KR102799424B1 - Modular design method for biomass raw material plant - Google Patents

Abstract

The modular design method of a biomass feedstock plant according to the embodiment provides a split module design system that can shorten the overall construction period and reduce construction costs by modularizing the plant structure into units of a size suitable for sea and land, thereby facilitating on-site transportation and assembly, and determines the feasibility of the configuration facilities based on the possibility of manufacturing and transporting them in Korea, and optimizes the design, manufacturing, transportation, and installation of general facilities. The modular design method of a biomass feedstock plant contributes to extending the life of existing facilities, improving facility management, and enhancing operating efficiency. In addition, it provides an opportunity for mutual development as well as restoration of trust with local residents through 24-hour management of unused renewable fuel plant power generation facilities. In addition, it can contribute to increased exports by expanding the business of unused renewable fuel plant power generation facilities and operation management in Southeast Asia, India, China, and other developing countries in the environmental industry as well as in Korea.

Description

{MODULAR DESIGN METHOD FOR BIOMASS RAW MATERIAL PLANT}

The present disclosure relates to a modular design method for a biomass raw material plant, and more specifically, to a modular design method for a biomass raw material plant that modularizes plant structures into units of sizes suitable for sea and land, thereby facilitating on-site transportation and assembly, thereby shortening the overall construction period of the plant and reducing construction costs.

Unless otherwise indicated herein, the materials described in this section are not prior art to the claims of this application and their inclusion in this section is not an admission that they are prior art.

Plant split module design technology is a technology that can shorten the overall construction period and reduce construction costs by dividing the plant structure into unit parts to facilitate on-site transportation and assembly. Currently, the global biomass plant market is continuously developing, and the market is expected to expand in earnest. In line with this, China and Japan are also promoting biomass plant-related projects through collaboration with companies in the United States and Canada at the national level. On the other hand, Korea is still in the initial entry stage and is experiencing various legal, institutional, and environmental difficulties, so support and technology development at the national level are necessary.

Biomass feedstock plants have a limited construction period and it is not easy to secure local construction workers, so on-site construction must be minimized. In particular, because shortening the construction period leads to faster power generation, which allows clients to see the return on their investment, there is a particularly high level of interest in modular technology (design-manufacture-installation).

Most of the materials used in biomass feedstock plant modules are supplied by contractors after the ordering party and the design company select suppliers, so the domestic material certification is not carried out, and the localization rate of materials is very low. Therefore, technology development is required to increase the foreign exchange rate through localization of materials. To this end, research and development in various technology fields for operating biomass feedstock plants is being promoted.

Among the technologies related to biomass plants, compact function modules are technologies that improve the modularization ratio by dividing functional modules into appropriate sizes, and optimize compact space design while achieving plant process efficiency at the same level as existing ones by utilizing small machines and equipment, since existing plant configuration facilities cannot be manufactured domestically due to module transport size restrictions. Labor costs in plant demand countries including Vietnam are low, but cultural differences can increase the construction period due to difficulties in work efficiency, so the construction period can be shortened through the modularization technology mentioned above. In addition, protecting the air is essential in construction contracts, but the construction environment in demand countries such as Vietnam does not allow for this. Recently, most plant projects commissioned by advanced engineering companies are trending toward modularization design centered on partial or full construction block modules.

1. Korean Patent Application No. 10-2016-0015713 (2016.02.11) 2. Korean Patent Application No. 10-2019-7018749 (May 29, 2019)

The modular design method of a biomass feedstock plant according to an embodiment provides a split module design method that can shorten the overall construction period and reduce construction costs by modularizing the plant structure into units of a size suitable for sea and land, thereby facilitating on-site transportation and assembly, and determines the feasibility of the configuration equipment based on the possibility of manufacturing and transporting it in Korea, and optimizes the design, manufacturing, transportation, and installation of general facilities.

In addition, the modular design method of the biomass feedstock plant according to the embodiment determines the feasibility of the configuration facilities based on the module size of the plant as well as the transportability, and designs the split modules of the biomass feedstock plant to optimize the design, manufacturing, transport, and installation for a general facility.

In addition, the modular design method of the biomass raw material plant according to the embodiment performs a modularization study report at the basic design stage, considering the transportation plan (Logistics Study report) and ease of construction. In addition, in the embodiment, a modulation plan including module manufacturing, transportation, and installation plans is created before performing FEED (Front End Engineering and Design) and detailed design (Detail Design), and detailed design drawings (Detail Drawings) and shop drawings (Shop Drawings) are created based on this.

In addition, in the embodiment, the optimal shape of the structural frame according to the oil sand modularization considering maritime and land transportation is derived, and the structural analysis using the finite element method and the design variables considering the static load, dynamic load, and wind load are secured.

A modular design method of a biomass raw material plant according to an embodiment includes: (A) a step of modularizing a plant structure into units of sizes suitable for offshore and onshore use in a divided module design unit; (B) a step of collecting plant facility operation data and divided module design operation information in an information collection unit; (C) a step of performing a performance diagnosis of the divided plant modules based on intelligent information technology in a diagnosis unit; and (D) a step of designing intelligent operation guidance of the modularized plant facility based on the plant facility operation data and the performance diagnosis results in a guidance design unit.

The modular design method of biomass raw material plants as described above contributes to extending the life of existing facilities, improving facility management, and enhancing operational efficiency. In addition, it provides opportunities for mutual development as well as restoration of trust with surrounding residents through 24-hour management of unused renewable fuel plant power generation facilities. In addition, it can contribute to increasing exports by expanding business for unused renewable fuel plant power generation facilities and operation management in Southeast Asia, India, China, and other developing countries in the environmental industry, as well as in Korea.

The effects of the present invention are not limited to the effects described above, and should be understood to include all effects that can be inferred from the detailed description of the present invention or the composition of the invention described in the claims.

Figure 1 is a drawing showing an example of modular design of a modular design system for a biomass raw material plant according to an embodiment and an example of plant design and construction through a combination of standard modules.
Figure 2 is a diagram showing the data processing configuration of a modular design system for a biomass raw material plant according to an embodiment.
Figure 3 is a drawing showing the data processing configuration of the split module design unit (110) according to the embodiment.
Figure 4 is a drawing showing the performance task of a split module design system of a biomass raw material plant according to an embodiment.
Figure 5 is a drawing showing an example of performing module design of a split module design system of a biomass raw material plant according to an embodiment.
Figure 6 is a diagram showing the data processing flow of a modular design method for a biomass raw material plant according to an embodiment.

The advantages and features of the present invention, and the methods for achieving them, will become clear with reference to the embodiments described in detail below together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various different forms, and the present embodiments are provided only to make the disclosure of the present invention complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined only by the scope of the claims. Like reference numerals refer to like elements throughout the specification.

In describing embodiments of the present invention, if it is judged that a detailed description of a known function or configuration may unnecessarily obscure the gist of the present invention, the detailed description will be omitted. In addition, the terms described below are terms defined in consideration of functions in embodiments of the present invention, and these may vary depending on the intention or custom of the user or operator. Therefore, the definitions should be made based on the contents throughout this specification.

Figure 1 is a drawing showing an example of modular design of a modular design system for a biomass raw material plant according to an embodiment and an example of plant design and construction through a combination of standard modules.

Referring to FIG. 1, the modular design system of a biomass feedstock plant according to an embodiment determines the feasibility of a configuration facility based on the module size of a functional module, for example, a 10,000 BPD oil sands SAGD CPF plant of a basic design, as well as transportation possibility, and designs a split module of the biomass feedstock plant to optimize the design, manufacturing, transportation, and installation for a general facility. In addition, in the embodiment, based on the modularization philosophy, a logistics study report and a modularization study report are performed in the basic design stage in consideration of the ease of construction. In addition, in the embodiment, a modulation plan including a module manufacturing, transportation, and installation plan is created before performing FEED (Front End Engineering and Design) and detailed design, and detailed design drawings (Detail Drawings) and shop drawings (Shop Drawings) are created based on the modularization plan. In addition, in the embodiment, the optimal shape of the structural frame according to the oil sand modularization considering maritime and land transportation is derived, and the structural analysis using the finite element method and the design variables considering the static load, dynamic load, and wind load are secured.

In addition, it provides a split module design system that can shorten the overall construction period and reduce construction costs by modularizing the plant structure into units of a size suitable for sea and land, thereby facilitating on-site transportation and assembly, and determines the feasibility of the configuration equipment based on the possibility of manufacturing and transporting it in Korea, and optimizes the design, manufacturing, transportation, and installation of general facilities. Through this, it contributes to extending the life of existing equipment, improving equipment management, and enhancing operational efficiency.

In addition, it provides opportunities for mutual development as well as restoration of trust with surrounding residents through 24-hour management of unused renewable fuel plant power generation facilities. In addition, it contributes to increased exports through expansion of business for unused renewable fuel plant power generation facilities and operation management in Southeast Asia, India, China, and other developing countries in the environmental industry, as well as in Korea.

FIG. 2 is a diagram showing the data processing configuration of a modular design system for a biomass raw material plant according to an embodiment.

Referring to Fig. 2, the modular design system of a biomass raw material plant according to an embodiment may be configured to include a split module design unit (110), an information collection unit (120), a diagnosis unit (130), and a guidance design unit (140). The split module design unit (110) modularizes the plant structure into units of a size suitable for sea and land. The information collection unit (120)

Collects plant facility operation data and divided module design operation information. The diagnosis unit (130) performs performance diagnosis of divided plant modules based on intelligent information technology. The guidance design unit (140) designs intelligent operation guidance of modularized plant facilities based on plant facility operation data and performance diagnosis results.

In the embodiment, the split module design unit (110) modularizes the plant structure into units of sizes suitable for offshore and onshore. In the embodiment, the split module design unit (110) determines the feasibility of the configuration facility based on the module size of the 10,000 BPD oil sands SAGD CPF plant of the basic design of the functional module as well as the possibility of manufacturing and transporting it in Korea. In addition, it optimizes the design, manufacturing, transport, and installation of general facilities. In the embodiment, the split module design unit (110) considers the module assembly and manufacturing conditions on site when designing the split module. In the embodiment, the module is composed of parts of the entire system and units and can be divided into a structural part and a ground part. Each module is transported and assembled on site as a unit that constitutes a complete process plant, and in the embodiment, modularization is considered only when all assembly work within the structural frame is completed and no separate additional assembly or construction work is required on site. In addition, some devices may not be included in the module and may be installed separately on site.

In the embodiment, the confirmation of the modular design includes not only the in-place analysis, which is the design for general operating requirements, but also the pre-service analysis, which is the design for transportation requirements including load-in/out, sea transportation, and in-land transportation. In the pre-service analysis, analysis is performed for cases where the module support is lost or excessive displacement occurs to ensure safety during load-in/out and transportation. In addition, in order to secure the stability of the transport vessel during sea transportation, the design for sea fastening, which is a temporary reinforcement, can be additionally performed. In the embodiment, the modular concept is determined by considering the assembly and manufacturing conditions at the application site. The module consists of parts of the entire system and units, and is divided into a structure part and a ground part. Each module can be transported and assembled locally as a unit that constitutes a complete process plant. In the embodiment, modularization is considered only when all assembly work within the structural frame is completed and no additional assembly or erection work is required on site. In addition, some devices may not be included in the modules and may be installed separately on site.

In the embodiment, the diagnostic unit (130) performs process diagnosis of a biomass raw material plant segmentation modularization design, analysis of the operator operation pattern of the biomass raw material plant, comprehensive reporting service for plant operation, and LCC (Life Cycle Cost) analysis. In addition, the diagnostic unit (130) performs real-time process efficiency analysis, real-time operation management, and equipment history management of the plant for plant modularization, and performs 3D process analysis and monitoring. In addition, the diagnostic unit (130) can analyze the cause of failure of plant equipment and perform non-face-to-face remote control of plant equipment through the manager's smart terminal and control server.

Figure 3 is a drawing showing the data processing configuration of the split module design unit (110) according to the embodiment.

Referring to FIG. 3, the split module design system according to the embodiment may be configured to include a database (141) and an analysis unit (143). The analysis unit (143) performs an in-place analysis and a pre-service analysis to create a biomass plant split module. In addition, in order to secure load in out and transportation stability, it may analyze information on the loss of module points and occurrence of excessive displacement. In addition, the split module design system (140) according to the embodiment may additionally perform a design for a sea fastening facility, which is a temporary reinforcing material, to secure the stability of a transport vessel during ocean transport.

In the embodiment, the divided module design system designs the modules of the plant by classifying them in detail into a PAS (Pre-Assembled Steel structure), PAR (Pre-Assembled pipe Rack), PAU (Pre-Assembled Unit), VAU (Vendor Assembled Unit), and VPU (Vendor Package Unit). In the embodiment, unlike a stick built type structure, when designing and manufacturing a module, land or sea transportation conditions are considered, and module division design according to the transportation conditions is performed. In the embodiment, for land transportation and installation, the center of gravity is managed, and for sea transportation, the structure is designed to ensure safety against sea acceleration force. In the embodiment, the transportation conditions and installation method limit the size and weight of the structure, and this is considered as a requirement when selecting a module target structure and when planning the division of the selected module.

In the embodiment, the module division design system starts by determining the module target structure by considering the plant plot plan and transportability for the module division design, and then establishing a module division plan. Thereafter, the detailed design is supplemented to design the divided modules to be safe for land and sea transportation and to avoid problems during on-site installation, and the design is completed. In the embodiment, the module division design is a plan to divide one structure into a main module, a sub module, and a ship loose part by considering the transportation method and the on-site installation method, and piping, cable trays, etc. are also divided accordingly. In the embodiment, when designing the module division, the transportability for reaching the site according to the transportation method is also considered important, but due to the movement route conditions within the site, the height, width, and length of the module are limited, and this is considered when establishing the module division plan. In addition, in the embodiment, when transporting by land using a Self-Propelled Modular Transporter (SPMT) or a trailer, restrictions on the height and width of the road are taken into consideration, and plans for the weight limits of the modules and related lug plates and spread beams are established so that the structure can be safely lifted and installed after being brought into the site according to the installation method. In addition, when transporting by sea using a barge ship, the height and width of the modules are restricted according to the size of the cargo ship to be mobilized, and the possibility of the cargo ship itself docking is reviewed.

Figure 4 is a drawing showing the performance task of a split module design system of a biomass raw material plant according to an embodiment.

Referring to FIG. 4, the split module design system according to the embodiment performs data interpretation and experimental comparative analysis, software monitoring, and digital twin through 3D design for split module design of the plant. A digital twin is a technology that creates a twin of a real object on a computer and predicts results in advance by simulating situations that may occur in reality on a computer. A digital twin is a technology that can solve not only manufacturing but also various industrial society problems. In addition, in the embodiment, an interface that can understand the past and present operating status and predict the future is constructed by combining data and information representing the structure, context, and operation of various physical systems, thereby optimizing the plant split module design, thereby significantly improving module operation performance and the plant split module design process. In addition, in the embodiment, the split module design system analyzes and models plant equipment and design factors for plant operation optimization through numerical analysis of mechanical devices. In the embodiment, analysis and modeling of IGF (Induced Gas Flotation) design factors can be performed, and analysis and modeling of FWKO (Free-water Knock Out) design factors can be performed. In addition, the computer numerical values of plant equipment IGF and FWKO are analyzed. In addition, in the embodiment, the flow analysis of IGF computational fluid dynamics (CFD) and FEKO CFD can be performed. In the embodiment, the computational fluid dynamics (CFD) is to discretize the Navier-Stokes equations, which are nonlinear partial differential equations describing fluid phenomena, using the finite difference method, the finite element method, the finite volume method, etc., to convert them into algebraic equations, and to solve and analyze fluid flow problems using the algorithm of numerical methods. That is, in the embodiment, the program is used to simulate the interaction between fluid and gas in engineering problems. In an embodiment, program verification can be performed by comparing quantitative and qualitative data obtained by performing experiments with their errors.

In addition, an analysis of assumptions for structural design of a split module design system of a biomass raw material plant according to an embodiment (Design Assumption for Steel Structure Analysis & Design) is performed. Since a module includes a package for each process, such as a structural frame, piping, electricity, instrumentation, and equipment (heat exchangers, pumps, etc.), the split module design system of a biomass raw material plant according to an embodiment designs an integrated module for optimization by considering the manufacturing of the module, the process process, the system of equipment, capacity, economy, transportation and manufacturing air, etc. In the embodiment, for a practical and economical optimized module, various modularization methods, such as process process, manufacturing, transportation (land transportation, sea transportation), and construction, are examined, and then the module size that can maximize efficiency is calculated through comparative analysis and simulation.

In addition, the split module design system of the biomass raw material plant according to the embodiment designs a package for each component module, and secures the performance, safety, and operability of each functional module after designing an integrated functional module. In addition, the structural frame fastening mechanism and the functional module connecting mechanism are calculated, and the connecting mechanism is designed in accordance with the transportation standard specifications. In addition, in the embodiment, in order to provide all elements that are practically feasible within the module boundary according to the proposed module type, a process is designed that integrates each unit of the structural frame (steel frame, platform, handrail, etc.), piping, electricity, instrumentation, equipment, etc. (including all elements completed inside the module). In addition, all units in the designed module can be compactified and modularized in the design stage, and a layout design optimized for space utilization can be performed. This creates the effect of minimizing direct and indirect costs.

In addition, the split module design system of the biomass raw material plant according to the embodiment performs process analysis modularization rate improvement for plant configuration facilities, process optimization for small module application, content economic analysis and effect quantification, and process unit optimal design and process simulation evaluation.

FIG. 5 is a drawing showing an example of module design performance of a split module design system of a biomass raw material plant according to an embodiment.

Referring to FIG. 5, since the module according to the embodiment is transported by a large container ship such as a barge or a motor vessel, in the case of a large module that cannot be transported and installed due to constraints of local roads and site conditions, it is separated into individual transport items upon receiving approval from the ordering party. In addition, the module design system in the embodiment designs the module by considering the maritime transport equipment and route, and the conditions of the local transport and installation site when transporting the module by ship. In addition, the joint between the deck and the module is designed by considering the waves and wind speed at sea. In addition, the module loading plan, the unloading method of the shipment, and the weather forecast during the transportation period can be performed.

Below, the modular design method of a biomass raw material plant is sequentially described. Since the function of the natural language processing method for identifying counterfeit goods according to the embodiment is essentially the same as the function of the modular design system of a biomass raw material plant, any description overlapping with that of Figs. 1 to 5 will be omitted.

Figure 6 is a diagram showing the data processing flow of a modular design method for a biomass raw material plant according to an embodiment.

Referring to Fig. 6, in step S100, the split module design department modularizes the plant structure into units of sizes suitable for offshore and onshore use. In step S200, the information collection department collects plant facility operation data and split module design operation information. In step S300, the diagnosis department performs performance diagnosis of the split plant modules based on intelligent information technology. In step S400, the guidance design department designs intelligent operation guidance of the modularized plant facilities based on the plant facility operation data and performance diagnosis results.

In the embodiment, in step S100, in-place analysis and pre-service analysis are performed. In the embodiment, in the analysis process, in order to secure load in/out and transport stability, information on loss of module points and occurrence of excessive displacement can be analyzed. In addition, in step S100, in order to secure the stability of a transport vessel during ocean transport, design for a sea fastening facility, which is a temporary reinforcement, can be additionally performed. In addition, the modules of the plant can be designed by classifying them into PAS (Pre-Assembled Steel structure), PAR (Pre-Assembled pipe Rack), PAU (Pre-Assembled Unit), VAU (Vendor Assembled Unit), and VPU (Vendor Package Unit).

In addition, in step S100 according to the embodiment, a structure may be divided into a main module, a sub module, and a ship loose part, considering the method of transporting the module and the method of installing it on site, and piping and cable trays may be divided according to the divided modules and parts. In addition, for land transport and installation, the center of gravity is managed, and for modules requiring sea transport, safety is secured by considering sea acceleration force.

The modular design method of biomass raw material plants as described above contributes to extending the life of existing facilities, improving facility management, and enhancing operational efficiency. In addition, it provides opportunities for mutual development as well as restoration of trust with surrounding residents through 24-hour management of unused renewable fuel plant power generation facilities. In addition, it can contribute to increasing exports by expanding business for unused renewable fuel plant power generation facilities and operation management in Southeast Asia, India, China, and other developing countries in the environmental industry, as well as in Korea.

The disclosed content is merely an example, and various modifications and implementations can be made by a person skilled in the art without departing from the gist of the claims claimed in the patent, so the scope of protection of the disclosed content is not limited to the specific embodiments described above.

Claims (6)

In a modular design method for a biomass feedstock plant,
(A) A step of modularizing the plant structure into units of size for each offshore and onshore unit in the split module design department;
(B) A step of collecting plant facility operation data and divided module design operation information from the information collection department;
(C) a step of performing performance diagnosis of the divided plant modules based on intelligent information technology in the diagnostic department; and
(D) A step for designing operation guidance for modularized plant facilities based on plant facility operation data and performance diagnosis results in the guidance design department; including;
Step (A) above;
In order to secure the stability of the transport vessel during maritime transport, additional designs for temporary reinforcement, sea fastening equipment, are being carried out.
Step (A) above;
The plant's modules are designed by classifying them into PAS (Pre-Assembled Steel structure), PAR (Pre-Assembled pipe Rack), PAU (Pre-Assembled Unit), VAU (Vendor Assembled Unit), and VPU (Vendor Package Unit).
Step (A) above;
Considering the method of transporting the module and the method of installing it on site, one structure is divided into a main module, a sub module, and a ship loose part, and piping and cable trays are divided according to the divided modules and parts.
Step (C) above
Steps for conducting process diagnosis of biomass raw material plant segmentation modular design, analysis of operator operation patterns of biomass raw material plant, comprehensive reporting service of plant operation, and LCC (Life Cycle Cost) analysis;
For plant modularization, a step of performing real-time process efficiency analysis, real-time operation management, equipment history management of the plant, and 3D process analysis and monitoring; and
A modular design method for a biomass raw material plant, comprising: a step of analyzing the cause of a failure of plant equipment and performing non-face-to-face remote control of the plant equipment through a manager's smart terminal and control server;

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