figure 16: Short term response of generator output to full step of
sient Test Case power boost load demand.
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Figure 18: Efficiency of System in the Transient Analysis Figure 21: Feedwater Inlet Temperature for Transient Test Case
Figure 19: Mass Flow in LPT-BV for Transient Test Case Figure 22: Steam Generator Pressure for Transient Test Case
Figure 20: Heat Transferred to Feedwater in Secondary Feedwater Figure 23: Turine Inlet Mass Flow Rate for Transient Test Case
Heater for Transient Test Case
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8. Future Work 10. Acknowledgements
The transient analysis builds a firm simulation capabil- The authors would like to thank Cory Stansbury at
ity with which to perform future work. Improved system Westinghouse Electric Company who provided valuable ex-
control is necessary to eliminate large fluctuations in feed- pertise with regards to thermal energy storage and thermal
water inlet temperatures, reactor thermal power, steam integration in nuclear cycles.
pressure, and steam generator mass flow rate. Improved
control may decrease the response time to transients, thus
11. Funding
improving the economics of such a system by providing
the auxiliary service of fast dispatchable power for an en- This project was supported by funding received from
ergy grid. A future study of optimised control using this the DOE office of Nuclear Energy’s Nuclear Energy Uni-
transient model will help answer these questions. versity Research Program under contract number DE-
Beyond this, the techno-economics of adding such a sys- NE0008988
tem to an existing nuclear power plant should be analysed
to provide an economic case for the deployment of such a
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