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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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 3
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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 4
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
d Po
wer
050
010
0015
0020
01.07. 21.07. 10.08. 30.08. 19.09. 09.10. 29.10. 18.11. 08.12. 28.12.
Ein
4.000
6.000
W
III. Long calm periods
01.07.10 – 31.12.10
0
2.000
02.02. 03.02. 04.02. 05.02. 06.02. 07.02.
Sandra Schmidt, RWE Power AG 20.06.2011 Page 5
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)
Sandra Schmidt, RWE Power AG 20.06.2011 Page 6
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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 7
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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 8
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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 9
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)
Sandra Schmidt, RWE Power AG 20.06.2011 Page 10
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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 11
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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 12
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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 13
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
Sandra Schmidt, RWE Power AG 20.06.2011 Page 14
demonstration and the full scale plant.
Thank you very muchfor yourfor your attention
Sandra Schmidt, RWE Power AG 20.06.2011 Page 15