Milestones for Prosim
The development of Prosim is based on long industrial experience. The leader of the development team, Prof. Carl-Johan Fogelholm, has more than fifteen years experience in different positions with manufacturers, utility companies and engineering companies. Prosim is used as a tool for the design and retrofit of power plants and also for condition monitoring systems (CMS) and acceptance tests of power plants. As the chairman for the Nordic Process integration research program Prof. Fogelholm has a very good insight to the latest research in Northern Europe. Optimisation of power plants using Exergy and Pinch methods in Prosim are results of Nordic co-operation. Combined heat and power production has always played an important role in the Nordic countries. Therefore both industrial and district heating power plants have been included in Prosim from the beginning. In Prosim simulations it is possible to use all fuels; coal, oil, natural gas and synthetic gases, all types of bio fuels, industrial and municipal waste. Prosim 4 will be available next year, and will include more curve presentations; modules for both diesel and gas engines and a library of the most common motors for power plants.
First commercial release
The first commercial release of Prosim was in 1985. It included the simulation of the complete steam cycle for condensing, industrial and district heating power plants; also the simulation of combined cycles. The calculation of gas turbines was based on a gas turbine library that included the correction curves from several manufacturers.
In 1990 the development work of the boiler modules was ready for commercial release. This included conventional steam boilers with radiant furnace and fluidised bed boilers. The fluidised bed boiler can be atmospheric or pressurised; a circulating (CFB) or a bubbling bed fluidised bed boiler. On the steam side, it is possible to simulate both drum constructions and once through boilers, also for supercritical steam conditions. The fluidised bed includes sulphur reduction, form the flue gases, by adding limestone to the bed.
IGCC and PFBC, HAT and STIG
In 1991 all the modules needed for simulating IGCC and PFBC processes were ready, including pressurised gasification of coal, bio fuels and oil residuals. Manufacturers of both IGCC and PFBC power plants and also research institutes are using Prosim when developing new power plant processes. The simulation of processes where a fuel cell is combined with gas turbine and humid air turbine (HAT) cycles are other examples where Prosim is used for research. Prosim also includes compressor map and cooling of the blades in gas expanders.
In 1994 Prosim was developed to run under AutoCad. Connecting Prosim to the leading CAD program in the world gives significant advantages. All the features of AutoCad can be used to make Prosim really user friendly. Steam turbine expansion lines and boiler heat flow diagrams are presented in Execl.
Pulp and paper processes
Pulpsim and Prosim were integrated into one program in 1995. This makes it possible to simulate both the chemical and the energy balance of a whole pulp mill including the chemical recovery of the cooking chemicals in the steam boiler.
Exergy and Pinch analyses are powerful tools for the optimisation of power plants. Both methods were recently included in Prosim. The Pinch program, Pro_Pi, is developed at Chalmers Industry Energy Analyses.
Prosim has been used for CMS systems since 1999. In an industrial power plant Prosim is used for condition monitoring of the steam boiler, turbine and the district heating system. Prosim CMS system includes the optimisation of sootblowing intervals and a possibility for the operating personnel to make "what if" (simulation) calculations in the control room.
Development of boiler simulations
Tekes, the National Technology Agency, has assigned funding for s development program, where ll further develop our boiler calculations (furnace, superheater and other heatexchangers). In the furnace model will be used "Zone"-model and Monte-Carlo techniques. Executive group contain now persons from Vattenfall AB Sweden, Foster Wheeler Energia Oy Finland, Helsinki Energy Oy and Endat Oy. This work has started in the August 2000 and continue to the end of 2002.
Other rather big development project has been started with Technical Research Centre of Finland In this project s dynamic simulator Apros and Prosim will be integrated together. This project is supported by the National Technology Agency too. First results of this work will be available in the year 2002.
First commercial version of WebProsim was delivered in the summer 2003 into a Finnish industrial Power plant. WebProsim is a easy to use simulator. The interface runs in different browsers (IE, Netscape...). WebProsim is capable for process simulation, cost calculation, turbine condition calculation...
Prosim has been utilized for on-line process calculations for thermal power plants since 2001. Endat was acquired by Clyde Bergemann in 2007. After Endat became a member of Clyde Bergemann Power Group Prosim has been used for several intelligent sootblowing applications.
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