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RWE Power’s Coal Innovation Centre

at Niederaussem, Germany

Dr. Peter Moser

Emission Reduction Technologies

RWE Power AG

UNECE

20./21.10.2014, Geneva

RWE Power AG, POR-FE 20./21.10.2014

Coal Innovation Center Niederaussem

FGDplus

Since 2009

→ SO2/Dust-Mitigation

Power-to-Gas

2013

→ Energy Storage

WTA®-Drier since late 2008

→ Efficiency enhancement

CO2-Scrubber since 2009

→ CO2-Capture

CO2-Filling station since 2011

→ CO2-Utilisation

Catalyst testing

since 2013

→ CO2 usage


Coal Innovation Center Niederaussem

Power plant

Capture Plant

Flue gas, raw lignite

Lignite

Pre-drying WTA®

Flue gas, dry lignite

Lignite combustion Flue gas pre-treatment Post-combustion

capture Conventional FGD

Dust dosing

SO2/SO3 dosing

FGDplus

Wet ESP

CO2

CO2-lean flue gas


1 WTA

2 FGDplus

3 CO2 Capture and Utilisation

Selected R&D projects


4,0

5,4

4,4

6,2

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

1 2

Eff

icie

nc

y in

cre

as

e [%

-pts

.]

Coal from Hambach mine

Water content: 50,7 wt.-%

Coal from Garzweiler mine

Water content: 55,5 wt.-%

WTA +

Vapour condensation

WTA +

Vapour recom-

pression

WTA +

Vapour condensation WTA

+ Vapour recom-

pression

Power Plant Efficiency Increase

due to WTA


WTA -Prototype - Revolving Chute Distributer


1 WTA

2 FGDplus





FGDplus Pilot Plant Joint project of RWE Power and Andritz

Duration 2009 – 2014

Highest removal rates for SO2

(Target: >99,5%)

Reduction of SO3, Aerosols and Dust,

with and without Wet Electrostatic

Precipitator

Flue gas treatment according to the

requirements of PCC systems

FGDplus Pilot Plant

at the Coal Innovation Center Niederaussem

Raw flue gas

Clean flue gas

Gypsum slurry

Process water

Limestone slurry

Sump

Counterflow Module

„REAplus“ Module

Spray Tower Module

Wet Electrostatic Precipitator

Demister Module


FGDplus - Full-scale Validation

Absorber G1, 600 MW unit G, power plant Niederaussem


1 WTA

2 FGDplus





PCC optimisation: Holistic approach and

interdisciplinary cooperation

Cooperation BASF - Linde - RWE Power

chemistry,

process

engineering

Goal: 90% CO2-capture rate with a high efficient PCC-technology , loss of efficiency <10%-points, PCC-design for a 1,100 MW power plant

Tasks for optimisation:

> BASF

Capture process, solvent performance

(efficiency, solvent stability, economics)

> Linde

Engineering capture plant, components

(efficiency, scale-up, economics)

> RWE Power

Integration of PCC into power plants

(efficiency, operation, economics)

power plant


Solvent regeneration

CO2-capture Flue gas cooling,

SO2-pre scrubbing CO2

Desorber

Flue gas

Absorber Prescrubber

CO2-lean

flue gas

NaOH

solution tank Solvent tank

CO2 Capture Pilot Plant at Niederaussem

Flue gas: 1,550 m3N/h Availability: 97%

CO2 product: 7.2 tCO2/day; capture rate 90% Budget of RWE for phases I/II/III: 20 Mio. €

Absorber height corresponds to full scale 40% funding by the Federal Ministry of

Instrumentation: 275 measuring points Economics and Technology


A big step forward for Post-Combustion Capture Technology

Results of measurements and simulations show perfect match

Innovative material concept holds promise

Further potential for optimisation identified Modification & long-term trials

MEA

Ludwig540

> Energy demand for solvent regeneration

20% better for new solvents than for an

optimised MEA process.

> Solvent flow rate significantly lower than

for MEA.

> Low solvent losses for new

scrubbing agents compared to

MEA.

> OASE blue is more stable against

oxidation than MEA.

Operating time

Co

nte

nt

of

he

at

sta

ble

salt

s

Solvent flow

Sp

ecif

ic E

ne

rgy D

em

an

d [

MJ/t

CO

2]

Gustav200

®


Test run history with OASE blue

0

3000

6000

9000

12000

15000

18000

21000

24000

0

1000

2000

3000

4000

5000

6000

7000

8000

Betr

ieb

sze

it O

AS

E b

lue [

h],

Wasch

mit

telf

luss [

-]

Ab

ge

tren

nte

s C

O2

[t],

Leis

tun

g B

l. K

[M

W]

OASE blue Versuchszeit [h]

CO2

Pel

Solvent circulation

OASE® blueoperating time

Time of the trial phase with the solvent OASE® blue [h]

Cap

ture

dC

O2

[t],

Po

wer

ou

tpu

tB

l. K

[M

W]

OA

SE

®b

lue o

pera

tin

g t

ime [

h],

So

lven

t cir

cu

lati

on

[-]

More than 24,000 h operating time with OASE® blue provide reliable results


Change of the Packing in the Absorber Column Smaller column design is possible


Emission Mitigation „Dry Bed”

Reduction of amine emissions by an order of magnitude: Process configuration

„Dry Bed“

1 3 5 7 9 11 13 15 17 19 21 23 25 27

Am

ink

on

ze

ntr

ati

on

Zeit [Tage]

Absorber

Flue gas

Long column short column & „Dry Bed"

Absorber

Flue gas

„Dry Bed"

Make-up

Wasser

Am

ine

Co

nc

en

tra

tio

n

Time [days]


Emission Reduction by Upstream Measure OASE blue run

Reduction of amine emissions by an order of magnitude: Process configuration

„Upstream Measure“


Lignite and CO2 as raw materials for chemistry and biotechnology

Power plant

CO2 CO2 scrubbing

CO2

CO2

Flue gas

Flue gas

Flue gas

Coal-to-gas (CtG)

hydrogen/methane

Coal-to-liquid (CtL)

methanol / fuels

Lignite

Direct use

Chemistry

Dream Production project

Biotechnology

BRAIN AG co-operation

Chemical energy storage

project CO2RRECT

Biology

Pilot algae installation

Gasification

Synthetic gas

Synthetic gas

Opening up new business areas outside

the power and heat market

However, the overall potential for CO2 Utilisation in Germany is < 10 MT/a.

Reward for CCU in form of free Allocated EUAs is not given.

Challenges for Power Generation

and CCS at Germany

Dr. Peter Moser

RWE Power AG

UNECE

20./21.10.2014, Geneva


To be considered:

Deployment

potential of

renewables

Security of supply

and power quality

Price development

Grid stability and

grid extension 25%

17%

58%

80 %

20 %

(EWI/Prognos/GWS Studie)

2020 2030 2040 2050 2010

10%

conventional

generation

renewables

import

demand reduction

45%

20%

25%

gross power generation

Power Generation Sector to Realize Highest Contribution to match goals of government‘s „Energy Concept“


In Germany a dramatically increasing Asymmetry

between Demand and Supply is expected

- -

++

++

Offshore-Wind

Conventional PP

New-Builds

Nuclear PP

decommissioning

!

!

!

Regional Power Balance 2008 Regional Power Balance 2030 Source: Amprion

Some pumped

hydro feasible

No pumped

hydro feasible, but

salt deposits exist

Power [MW] Power [MW]


Dramatic Changes of Wind Power Output

Datenquelle: ISET

0

2.000

4.000

6.000

8.000

10.000

12.000

14.000

16.000

18.000

20.000

02.02. 03.02. 04.02. 05.02. 06.02. 07.02.

2009

Win

d P

ow

er

[MW

]

I. high fluctuation between 0 - 85% of installed power

II. High power gradients

III. back up for longer calm weather required

Pumped Hydro Capacity in Germany

(approx. 40 GWh)

Feb 2009

Initial strong wind phase

Several days of calm &

foggy weather with very

low temperatures

(inversion weather)

Peak residential heating

demand

Whole Germany was

affected

Installed Wind Power 2009: 25 GW

When doubling installed capacity until 2020 to 50 GW:

grid enforcement required, but alone not sufficient to solve the problem

existing storage capacity too low

at least 90% of demand as back-up required by conv. power plants

focus on NG (CC & OCGT) appears to be very risky


Dec

Periods of Calm Wind happen regularly (Pel_wind<10%Pinst.)

Sep

calm wind period 10-12 days calm wind period > 12 days

Definition of

Calm wind day:

Calender day with

wind power

generation of less

than 10% of

installed wind

power generators

1990

Mar

1995 2000 2005 2010

Jun

Jahr

Month

Feb

Jan

Apr

May

Jul

Aug

Oct

Nov

Experience made during more than 20 years (1989 to 2010)


0.0

20.0

40.0

60.0

80.0

100.0

GW residual load 2050

Properties of conventional Power Plants will

need to change

large power plant fleet, three different

dispatch schemes:

base load power plant

mid load power plant

peak load power plant

High efficiency at nominal power

Still large power plant fleet, three different

dispatch schemes:

fast load gradients

Low min load and many load changes

Good efficiency over wide load range

6. KW 7. KW 8. KW 9. KW 6. KW 7. KW 8. KW 9. KW

future up to now

0.0

20.0

40.0

60.0

80.0

100.0

GW residual load 2008


Increased not-demand-driven Generation does not

automatically lead to enhanced Economics for Storage e

lec

tric

ity p

ric

e [

€/M

Wh

]

nuclear lignite

hard coal

CCGT

gas

conv.

electrical demand [GW]

regulated

generation

RES and CHP

Must run

wind,

PV,

CHP,

water

bandwidth of

demand

Price mechanisms influenced by regulatory measures,

Merit-Order-Market is distorted

Large

price spread

due to low

generation

by RES


ele

ctr

icit

y p

ric

e [

€/M

Wh

]

nuclear lignite

hard coal

electrical demand [GW]

regulated

generation

RES and CHP

Must run

wind,

PV,

CHP,

water

bandwidth of

demand

Price mechanisms influenced by regulatory measures,

Merit-Order-Market is distorted

lowered

peak-price

lowered

price spread

Increased not-demand-driven Generation does not

automatically lead to enhanced Economics for Storage


In summer time residual load is more even due to PV price drop, no price spread

PV cuts at Noon Peak of residual Load and Price


NG power plants first to be decommissioned; a reasonable CO2-Price will not change this

Though: Due to lower CO2 foot print, NG plants planned to be complementary to RES in the

government’s Energy Concept

Consequence for Natural gas-fired Power Plants:

Dramatically reduced Operation

Comparison of the dispatch of a 400 MW NG-combi-plant (topping GT + gas fired boiler) 2009 vs 2011

dispatch June/July 2009 dispatch June/July 2009

Thank you for your attention!

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