IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v320y2025ics0360544225010618.html
   My bibliography  Save this article

Hybrid modeling-based digital twin of the direct air cooling system for operational performance optimization

Author

Listed:
  • Cui, Zhipeng
  • Jing, Hao
  • Wang, Dengliang
  • Wang, Bo
  • Chen, Weixiong

Abstract

Direct air-cooling systems are susceptible to environmental changes and dust accumulation, which can result in abnormally high and fluctuating back-pressure values. Such circumstances may result in a reduction in the unit's economic efficiency. This study proposes implementing a digital twin (DT) system, driven by both mechanism and data, to determine the optimal back pressure of direct air-cooling units in various environmental contexts and dust accumulation states. Furthermore, a mathematical airflow model is proposed to quantify the impact of dust accumulation on airflow and heat transfer within an air-cooling island. Subsequently, based on the numerical simulation method, coefficients are proposed to correct the air temperature and quantity in the DT model, respectively, to ensure the accuracy of the back pressure calculation. The proposed DT was finally applied to a 660 MW direct air-cooling unit. In an industrial case study, the system was found to have saved 565.998 tonnes of standard coal and reduced 1411.034 tonnes of carbon emissions in a fortnight, which represents a significant impact.

Suggested Citation

  • Cui, Zhipeng & Jing, Hao & Wang, Dengliang & Wang, Bo & Chen, Weixiong, 2025. "Hybrid modeling-based digital twin of the direct air cooling system for operational performance optimization," Energy, Elsevier, vol. 320(C).
    • Handle: RePEc:eee:energy:v:320:y:2025:i:c:s0360544225010618
    DOI: 10.1016/j.energy.2025.135419
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0360544225010618
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2025.135419?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to

    for a different version of it.

    References listed on IDEAS

    as
    1. Zhang, Yi & Liu, Jinfeng & Yang, Tingting & Liu, Jianbang & Shen, Jiong & Fang, Fang, 2021. "Dynamic modeling and control of direct air-cooling condenser pressure considering couplings with adjacent systems," Energy, Elsevier, vol. 236(C).
    2. Chen, Lei & Yang, Lijun & Du, Xiaoze & Yang, Yongping, 2016. "A novel layout of air-cooled condensers to improve thermo-flow performances," Applied Energy, Elsevier, vol. 165(C), pages 244-259.
    3. Yu, Jianxi & Petersen, Nils & Liu, Pei & Li, Zheng & Wirsum, Manfred, 2022. "Hybrid modelling and simulation of thermal systems of in-service power plants for digital twin development," Energy, Elsevier, vol. 260(C).
    4. Xu, Jing & Cui, Zhipeng & Ma, Suxia & Wang, Xiaowei & Zhang, Zhiyao & Zhang, Guoxia, 2024. "Data based digital twin for operational performance optimization in CFB boilers," Energy, Elsevier, vol. 306(C).
    5. Zhu, Mingjuan & Liu, Yudong & Wu, Xiao & Shen, Jiong, 2023. "Dynamic modeling and comprehensive analysis of direct air-cooling coal-fired power plant integrated with carbon capture for reliable, economic and flexible operation," Energy, Elsevier, vol. 263(PA).
    6. Zhao, Guanjia & Cui, Zhipeng & Xu, Jing & Liu, Wenhao & Ma, Suxia, 2022. "Hybrid modeling-based digital twin for performance optimization with flexible operation in the direct air-cooling power unit," Energy, Elsevier, vol. 254(PC).
    7. Yang, Tingting & Wang, Wei & Zeng, Deliang & Liu, Jizhen & Cui, Can, 2017. "Closed-loop optimization control on fan speed of air-cooled steam condenser units for energy saving and rapid load regulation," Energy, Elsevier, vol. 135(C), pages 394-404.
    8. Li, Xiaoen & Wang, Ningling & Wang, Ligang & Yang, Yongping & Maréchal, François, 2018. "Identification of optimal operating strategy of direct air-cooling condenser for Rankine cycle based power plants," Applied Energy, Elsevier, vol. 209(C), pages 153-166.
    9. Yang, L.J. & Wang, M.H. & Du, X.Z. & Yang, Y.P., 2012. "Trapezoidal array of air-cooled condensers to restrain the adverse impacts of ambient winds in a power plant," Applied Energy, Elsevier, vol. 99(C), pages 402-413.
    10. Cui, Zhipeng & Xu, Jing & Liu, Wenhao & Zhao, Guanjia & Ma, Suxia, 2023. "Data-driven modeling-based digital twin of supercritical coal-fired boiler for metal temperature anomaly detection," Energy, Elsevier, vol. 278(PA).
    11. Liu, Shuwei & Tian, Jianyan & Ji, Zhengxiong & Dai, Yuanyuan & Guo, Hengkuan & Yang, Shengqiang, 2024. "Research on multi-digital twin and its application in wind power forecasting," Energy, Elsevier, vol. 292(C).
    12. Chen, Chen & Liu, Ming & Li, Mengjie & Wang, Yu & Wang, Chaoyang & Yan, Junjie, 2024. "Digital twin modeling and operation optimization of the steam turbine system of thermal power plants," Energy, Elsevier, vol. 290(C).
    13. Marcinkowski, Mateusz & Taler, Dawid & Sacharczuk, Jacek & Węglarz, Katarzyna & Taler, Jan, 2024. "Innovative analysis of local and average air-side heat transfer coefficients in fin-and-tube heat exchangers using CFD and experimental method," Energy, Elsevier, vol. 309(C).
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Wenhui Huang & Lei Chen & Weijia Wang & Lijun Yang & Xiaoze Du, 2020. "Cooling Performance Optimization of Direct Dry Cooling System Based on Partition Adjustment of Axial Flow Fans," Energies, MDPI, vol. 13(12), pages 1-22, June.
    2. Wenhui Huang & Lei Chen & Lijun Yang & Xiaoze Du, 2021. "Energy-Saving Strategies of Axial Flow Fans for Direct Dry Cooling System," Energies, MDPI, vol. 14(11), pages 1-25, May.
    3. Li, Xiaoen & Wang, Ningling & Wang, Ligang & Yang, Yongping & Maréchal, François, 2018. "Identification of optimal operating strategy of direct air-cooling condenser for Rankine cycle based power plants," Applied Energy, Elsevier, vol. 209(C), pages 153-166.
    4. Wu, Chunlei & Wang, Chao & Hou, Zongyu & Wang, Zhe, 2025. "Flexible peak shaving in coal-fired power plants: A comprehensive review of current challenges, recent advances, and future perspectives," Energy, Elsevier, vol. 327(C).
    5. Zhang, Yi & Liu, Jinfeng & Yang, Tingting & Liu, Jianbang & Shen, Jiong & Fang, Fang, 2021. "Dynamic modeling and control of direct air-cooling condenser pressure considering couplings with adjacent systems," Energy, Elsevier, vol. 236(C).
    6. Xu, Jing & Cui, Zhipeng & Ma, Suxia & Wang, Xiaowei & Zhang, Zhiyao & Zhang, Guoxia, 2024. "Data based digital twin for operational performance optimization in CFB boilers," Energy, Elsevier, vol. 306(C).
    7. Semeraro, Concetta & Aljaghoub, Haya & Abdelkareem, Mohammad Ali & Alami, Abdul Hai & Dassisti, Michele & Olabi, A.G., 2023. "Guidelines for designing a digital twin for Li-ion battery: A reference methodology," Energy, Elsevier, vol. 284(C).
    8. Zhiling Luo & Qi Yao, 2022. "Multi-Model-Based Predictive Control for Divisional Regulation in the Direct Air-Cooling Condenser," Energies, MDPI, vol. 15(13), pages 1-18, June.
    9. Tarun Kumar Aseri & Chandan Sharma & Tara C. Kandpal, 2022. "Condenser cooling technologies for concentrating solar power plants: a review," Environment, Development and Sustainability: A Multidisciplinary Approach to the Theory and Practice of Sustainable Development, Springer, vol. 24(4), pages 4511-4565, April.
    10. Wang, Pengfei & Zhu, Ze & Liang, Wenlong & Liao, Longtao & Wan, Jiashuang, 2023. "Hybrid mechanistic and neural network modeling of nuclear reactors," Energy, Elsevier, vol. 282(C).
    11. Xiao, Xiao & Zhang, Xuan & Song, Meiqi & Liu, Xiaojing & Huang, Qingyu, 2024. "NPP accident prevention: Integrated neural network for coupled multivariate time series prediction based on PSO and its application under uncertainty analysis for NPP data," Energy, Elsevier, vol. 305(C).
    12. Semeraro, Concetta & Aljaghoub, Haya & Abdelkareem, Mohammad Ali & Alami, Abdul Hai & Olabi, A.G., 2023. "Digital twin in battery energy storage systems: Trends and gaps detection through association rule mining," Energy, Elsevier, vol. 273(C).
    13. Angjun Xie & Gang Xu & Chunming Nie & Heng Chen & Tailaiti Tuerhong, 2024. "Operation Data Analysis and Performance Optimization of the Air-Cooled System in a Coal-Fired Power Plant Based on Machine Learning Algorithms," Energies, MDPI, vol. 17(22), pages 1-23, November.
    14. Zhao, Guanjia & Cui, Zhipeng & Xu, Jing & Liu, Wenhao & Ma, Suxia, 2022. "Hybrid modeling-based digital twin for performance optimization with flexible operation in the direct air-cooling power unit," Energy, Elsevier, vol. 254(PC).
    15. Adamczyk, Wojciech & Myöhänen, Kari & Klajny, Marcin & Kettunen, Ari & Klimanek, Adam & Ryfa, Arkadiusz & Białecki, Ryszard & Sładek, Sławomir & Zdeb, Janusz & Budnik, Michał & Peczkis, Grzegorz & Prz, 2024. "Development and demonstration of advanced predictive and prescriptive algorithms to control industrial installation," Energy, Elsevier, vol. 313(C).
    16. Tong, Xi & Zhao, Shuyuan & Chen, Heng & Wang, Xinyu & Liu, Wenyi & Sun, Ying & Zhang, Lei, 2025. "Optimal dispatch of a multi-energy complementary system containing energy storage considering the trading of carbon emission and green certificate in China," Energy, Elsevier, vol. 314(C).
    17. Li, Xiaoxiao & Gurgenci, Hal & Guan, Zhiqiang & Wang, Xurong & Duniam, Sam, 2017. "Measurements of crosswind influence on a natural draft dry cooling tower for a solar thermal power plant," Applied Energy, Elsevier, vol. 206(C), pages 1169-1183.
    18. Li, Guolong & Li, Yanjun & Li, Site & Sun, Shengdi & Wang, Haotong & Su, Jian & Shi, Jianxin & Zhou, Xin, 2025. "Research on anomaly detection of steam power system based on the coupling of thermoeconomics and autoencoder," Energy, Elsevier, vol. 318(C).
    19. Huang, Chenchen & Lin, Boqiang, 2023. "Promoting decarbonization in the power sector: How important is digital transformation?," Energy Policy, Elsevier, vol. 182(C).
    20. Chen, Lei & Yang, Lijun & Du, Xiaoze & Yang, Yongping, 2016. "A novel layout of air-cooled condensers to improve thermo-flow performances," Applied Energy, Elsevier, vol. 165(C), pages 244-259.

    More about this item

    Keywords

    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:energy:v:320:y:2025:i:c:s0360544225010618. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.journals.elsevier.com/energy .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.