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add crystallizer flowsheet #1482

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add crystallizer flowsheet #1482

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f52db5e
add crystallizer flowsheet
ElmiraShamlou Aug 20, 2024
2b16d2e
modifications
ElmiraShamlou Aug 21, 2024
bd85f8a
modifies costig
ElmiraShamlou Aug 22, 2024
deef8f9
modifies steam heater
ElmiraShamlou Aug 22, 2024
f4d56c0
modifies chiller
ElmiraShamlou Aug 22, 2024
b790eab
add revised crystallizer model
ElmiraShamlou Sep 11, 2024
45d86d0
add purge to MVR config
ElmiraShamlou Sep 12, 2024
2358454
add chiller for crystallizer vapor condensation
ElmiraShamlou Oct 1, 2024
eb4acd6
transfer revised crystallizer model to the original crystallizer mode…
ElmiraShamlou Oct 1, 2024
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92 changes: 1 addition & 91 deletions watertap/costing/unit_models/crystallizer.py
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Original file line number Diff line number Diff line change
Expand Up @@ -93,7 +93,7 @@ def build_crystallizer_cost_param_block(blk):
)

costing = blk.parent_block()
costing.register_flow_type("steam", blk.steam_cost)
#costing.register_flow_type("steam", blk.steam_cost)
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delete commented code

costing.register_flow_type("NaCl", blk.NaCl_recovery_value)


Expand All @@ -120,27 +120,6 @@ def cost_crystallizer(blk, cost_type=CrystallizerCostType.default):


def _cost_crystallizer_flows(blk):
blk.costing_package.cost_flow(
pyo.units.convert(
(
blk.unit_model.magma_circulation_flow_vol
* blk.unit_model.dens_mass_slurry
* Constants.acceleration_gravity
* blk.costing_package.crystallizer.pump_head_height
/ blk.costing_package.crystallizer.efficiency_pump
),
to_units=pyo.units.kW,
),
"electricity",
)

blk.costing_package.cost_flow(
pyo.units.convert(
(blk.unit_model.work_mechanical[0] / _compute_steam_properties(blk)),
to_units=pyo.units.m**3 / pyo.units.s,
),
"steam",
)
Comment on lines -123 to -143
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Curious about why these lines are being deleted. I probably didn't look closely enough, but have they been moved elsewhere or completely removed? And why?

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@adam-a-a They are removed as we integrate the steam heater, pump, and other essential components into the full FC crystallizer flowsheet. Therefore, the flow rates of the steam and recycle streams, along with their associated costs, are incorporated within the cost calculations of the steam heater and pump unit models.

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@ElmiraShamlou but removing this hinders whoever wants to use the combined unit we had previously.

Maybe what we need is a configuration argument that determines the mode the user wants (broken down or combined), and then adds the necessary equations for each case?


blk.costing_package.cost_flow(
blk.unit_model.solids.flow_mass_phase_comp[0, "Sol", "NaCl"],
Expand Down Expand Up @@ -215,72 +194,3 @@ def cost_crystallizer_by_volume(blk):
)
)
_cost_crystallizer_flows(blk)


def _compute_steam_properties(blk):
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Same question here, except it makes more sense immediately as to why we wouldn't want/need this in a costing module

"""
Function for computing saturated steam properties for thermal heating estimation.

Args:
pressure_sat: Steam gauge pressure in bar

Out:
Steam thermal capacity (latent heat of condensation * density) in kJ/m3
"""
pressure_sat = blk.costing_package.crystallizer.steam_pressure
# 1. Compute saturation temperature of steam: computed from El-Dessouky expression
tsat_constants = [
42.6776 * pyo.units.K,
-3892.7 * pyo.units.K,
1000 * pyo.units.kPa,
-9.48654 * pyo.units.dimensionless,
]
psat = (
pyo.units.convert(pressure_sat, to_units=pyo.units.kPa)
+ 101.325 * pyo.units.kPa
)
temperature_sat = tsat_constants[0] + tsat_constants[1] / (
pyo.log(psat / tsat_constants[2]) + tsat_constants[3]
)

# 2. Compute latent heat of condensation/vaporization: computed from Sharqawy expression
t = temperature_sat - 273.15 * pyo.units.K
enth_mass_units = pyo.units.J / pyo.units.kg
t_inv_units = pyo.units.K**-1
dh_constants = [
2.501e6 * enth_mass_units,
-2.369e3 * enth_mass_units * t_inv_units**1,
2.678e-1 * enth_mass_units * t_inv_units**2,
-8.103e-3 * enth_mass_units * t_inv_units**3,
-2.079e-5 * enth_mass_units * t_inv_units**4,
]
dh_vap = (
dh_constants[0]
+ dh_constants[1] * t
+ dh_constants[2] * t**2
+ dh_constants[3] * t**3
+ dh_constants[4] * t**4
)
dh_vap = pyo.units.convert(dh_vap, to_units=pyo.units.kJ / pyo.units.kg)

# 3. Compute specific volume: computed from Affandi expression (Eq 5)
t_critical = 647.096 * pyo.units.K
t_red = temperature_sat / t_critical # Reduced temperature
sp_vol_constants = [
-7.75883 * pyo.units.dimensionless,
3.23753 * pyo.units.dimensionless,
2.05755 * pyo.units.dimensionless,
-0.06052 * pyo.units.dimensionless,
0.00529 * pyo.units.dimensionless,
]
log_sp_vol = (
sp_vol_constants[0]
+ sp_vol_constants[1] * (pyo.log(1 / t_red)) ** 0.4
+ sp_vol_constants[2] / (t_red**2)
+ sp_vol_constants[3] / (t_red**4)
+ sp_vol_constants[4] / (t_red**5)
)
sp_vol = pyo.exp(log_sp_vol) * pyo.units.m**3 / pyo.units.kg

# 4. Return specific energy: density * latent heat
return dh_vap / sp_vol
3 changes: 2 additions & 1 deletion watertap/costing/unit_models/heat_exchanger.py
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Original file line number Diff line number Diff line change
Expand Up @@ -34,7 +34,8 @@ def build_heat_exchanger_cost_param_block(blk):
doc="steam cost per kg",
)

blk.parent_block().register_flow_type("steam", blk.steam_cost)
costing = blk.parent_block()
costing.register_flow_type("steam", blk.steam_cost)


@register_costing_parameter_block(
Expand Down
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