Power Plant FGD Training Model

Simulation and Visualization of a Power Plant FGD Unit


Isometric view of FGD absorber unit. NIPSCO has two new Flue Gas Desulfurization (FGD) systems at its Schahfer Generating Station.  The FGD systems are designed to remove SO2 from flue gas generated by the boiler. The flue gas enters the absorber just above the reaction tank liquid level and rises upwards. As it rises, it contacts fine droplets of recycled limestone slurry, which absorb the SO2. The clean gas is then passed through two stages of mist eliminators to remove slurry and water droplets. The gas then flows through ductwork at the top of the absorber to a wet stack.  A training model is desired as a tool to train current and future operators.


Flow path lines inside FGD unitThe objective of this project is to develop a 3D Virtual Reality (VR) model of the FGD unit using Computational Fluid Dynamics (CFD) and VR visualization. CFD model of the turbulent reacting flow inside the #14 FGD unit at NISPCO Schahfer Generating Station is developed, and the flow data obtained from the model are integrated with VR visualization models to provide a 3D representation of the unit to be used as an efficient training media for the FGD operators.


Virtual FGD unitBy integrating CFD simulation and VR visualization, a 3D Virtual Reality FGD unit is developed to provide a comprehensive teaching tool for operator training. This virtual model allows FGD operators to explore into the operating FGD unit to not only observe the detailed structural components but also flow characteristics such as temperature, velocity, chemical species distributions, etc. The interactive learning process provides a more effective and efficient way for operator training at NIPSCO training center


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