Energy Systems and Thermal Processes MSc

• Dr Ali Nabavi

This module provides an understanding of the fundamentals of operation, configuration and characteristics of thermal energy systems. You will also learn how to apply these for the design of energy-efficient furnaces and boilers, as well as the key implementation issues of various types of power plant.

 

• Fuels and thermal conversion processes: primary solid and liquid fuels. Carbonisation of solid fuels. Thermodynamic equations. Dissociation and chemical equilibrium. Process efficiency, emission control and standards,
• Furnaces and boilers: types of furnaces and classification. Heat transfer in furnaces, efficient furnace and boiler design. Boiler efficiency and part-load operation and its maintenance,
• Overview: World electricity demand and generation. Fuels. Environmental impacts,
• Steam power plants: Thermodynamic principles. Fuels. Steam power generation cycles,
• Gas turbine and combined-cycle power plants: Gas turbine engines and performance. Gas turbine cycles. Combined-cycle power plants,
• Diesel- and gas-engine power plants: Diesel engines. Fuels. Emission control. Heat recovery systems,
• Nuclear power generation: Basic nuclear physical processes (fission and fusion). Nuclear fuels. Types of reactors. Safety considerations in the nuclear industry. Developments in nuclear fusion. Decommissioning problems of nuclear sites. Nuclear waste disposal systems,
• Fuel cells: Definition and principles of operation. Losses and efficiency. Possible fuels. Fuel-cell technologies and applications (alkaline fuel cells, molten carbonate fuel cells, phosphoric acid fuel cells, solid oxide fuel cells, and regenerative fuel cells),
• CHP systems: CHP schemes (micro-scale CHP systems, small scale CHP systems, large scale CHP systems including district heating schemes). Application of CHP systems for the provision of heating, cooling and electric power. Selection criteria of CHP prime-movers. Integration of CHP systems into site services. Feasibility analysis of CHP schemes using spreadsheets/software tools. Case study (site appraisal for CHP scheme and evaluation of economic and environmental viability),
• Advanced power plants: geothermal plants and its applications. Solar thermal enhanced designs and new materials. Innovative SCO2 cycles to operate at higher temperatures, bringing higher energy output.

On successful completion of this module you should be able to:

• Critically evaluate the fundamentals and laws governing energy conversion and appraise various fuels and their characteristics.
• Assess the operation of furnaces and boilers based on a fundamental understanding of the governing laws, and debate issues influencing the design/selection of furnaces and boilers and future trends.
• Debate issues related to the performance of conventional power-generation plants and identify appropriate routes for improving energy-utilisation efficiency.
• Assess the need of a particular industrial/commercial site for a CHP system, identify the appropriate systems and undertake design, sizing and economic analyses.
• Critically review technologies employed for advanced power generation systems (Geo-thermal, solar thermal, SCO2 cycle) and it’s applications.

• Dr Kranthi Jonnalagadda

Industrial sector uses thermal heat directly in the preparation or treatment of materials used to manufacture goods. This module is designed to provide detailed working knowledge and understanding of the operational principles of small and medium scale industrial thermal plants and their power and heat production needs. The module will cover a wide variety of recent developments in thermal driven technologies to enhance energy efficiency and to improve environmental performance. In addition, this module also evaluates the renewables share to provide industrial process heat while replacing fossil fuels use.  

• Waste heat sources and its common uses: steam turbine exhaust from high temperature applications, gas turbine exhausts, reciprocating engines, process waste fluids and gas streams from oven/kilns; depends on its quality the waste heat can use for boiler feed water pre-heating, combustion air pre-heating, building space heating and drying ovens,
• Industrial thermal operations enhancement: to improve efficiency by integrating organic Rankine cycles, Supercritical CO2 cycles, electric turbo compounding or a thermos-electric generator to delivery additional power to grid,
• Thermal driven technologies: Absorption chillers, desalination, heat pumps, food processing, water purification and treatment and greenhouses; these technologies aimed to significant energy savings, lowering global warming and ensuring higher indoor air quality,
• Thermal energy storage: types of storage and its operational characteristics; costs and pricing; integration of thermal storage into electrical grids; off-grid systems; seasonal storage scenarios; future developments including hydrogen storage,
• Fuel cells: Definition and principles of operation. Losses and efficiency. Possible fuels. Fuel-cell technologies and applications (alkaline fuel cells, molten carbonate fuel cells, phosphoric acid fuel cells, solid oxide fuel cells, and regenerative fuel cells),
• CHP systems: CHP schemes (micro-scale CHP systems, small‑scale CHP systems, large‑scale CHP systems including district heating schemes). Application of CHP systems for the provision of heating, cooling and electric power. Selection criteria of CHP prime-movers. Integration of CHP systems into site services. Feasibility analysis of CHP schemes using spreadsheets/software tools. Case study (site appraisal for CHP scheme and evaluation of economic and environmental viability).

On successful completion of this module you should be able to:

• Analyse principles for any relevant industrial thermal operation systems and assess qualitatively and quantitatively,
• Evaluate efficiency improvements by integrating the waste heat recovery concepts,
• Explain different thermal driven technologies and assess its applicability in order to meet user defined specifications,
• Distinguish between available and relevant thermal energy storage systems and its system evaluation.

• Dr Patrick Verdin

This module introduces you to the CFD techniques and tools for modelling, simulating and analysing practical engineering problems with hands on experience using commercial software packages used in industry.

• Introduction to CFD & thermo-fluids: introduction to the physics of thermo-fluids, governing equations (continuity, momentum, energy and species conservation) and state of the art computational fluid dynamics including modelling, grid generation, simulation, and high performance computing. Case study of industrial problems related to energy, process systems, offshore engineering, and the physical processes where CFD can be used,
• Computational engineering exercise: specification for a CFD simulation, requirements for accurate analysis and validation for multi scale problems, introduction to turbulence & practical applications of turbulence models, introduction to turbulence and turbulent flows, traditional turbulence modelling,
• Advanced turbulence modelling: introduction to Reynolds-averaged Navier Stokes (RANS) simulations and large-eddy simulation (LES),
• Practical sessions: fluid process problems are solved employing the widely-used industrial flow solver software FLUENT. Lectures are followed by practical sessions on single/multiphase flows, heat transfer, to set up and simulate a problem incrementally.  Practical sessions cover the entire CFD process including geometric modelling, grid generation, flow solver, analysis, validation and visualisation.

On successful completion of this module you should be able to:

• assemble and evaluate the different components of the CFD process,
• explain the governing equations for fluid flows and how to solve them computationally,
• compare and contrast various methods for simulating turbulent flows applicable to mechanical and process engineering,
• set up simulations and evaluate a practical problem using a commercial CFD package,
• design CFD modelling studies for use in industrial design of complex systems.

• Dr Liyun Lao

This modules introduces you to the fundamental concepts, principles, methodologies, and application for the design of advanced control systems for industrial applications.

• System dynamics:
  • modelling of typical physical systems, operating point, linearization, differential equation representation, state space representation of systems, laplace transforms, transfer functions, block diagrams, SISO and MIMO systems, time and frequency domain responses of systems,
• Feedback control:
  • positive and negative feedback, stability, methods for stability analysis, closed loop performance specification, PID controllers, Ziegler-Nichols, self-tuning methods,
• Enhanced controllers:
  • cascade control, feedforward control, control of non-linear systems, control of systems with delay,
• Digital controllers:
  • effects of sampling, implementation of PID controller, stability and tuning,
• Advanced control topics:
  • hierarchical control Kalman filter, system identification, model predictive control, statistical process control, the use of expert systems and neural networks in industrial control,
• Design packages for process control systems:
  • examples including Simulink and MATLAB.
• Case studies:
  • examples will be chosen from a range of industrial systems including mechanical, chemical and fluid systems.

On successful completion of this module you should be able to:

• Evaluate and select appropriate modelling techniques for dynamic systems,
• Formulate control methodologies in feedback, feedforward and cascade loops,
• Recognise and critically appraise the key design tools and procedures for continuous and discrete controllers of dynamic systems.

• Dr Joy Sumner

This module provides an in-depth applied knowledge for different thermal energy systems to help spur the next industrial revolution for improving efficiency, reducing water consumption and efficient way of utilising waste heat streams. During this module you will learn how to develop these integrated schemes and play an important role in thermodynamic modelling, data collection, analysis, and prediction of the performance and control of these advanced/applied thermal systems.

• Thermodynamic simulation tool selection: ASPEN Plus, Thermoflex, Ebsilon, MATLAB, EES and/or combination of these software packages,
• Modelling of heat source: Coal-fired boilers, solar field, biomass incinerators and nuclear reactors, and its typical steam conditions, thermal energy storage etc.
• Power block configuration for large Rankine cycle: Steam generators, Steam turbine, condenser, pumps, Deaerators, super heaters, pre heaters, heat exchangers, Control valves etc. Introducing the concept of Exergy and how it can be used to understand how processes can be made more efficient for large Rankine steam cycle,
• Cooling technologies for heat rejection: Once through cooling, wet cooling towers, Dry cooling towers, Hybrid cooling systems, Versatile coolers, Cold Thermal Energy Storage (cTES) systems, PCM storage, Water consumption calculations,
• Integration of components and systems: Integration of detail component model into global model (of heat source, power block and cooling systems), Design vs Off Design analysis,
• Waste heat recovery systems: Absorption chiller simulations, de-humidification calculations, desalination model development (Multi-effect distillation, Membrane distillation),
• Dynamic model: Transient simulation, Annual performance of the developed thermal energy system,
• Economics of thermal energy systems: Economic models for thermal energy systems, CAPEX and OPEX, Levelized cost of energy (LCE) calculations.

On successful completion of this module you should be able to:

• Critically evaluate the detailed thermodynamics of different thermal energy processes,
• Articulate the details of thermodynamic modelling of different energy sources, power blocks, cooling technologies and waste heat from thermal systems to drive desalination and absorption systems,
• Assess the integration of these thermal sub system components into whole plant configuration for design and off-design scenarios,
• Propose appropriate routes for improving energy-utilisation efficiency and its trade-offs,
• Investigate the economic and environmental impacts of the proposed technologies.

• Dr Dawid Hanak

This module aims to introduce you to the modern techniques and computer aided engineering tools for the design, simulation and optimisation of process systems. Via a large share of process simulation and optimisation case studies, the module will enable you to gather the hands-on experience of using the commercial software.

Process Design
• Overview: Conceptual process design. Process flow-sheeting,
• Process synthesis: Overview of a process system. Recycle structure of the flowsheet. Design of reaction and separation systems,
• Process integration: Basic concepts of process integration for heat exchanger network design,
• Process economic analysis: Equipment capital cost estimation. Process profitability analysis.
Process Modelling, Simulation and Optimisation
• Modelling and simulation: Basic concepts of process modelling. General concepts of simulation. Introduction to steady and dynamic process simulation. Introduction to commercial simulation software packages (i.e, Aspen HYSYS) for process flow-sheeting, design and analysis,
• Process optimisation techniques: Basic principles of optimisation. Presentation of a number of industrial case studies (e.g., heat exchanges network synthesis).
Case Studies (PC Lab and Demonstration Sessions)
• A number of process simulation and optimisation case studies will be carried out using Aspen HYSYS and Aspen Plus.

On successful completion of this module you should be able to:

• Formulate strategies to carry out a process design and critically appraise the techniques and major commercial simulation tools for steady and dynamic process simulation,  
• Competently apply the basic principles of process optimisation,
• Design and analyse the performance of a process plant using simulation or optimisation tools.

• Dr Kumar Patchigolla

Heat exchangers are critical to a wide variety of engineering applications and power to chemical plants. Any process changes leads to intensive replacement of these heat exchangers, hence this module provides in depth understanding of practically proven heat exchanger technologies and its limitations. This course will provide good mix of state-of-the-art technologies and novel designs using interactive case studies and rigorous design strategies for an efficient heat exchanger sizing, specification and its operational performance. 

• Principles of heat transfer and fluid flow: one and two-dimensional steady state conduction and transient heat conduction; Forced and free convection-fluid flow and boundary layer concept; convective coefficients, resistance caused by the walls and by fouling; Flows over flat plates. A cylinder and a sphere in cross flow. Tube bundles in cross flow. Forced convection in packed beds. Forced convection inside tubes and ducts. 
• Heat exchanger characteristics/specification: heat exchange area estimate--tubes diameter, length, tube pattern and pitch; baffle—type and spacing; design criteria-number of shell in series or in parallel and number of tube passes; two phase flows and hydrodynamics,
• Design techniques and heat source: ϵ-NTU method, Effectiveness-Number of Transfer Unit relationships, P-NTU Method, P-NTU relationships, Mean Temperature Difference Method, Comparison of the ϵ-NTU, P-NTU, and MTD Methods, ψ-P and P1-P2 Methods, Solution Methods for Determining Exchanger Effectiveness; Modelling a Heat Exchanger Based on the First Law of Thermodynamics, Irreversibility in Heat Exchangers, Thermodynamic Irreversibility and Temperature Cross Phenomena, Heuristic Approach to an Assessment of Heat Exchanger Effectiveness, Energy, Exergy, and Cost Balances in the Analysis and Optimisation of Heat Exchangers,
• Conventional heat exchanger configurations: air-cooled heat exchangers, Tubular Heat Exchangers, Tube-Fin Heat Exchangers, Plate-Fin Heat Exchangers, Shell-and-Tube Exchangers with Segmental Baffles, Gasketed Plate Heat Exchangers, Selection Criteria Based on Operating Parameters, General Selection Guidelines for Major Exchanger Types; heat exchanger pressure drop analysis; Low-fin, High-flux, Corrugated and Twisted Tube applications,
• Industrial problems and advanced configurations: high temperature high pressure applications-supercritical CO2, solar receivers, evacuated tube collectors; printed circuit heat exchangers; hybrid systems with efficient heat exchanger; exchange area requirement and thermal performance
  

On successful completion of this module you should be able to:

• Debate on different modes of heat transfer and its applicability for designing heat exchanger concepts,
• Differentiate various types of heat exchangers commonly used in industrial and process engineering contexts, and evaluate the design practices employed,
• Evaluate energy, exergy, and cost balances to rationalise heat exchanger selection,
• Discuss the novel heat exchanger design aspects related to power cycles including recuperators, regenerators, reboiler, condenser etc.
• Select the appropriate heat exchanger for any given application (conventional vs advanced).

• Dr Richard Adams

The importance of technology leadership in driving the technical aspects of an organisation's products, innovation, programmes, operations and strategy is paramount, especially in today’s turbulent commercial environment with its unprecedented pace of technological development. As demand for ever more complex products and services has become the norm, one of the challenges for today’s manager is to deal with uncertainty, to allow technological innovation and change to flourish, whilst also remaining within planned parameters of performance. This module helps to develop your understanding of management processes within an organisational context, so that when you seek employment you are equipped with both the extensive subject/discipline knowledge and the ability to relate it to a management context.

• Engineers and Technologists in organisations:
  • the role of organisations and the challenges facing engineers and technologies,
• People management:
  • understanding you, understanding other people, working in teams and dealing with conflicts.
• The Business Environment:
  • understanding the business environment; identifying key trends and their implications for the organisation.
• Strategy and Marketing:
  • developing effective strategies, focusing on the customer, building competitive advantage, the role of strategic assets.
• Finance:
  • profit and loss accounts, balance sheets, cash flow forecasting, project appraisal.
• New product development:
  • commercialising technology, market drivers, time to market, focusing technology, concerns.
• Business game:
  • Working in teams (companies), you will set up and run a technology company and make decisions on investment, R&D funding, operations, marketing and sales strategy,
• Negotiation:
  • preparation for negotiations, negotiation process, win-win solutions.
• Presentation skills:
  • understanding your audience, focusing your message, successful presentations, getting your message across.

On successful completion of this module you should be able to:

• Recognise the importance of teamwork in the performance and success of organisations with particular reference to commercialising technological innovation,
• Operate as an effective team member, recognising the contribution of individuals within the team, and capable of developing team working skills in yourself and others to improve the overall performance of a team,
• Compare and evaluate the impact of the key functional areas (strategy, marketing and finance) on the commercial performance of an organisation, relevant to the manufacture of a product or provision of a technical service,
• Design and deliver an effective presentation that justifies and supports any decisions or recommendations made,
• Argue and defend your judgements through constructive communication and negotiating skills.