Framework for Optimization, Quantification of Uncertainty, and Surrogates (FOQUS) – Capabilities and Applications
Presented at the 2022 Carbon Management Project Review Meeting in Pittsburgh, PA
Deshpande, Anuja↗
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Framework for Optimization, Quantification of Uncertainty, and Surrogates (FOQUS) – Demonstration
Presented at the 2022 Carbon Management Project Review Meeting in Pittsburgh, PA
Deshpande, Anuja↗
CCSI Toolset 3.22 Release
CCSI Toolset 3.22 Release Highlights The Sequential Design of Experiments user interface was updated to resolve an issue where the results would fail to plot in some cases (e.g., Non-Uniform Space Filling designs). The Machine Learning/Artificial Intelligence module was updated to support Keras 3 and to reflect changes made to dependencies’ syntax. A check was added to ensure PSUADE is installed and available at FOQUS startup. If PSUADE is not installed, a link to the FOQUS documentation is displayed and FOQUS is closed. The copyright year was updated to include 2024 in places where it had not previously been updated. Typographical errors were corrected to improve clarity in variable names and documentation. The FOQUS documentation was updated to reflect the fact that ALAMO can have two executables and indicates the correct executable to add to the Settings path. SimSinter was updated to version 3.1.0. This version removed gPROMS support and included security updates.
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CCSI Toolset 3.17 Release
CCSI Toolset 3.17 Release Highlights A workaround was developed to allow complex Aspen Custom Modeler (ACM) models to be used in FOQUS. This workaround uses Visual Basic for Applications to connect the ACM models to FOQUS. The ability for User plugins to be uploaded to FOQUS Cloud was added. The documentation was updated to include Optional Software Install and Tutorial Notes to clarify the usage of Turbine and SimSinter in installation instructions and adds a link to the relevant tutorial page. The Sequential Design of Experiments documentation was updated with current screenshots. The copyright was updated to include 2023.
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CCSI Toolset 3.19 Release
CCSI Toolset 3.19 Release Highlights A gradient generation tool was developed to support GENN models in FOQUS. Certain machine learning tools train gradient-enhanced neural network (GENN) models which can be more accurate for complex datasets given a priori knowledge of model derivatives. However, the derivatives must be known beforehand and are not often available for process data. This tool automatically predicts the gradients for a training dataset in a form usable by common GENN trainers, such as Surrogate Modeling Toolbox. Support was added for Surrogate Modeling Toolbox GENN models in FOQUS, including updates to the run methods, node properties, test framework, documentation and optional dependencies list. Users can train/save Surrogate Modeling Toolbox gradient-enhanced neural network (GENN) models with custom objects and produce .pkl files compatible with the Machine Learning/Artificial Intelligence Plugin in FOQUS. A simpler implementation of the ordering algorithm in the Sequential Design of Experiments (SDOE) module was included. The SDOE examples documentation was updated. The Optimality-Based Design of Experiments was updated to improve the error handling when the results are None.
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CCSI Toolset 3.21 Release
CCSI Toolset 3.21 Release Highlights Parallelization support was added for Sequential Design of Experiments (SDOE) computations using Dask (preliminary). Input type dependent ordering capability was added to the SDOE module. With this implementation the user can specify the level of difficulty to change an input (Easy or Hard) and FOQUS will generate the appropriate ordered design depending on the input difficulty combination. Python version support was extended. FOQUS is now compatible with Python 3.8 through 3.12. Platforms used for automated testing were expanded to include macOS ARM (Apple Silicon). Updates to the FOQUS documentation to include information on how to set paths for SimSinter and TurbineLite. Turbine configuration section was added to Debugging Documentation.
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Framework for Optimization, Quantification of Uncertainty and Surrogates – Updated Capabilities
This poster presents updated capabilities within the FOQUS Toolset, covering core features as well as project-based applications. Specifically, the poster highlights advancements in FOQUS integration with cloud-based clients, plugin support for machine learning tools and external simulations, sequential design of experiments, and advanced support for dynamic process models. The applications demonstrate the breadth of FOQUS predictive capabilities for chemical, energy and economic system analysis.
Paul, Brandon↗
CCSI Toolset 3.18 Release
CCSI Toolset 3.18 Release Highlights FOQUS was updated to allow installation for users using MacOS on Apple silicon. FOQUS Cloud support was added for user plugins. The Optimality-Based Design of Experiments tutorials were updated to reflect the latest changes in the user interface flow. The plot discrete sliders were fixed for CDF and 3D plots within Uncertainty Quantification, which were not working due to a matplotlib depreciation. The installation was updated to set the default location for the PSUADE executable if found in the environment. Updates were made to allow compatibility with NumPy 1.25. Additional documentation changes were made to fix typographical errors and fix a broken link to optional software.
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Sequential Design of Experiments to Maximize Learning from Carbon Capture Pilot Plant Testing
Pilot plant test campaigns can be expensive and time-consuming. Therefore, it is of interest to maximize the amount of learning and the efficiency of the test campaign given the limited number of experiments that can be conducted. This work investigates the use of sequential design of experiments (SDOE) to overcome these challenges by demonstrating its usefulness for a recent solvent-based CO2 capture plant test campaign. Unlike traditional design of experiments methods, SDOE regularly uses information from ongoing experiments to determine the optimum locations in the design space for subsequent runs within the same experiment. However, there are challenges that need to be addressed, including reducing the high computational burden to efficiently update the model, and the need to incorporate the methodology into a computational tool. We address these challenges by applying SDOE in combination with a software tool, the Framework for Optimization, Quantification of Uncertainty and Surrogates (FOQUS) (Miller et al., 2014a, 2016, 2017). The results of applying SDOE on a pilot plant test campaign for CO2 capture suggests that relative to traditional design of experiments methods, SDOE can more effectively reduce the uncertainty of the model, thus decreasing technical risk. Future work includes integrating SDOE into FOQUS and using SDOE to support additional large-scale pilot plant test campaigns.
20 FOSSIL-FUELED POWER PLANTS↗
CCSI Toolset 3.25 Release
CCSI Toolset 3.25 Release Highlights The copyright in the CCSI Toolset was updated to include the year 2025. The code and notes within it were revised to correct minor typographical errors and clarify meanings of variables. The configuration of the FOQUS documentation via Read the Docs was updated to explicitly set the path.
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Isotherm modeling and techno-economic analysis of a TSA moving bed process using a tetraamine-appended MOF for NGCC applications
Tetraamine-appended metal-organic frameworks (MOF) are a new family of amine-functionalized MOF materials that show potential for CO 2 capture from flue gas conditions relevant to natural gas combined cycle (NGCC) power plants. This work presents isotherm modeling of the tetraamine-appended MOF Mg 2 (dobpdc)(3-4-3)(dobpdc 4- =4,4'-dioxidobiphenyl-3,3'dicarboxylate;3-4-3=N,N'bis(3-aminopropyl)-1,4-diaminobutane), process modeling, scale up, and a techno-economic optimization of a moving bed Temperature Swing Adsorption (TSA) process for carbon capture using this sorbent. This MOF exhibits a unique two-step CO 2 adsorption profile in three different pressure ranges. Thus, arctangent-based logistic functions and, quadratic and Langmuir models were employed to represent such isotherm behavior. The results of the isotherm model show good fitting vs the experimental data with an RMSE of 0.41. Here, to model the carbon capture process, the isotherm model was embedded into a moving bed contactor model, and this was used to simulate a TSA CO 2 capture cycle and evaluate cost-optimal designs considering flue gas from a -650 MWe NGCC power plant. The capital cost model consists of CAPEX correlations for reactors, compressors, ducting, etc., while the operating costs include steam, water, chemicals, and electricity (following NETL's quality guidelines for energy systems studies). A techno-economic optimization of the capture system was performed by using NETL's Framework for the Optimization and Quantification of Uncertainty and Surrogates tool (FOQUS). Results suggest that a moving bed carbon capture system with tetraamine-appended MOF can be competitive compared to conventional MEA solvent-based capture processes for NGCC plants, when a heat recovery efficiency of at least 40% is achieved, and MOF materials can be produced at a cost below -$9/kg.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Isotherm Modeling and Techno-Economic Analysis of Contactor Technologies for New Tetraamine-Appended MOF for NGCC Applications
Recently, a family of tetraamine-functionalized metal-organic frameworks (MOF) has been reported as promising sorbent materials for capturing CO2 from flue gas conditions relevant to natural gas combined cycle (NGCC) applications. The main advantages of these materials are their two-step cooperative CO2 adsorption, which gives rise to unusual two step-shaped CO2 adsorption profiles and their high thermal stability. This work presents the modelling of the two-transition isotherm of the tetraamine-appended MOF, N,N'-bis(3-aminopropyl)-1,4-diaminobutane (3-4-3)-appended Mg2(dobpdc), and the techno-economic analysis (TEA) of carbon capture processes utilizing this sorbent. Due to the unusual isotherm shapes of the experimental CO2 adsorption data for tetraamine-appended Mg2(dobpdc) and the strong nonlinearity of CO2 loading with respect to temperature and pressure, we tested two different models which use logistic functions for representing the different isotherm behaviors in the different pressure ranges. The first model uses the quadratic isotherm model in the low-pressure region, the Langmuir isotherm model in the middle pressure range, and the dual site Langmuir isotherm model in the high-pressure range. To model the transition between regions we used the arctangent functions independent of temperature and the thermal effect was accounted by using the Clausius-Clapeyron relation]. The second model is an extension of the weighted dual-site Langmuir isotherm model presented by Hughes et al.. In this extended model, the dual-site Langmuir isotherm is employed in the three transition regions, using temperature-dependent logistic functions to activate or deactivate the isotherm model in the low, middle, and high-pressure ranges. Both models fit the experimental data quite well with root mean squared errors (RMSE’s) of 0.41 and 0.17 for model 1 and model 2, respectively. Since model 2 resulted in a lower RMSE, it was leveraged for the development of the gas/solid contactor models used by the TEA. Specifically, two different contactor models, an axial-flow fixed bed and moving bed contactor, were developed as part of this work. These models are dynamic, pressure-driven, and consist of mass, energy, and momentum conservation equations. A kinetic model was also developed by performing parameter estimation using experimental fixed bed breakthrough data. These models are then used to simulate CO2 capture processes from the flue gas generated from a ~600 gross MW NGCC power plant. A cost model was developed which considers the capital cost of the reactors and the significant operating costs such as steam and electricity. Using NETL’s Framework for the Optimization and Quantification of Uncertainty of Uncertainty and Surrogates tool (FOQUS), which has the capability of linking models built using numerous modelling platforms with derivative-free optimization solvers, a techno-economic optimization of the carbon capture processes was performed which minimizes the cost of capture.
Caballero, Daison↗
Using the Carbon Capture Simulation Initiative (CCSI) Tool to Design the Experiments in the Parametric Campaign of a Novel Compact Absorber for Carbon Capture
Gas absorption towers with structured packing and solvent have been used for Carbon Dioxide (CO 2 ) Capture for about many decades. To overcome process limitations and practical disadvantages for CO 2 capture from the stationary emitter (e.g. NG and coal power plant), many new designs have been proposed and explored at the various scales in the last decade with aim of either low energy penalty or low capital cost. To reduce the size of the absorption tower and hence the total cost of CO 2 capture, the University of Kentucky Center for Applied Energy Research Center (UK CAER) has designed and built a novel CO 2 capture absorption tower or Compact Absorber, integrated into an existing large-bench scale CO 2 capture unit. The Compact Absorber has three sections. The top of the column is a fogging section where the solvent is sprayed through a nozzle producing droplets flowing downward in a co-current fashion with the flue gas. The center of the column is a frothing section where the solvent and flue gas flow through regenerative frothing screens designed by Industrial Climate Solutions, Inc. The bottom of the column is a typical structured packing section were the flue gas and solvent flow in a counter-current fashion. The parametric campaign will be conducted in order to optimize the operating parameters for CO 2 capture including liquid/gas ratio, lean loading, and temperature, liquid residence time. A simulated flue gas with 14% CO 2 will be used along with a UK CAER developed proprietary solvent. The 100-hour parametric campaign is designed using a statistical approach of the Sequential Design of Experiments (sDOE). sDOE is one of the CCSI tools that provides an adaptive statistical approach for designing future experiments based on the results of previous experiments. Application of a typical DOE provides the user with the minimum number of experiments required to get the same data, but sDOE allows the user to make an informed choice of experiments based on the results of previous experiments. The complete absorption column has been constructed and has been partially commissioned. Initial data has been collected by operating using the fogging section and the frothing section. The fogging section produces solvent droplets of about 100 μm sauter mean diameter and as small as 25 μm using a hydraulic nozzle by BETE. The frothing section produces bubbles of about 5mm with high mixing of solvent promoting the higher mass transfer from gas to liquid. The absorber reaches the capture efficiency of about 50% with only two sections in operation. Based on the current results, it can be deduced that increasing the solvent feed temperature and including the packed section for absorption the capture efficiency will increase further. Initial data will be collected using all three sections of the absorber and will be used for sDOE. Non-Uniform Space Filling model of sDOE will be used to prioritize the input conditions resulting into maximum capture efficiency. sDOE is performed using the platform called Framework Optimization, Quantification of Uncertainty, and Surrogates (FOQUS). The method and results demonstrating the progress of the parametric campaign from the initial set of experiments to the final stage of obtaining optimized parameters using sDOE tool will be presented in detail.
20 FOSSIL-FUELED POWER PLANTS↗
Investigation of a Hybrid Carbon Capture System at a NGCC Power Plant That Performs Direct Air Capture During Off-Peak Hours
The goal of this project was to investigate the feasibility of coupling NGCC power plants with membrane and solid sorbent carbon capture to achieve net negative carbon emissions. This novel hybrid system has a couple of potential benefits: 1) the carbon capture systems could help the NGCC plant by minimizing its carbon footprint and giving it a new revenue stream from direct air capture, and 2) the NGCC plant could help direct air capture scale up quickly and costeffectively by providing it with electricity, steam and compressed air streams. In order to investigate this hybrid design, we developed a complex, integrated system model consisting of: 1) a NGCC power plant model developed by Dr. Bhattacharyya’s team at WVU, 2) a membrane carbon capture model developed by Dr. Lipscomb’s team at U Toledo, and 3) a solid sorbent carbon capture model developed by Dr. Hornbostel’s team at U Pittsburgh. Mr. Matuszewski’s team at AristoSys LLC integrated these three models into a single, integrated model using FOQUS, an optimization tool developed by the NETL CCSI 2 program. Optimizations were then performed on this integrated model to determine the cost and carbon capture rates under a range of electricity and carbon price scenarios.
20 FOSSIL-FUELED POWER PLANTS↗
Framework for Optimization, Quantification of Uncertainty, and Surrogates, and CCSI2 Toolset Capabilities
This poster will present key features and capabilities of the CCSI2 software platform to relevant technical and research audience members at the 2024 FECM / NETL Carbon Management Research Project Review Meeting. Attendees will learn about available process models in the CCSI2 Toolset, as well as design of experiments and machine learning features in the Framework for Optimization, Quantification of Uncertainty, and Surrogates (FOQUS) software to support pilot plant work.
Paul, Brandon↗
Techno-Economic Optimization of Fixed Bed and Moving Bed Contactors for CO2 Capture from NGCC Plants Using a Functionalized Metal-Organic Framework
Amine-appended metal–organic frameworks (MOFs) have strong potential for post-combustion CO2 capture from NGCC plants. In this work, a specific tetramine-appended MOF, Mg2(dobpdc)(3-4-3) (dobpdc4− = 4,4′-dioxidobiphenyl-3,3′dicarboxylate; 3-4-3 = N,N′bis(3-aminopropyl)-1,4-diaminobutane), is evaluated due to its superior performance compared to other candidate diamine-appended and tetraamine-appended MOFs. Techno-economic optimization is performed to minimize the cost of capture by using the Framework for Optimization, Quantification of Uncertainty, and Surrogates (FOQUS), which is capable of optimizing systems by using derivative-free optimization solvers where process models are built using numerous modeling platforms. The technical and economic performances of both fixed bed and moving bed processes are compared with state-of-the-art amine-based solvent systems.
Hughes, Ryan↗
CCSI Toolset 3.20 Release
CCSI Toolset 3.20 Release Highlights Minimum Viable Product surrogate plugin was added for creating Machine Learning/Artificial Intelligence models. Corresponding documentation was added for the plugin. Sequential Design of Experiments plots were updated to eliminate an issue with the window stack ordering upon closure of the plots. Support for Python 3.7 was removed. Documentation was improved by adding new mandatory section to the ReadTheDocs configuration and adding installation instructions back for NLOpt. TurbineLite was updated to 3.0.0, which is compatible with SimSinter 3.0.0. The developer environment was updated and 32-bit support was removed. SimSinter was updated to 3.0.0. This version removed gPROMS support and included security updates.
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CCSI Toolset 3.23 Release
CCSI Toolset 3.23 Release Highlights The user interface was updated to allow timeouts in Aspen Custom Modeler and AspenPlus. The installation was updated to use 64-bit versions of TurbineLite and SimSinter by default. The documentation was improved for clarity.
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