A life cycle cost analysis (LCCA) has been done on the manufacturing and use phases of a system composed by Bio-HyPP system components. The analyses take into account the production and use phases.
Steady-state thermodynamic simulation models of the top-performance and top-economic layouts have been used to define the specifications. The thermodynamic models have been validated and used for further detailed analysis of the operating range, operation strategies and for defining components’ input conditions for further optimization.
A combustion system, which meets the needs for both SOFC off-gas combustion and biogas/natural-gas-fired combustion has been developed, manufactured, tested under atmospheric conditions and analyzed concerning the operating range. To widen the operating range, adding excess fuel has been analyzed. The combustor for the MGT hybrid test rig has been designed and manufactured. The combustion system and its interfaces have been adapted constructively and have been integrated into the hybrid emulation test and it has been tested on the test rig. Analysis of the combustor in the test rig conditions has been done.
Performance and robustness of the micro gas turbine (MGT) have been improved by efficiency improvements of the turbomachinery components and by power density improvement of the turbine generator.
A significant performance improvement has been obtained, mainly as a result of the combination of small optimisations on the turbomachinery components (introduction of compressor pre-whirl vanes, compressor diffuser vanes, compressor scroll cooling, compressor leading edge modification and modification of turbine heat shield), leading to an 840 W electrical power output increase for the 3 kW MGT.
Designs for the two recuperators for the top-efficiency and the top-economic power plant have been defined. The recuperator effectiveness has been improved as significantly lower costs.
A model predictive control based on multiple tools has been developed for control optimization of the top-economic hybrid power plant. Fluctuations / oscillations could be reduced, so the thermal stress to the SOFC could be decreased. Compressor surge under large variable volumes has been analysed to identify surge precursors. The impact of transient operations (e.g. operations on the cold bypass valve) on the compressor stability have been identified and tested SOFC degradation has been investigated and analysed.
The existing emulation facilities have been upgraded and used for experiments to define necessary valve control and investigation of surge. Models including model predictive controller have been connected to the experimental plant. Different control strategies considering degradation have been evaluated.
Two real subsystems with emulation have been set-up and assembled in the lab: the SOFC test rig and MGT test rig (each emulating the counterpart). Two control systems derived from a joint control concept (for the real coupling) have been developed, commissioned and iteratively adapted.
The top-economic layout has been set up and tested from both theoretical and experimental point of views. Control approaches for the different valves and for part-load operations have been analysed with the simulation tools. Components like recuperator and burner have been designed. Risk mitigation solutions and a plan to involve fire managers have been defined.
The results achieved were disseminated to a wide range of interested audience and stakeholders, thought a Newsletter (8 issues released twice a year), the participation of consortium members at a number of national and international events targeting both the scientific as well as the industrial community, through the publication of scientific articles and publications on the results achieved and the activities carried out and finally throught the website, countinuosly updated during the project with the latest results and news about the project.
