The CO2-post-combustion capture development programme

The CO2-post-combustion capture development programme

Coal Innovation Centre at Niederaussem

2nd International Conference on Energy Process Engineering,20-22 June 2011 Frankfurt a M20 22 June 2011, Frankfurt a. M.

Sandra Schmidt, New Technology, RWE Power AG

CO2 Mitigation Strategy for Power Plants 2 g gyEfficiency enhancement

Power Plant Neurath

Past- without lignite pre-drying -

spec. CO2-emission

1,5

Power Plant Neurath1100 MW units F/G (BoA 2/3)

- 30%

150 MW

1

t CO2MWh 300 MW

600 MW Status quo:BoA 1

1

> After commissioning ofBoA 2&3 the successive

0,5BoA 2&3 the successive decommissioning of all 16150 MW-units follows until end of 2012

025 30 35 40 45 50 55

Sandra Schmidt, RWE Power AG 20.06.2011 Page 2

43 %Efficiency %

CO2 Mitigation Strategy for Power Plants 2 g gyEfficiency enhancement and CCS

Futurespec. CO2-emission

1,5Past

- without lignite pre-drying -

Power plant with WTA®-technology

1

t CO2MWh

150 MW300 MW

600 MWStatus quo:

BoA 1®®- 40%1 WTA®

+ 700°CWTA®

ca.0,8

40%

0,5> 90%

Goal:Dry lignite fired

CCS

025 30 35 40 45 50 55

power plant with CCS


43 %Efficiency % 47 - 49 %

IEA: CCS is also in Europe important to achieve the climate protection targetsOECD/IEA World Energy Outlook Excerpt 2009OECD/IEA World Energy Outlook Excerpt 2009The 450 scenario of IEA for limiting the increase in global temperature to 2°C – example EU:

EU energy relatedCO2 emissions abatement

> End-use efficiency enhancement is most important to achieve the climate protection targets

> The meaning of CCS for reducing the CO2 emissions is similar to that of the renewables

> Th li ti f CCS i t ff ti th> The realisation of CCS is more cost effective than renewables

Intergovernmental Panel on Climate ChangeIntergovernmental Panel on Climate Change Working Group III „Mitigation of climate change“: CCS is an key technology for climate protection, commercial application should start from 2030


commercial application should start from 2030

Fossil-fired power plants are still necessary to guarantee a reliably power supply

20.000

16.000

18.000 I. High fluctuation

Wind‐und PV‐Stromeinspeisung AMPRION, Juli 2010

12.000

14.000

r [M

W] II. Extreme

power gradients

000

2500

3000

3500

4000

4500

nspe

isung

[GW]

Wind + PV

Wind

8.000

10.000

Win

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0015

0020

01.07. 21.07. 10.08. 30.08. 19.09. 09.10. 29.10. 18.11. 08.12. 28.12.

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III. Long calm periods

01.07.10 – 31.12.10

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Data Source: ISET0 0 03 0 0 0 05 0 06 0 0 0

2009Total pumped hydro storage capacity in Germany

PCC optimisation: Holistic approach and p ppinterdisciplinary cooperation

CooperationCooperation BASF - Linde - RWE Power

chemistry engineeringChallenges of optimisation: chemistry, process

engineeringChallenges of optimisation:> BASF

Capture process, solvent performance (efficiency solvent stability economics) power plant(efficiency, solvent stability, economics)

> LindeEngineering capture plant, components(efficiency scale-up economics)

power plant

(efficiency, scale up, economics)

> RWE PowerIntegration of the capture plant in power plants(efficiency operation economics)

Goal: 90% CO2-capture rate with a high efficient PCC-technology Power plant efficiency >40%,

(efficiency, operation, economics)


Power plant efficiency >40%, PCC-design for a 1.100 MW-power plant

Development to a 550 MWel full scale PCC plantp el pPCC process and integration into the power plant process PCC-concept (solvent, process)

Full scale design

2 x 550 MWel( ) Integration (waste heat recovery, flue gas conditioning)

2 x 550 MWel

Boundary conditions

Power plantTesting

programme atPower plant CO2 transport CO2 storage CO usage

programme at the pilot plant

in Niederaussem

CO2 usage

Preliminary design of a full scale PCC plant Plant concept optimisation and layout Techno/economical performance comparison of variations


Techno/economical performance, comparison of variations

Coal Innovation Centre

CO2-capture pilot plant CO capture

Coupled plant operations at BoA1REAplus pilot plant Reduction of SO /dust

WTA®-prototype Increase of efficiency CO2-capture Reduction of SO2/dust Increase of efficiency

Dream production CO f l CO2 for polymers


CO2 capture pilot plant at NiederaussemSolvent regeneration CO2-capture Flue gas cooling,

SO2-pre scrubbing CO2CO2-lean Solvent regeneration CO2-capture Flue gas cooling,

SO2-pre scrubbingCO2/CO A6

A1, A3-A6:Flanges, tubes

CO2/COO2

CxHx

O2CxHx

Individual measurementsGaseous flows:SO2, SO3, NO, NO2, CO, NH3, HCl HF heavy metals

amine

DesorberAbsorber

Prescrubber

flue gas

DesorberAbsorber

Prescrubber

2O2

CxHx

O2CxHx

T, P

F, T, P

SO2/NO

FF, ΔT, P

F, T, P

F

F

F, ΔT F, ΔT

FT

B2

B6

B3 B7

A6

A2 C t d l

x x

SO /NO

HCl, HF, heavy metals, particles, aldehydes, ketones, alcohols, organic acids, amine, other organic compounds

amine

Flue gasF, T, P T-profile,

ΔP´s

2CO2/COO2H2O

F, ΔT

F, ΔT

T-profile,Δp´s

F

F, ΔT F,P

F ΔT

F, ΔT, ΔP

F, ΔP´sT

ΔP´s

F, ΔT

F,T

T-profile,Δp´s A2

B1

B4

B5

B8

A3

A2: Concrete moduleSO2/NOCO2/COO2H2O

Lean solvent

NaOH

F, T, P SO2/NOCO2/CO

Index:F flowT temperature P pressure

pHLean solvent

F, T

F, ΔT

TT

FF

FRich solvent

Online gas analyticsSampling point

f d il l t

B5

A1 A5

A4B1-B8: Coupons

SO2/NOCO2/CO Rich solvent

Online gas analytics

Sampling point

Individual mesurementsCondensates:aniones: sulphate, sulphite, nitrate, Analysis of NaOH

solution tank Solvent tank

Flue gas: 1.550 m3N/h Commissioning July 2009

Processanalysis and optimisation

P pressure of daily solvent samples

Testing of innovative materials of daily solvent samples

nitrite, chloride, cationes, heavy metals, amine, pH, conductivity, TOC/DOC, AOX, CSB, BSB

a ys s oemissions and trace elements

g N g y CO2 product: 7,2 tCO2/day; capture rate 90% Budget of RWE for phases I/II: 15 Mio. € Absorption height corresponds to a full scale 40% funding by the Federal Ministry of Instrumentation: 250 measuring points Economics and Technology


Instrumentation: 250 measuring points Economics and Technology

Testing programme at the pilot plant g p g p pPCC-technology optimisation

2009 2010 2011 2012 2013

Preparatory work Solvent pre-testing “Mini Plant” BASF

phase I phase II2 3 5 0

2 8 5 0

3 3 5 0

nt flow

rate parameter studies long‐term tests

Solvent testing

Solvent pre testing Mini Plant BASF Commissioning pilot plant Start test programme

1 8 5 0

0 500 1000 1500 2000 2500 3000 3500 4000

Solve

Operating hoursSolvent testing Testing-phase MEA & process Testing-phase GUSTAV200 T ti h LUDWIG540

Operating hours

Testing-phase LUDWIG540 Selection of the optimal solvent

Long-term test, optimisationg p Special tests and measurements Installation of additional components Long-term test (conventional FGD)


Long-term test (high performance FGD)

Optimisation of the CO2-capture technology2Solvent, process and equipment

Optimised integration -Solvent criteria: Opt sed teg at oflue gas conditioning Low energy demand for solvent regeneration

High stability Low emissions High cyclic capacity Sufficient fast reaction kinetics Industrial availability of the solventProcess and equipment optimisation potential: Interstage cooling Waste heat recovery by process integration

Cooperation of RWE and Andritz:High performance FGD REAplus

Interaction of low pressure steam / pressure of the desorber column / CO2-compressor performance

Design of the solvent/solvent-heat exchangerHigh performance FGD REAplus Goal: Reduction of the SO2-

content < 10 mg/m3

Without increased invest- and

Column internals Cost-efficient materials Simple process configuration


Without increased invest and operation costs Cost-efficient flue gas conditioning

Results of the first testing phase g pComparison of the new solvents with MEA

MEA Gustav200 Ludwig540

solvent flowrate

10.000 test hours in 1,5 years of operation Pilot plant availability > 97 % Pilot plant availability > 97 % Very good reproducibility Test results correspond with

simulation resultspower plant output simulation results

captured CO2


Results of the first testing phase g pComparison of the new solvents with MEA

3900

CO

2]

3500

3700

and

[MJ/

tC

2900

3100

3300

ergy

dem

a

-20%

2500

2700

2900

spec

ific

en

l t fl t [ ]

MEAGustav200Ludwig540

The specific energy demand for the regeneration of the new solvents is < 2,8 GJ/tCO2, therewith 20% better than the best case of an optimised MEA-process

2500s solvent flowrate [-]

Lower solvent flow rate of the new solvents than of MEA. Very low solvent loss The realisation of an innovative material concept – concrete with PP-inliner as column


pmaterial and the application of fibre-glass reinforced plastics – is promising

Application of the results

Development of an optimised CO2-capture process with amines as CO2-solvent from pilot to a full scale plant

pp

from pilot to a full-scale plant.

Demonstration plant with CO2-storagePilot plant at Niederaußem

Pilot plant0 5 MW

Demo plant250 MW l

Full scale1100 MWel0,5 MWel

250 MWel

2008 2009 2010 2011 2012 2013 2014 2015 2016 20172007 2018 2019 2020

Goals for a commercial full scale application from 2020: Efficiency loss of the power plant by PCC-CCS < 10%-points

C t f CO t d t CO tifi t i Costs for CO2-capture and storage < CO2 certificate prices

The results of the pilot plant tests are directly used in the design study for a d t ti d th f ll l l t


demonstration and the full scale plant.

Thank you very muchfor yourfor your attention


The CO2-post-combustion capture development programme

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