Syngas-based Annex concepts in comparison with CO2-based Power-to-X concepts within
pulverized coal combustion power plants
Dipl.-Ing. Christian Wolfersdorf Institute of Energy Process Engineering & Chemical Engineering 15th June 20, Cologne, Germany
Background Process Description
Modelling Results
Cost Estimation Summary
Pumped Hydro
Renewables
Oil
NG SC
NG CC
Hard Coal
Lignite
Nuclear
2
Electricity generation – Example Germany
Jürgensen et al., Biomass and Bioenergy, 2014, 66, 126-132
Sources:
→ Challenges:→ Flexibility improvement of fossil-fueled power plants→ Concepts for excess electricity storage in countries with high Renewables share
Installed capacity in GW(el,net) Electricity generation in TWh(el)
2000 0.13
2010 0.42
2020 1.1–13
Excess Electricity in TWh(el)
Energy concept of the Federal Government, Germany, 2010
Wünsch et al., Maßnahmen zur nachhaltigen Integration von Systemen zur gekoppelten Strom- und Wärmebereitstellung in das neue Energieversorgungssystem, Prognos AG, 2013
Background
Background
Flexibility and part load capability of existing fossil fueled power plants (significant remaining lifetime) are limited
Flexibility
PC Hard Coal
PC Lignite
CC Natural Gas
SC Natural Gas
Load gradients % PN / min 4 / 6 2.5 / 4 4 / 8 12 / 15
Intervall % PN 40-90 50-90 40-90 40-90
Minimal load % PN 25 / 20 50 / 40 40 / 30 40 / 20
Start-up time
Hot (< 8 h) h 2.5 / 2 4 / 2 1 / 0.5 < 0.1
Cold (> 48 h) h 5 / 4 8 / 6 3 / 2 < 0.1
Source: Feldmüller, Siemens Energy, Flexibility of today‘s power plants from perspective of manufacturers, Germany, 2013
Information: State of the Art / Optimization potential
→ Challenge for lignite-fired power plants:→ Reducing minimal load to avoid lifetime-consuming start-up, shutdown processes
8th International Freiberg Conference, 12 – 16 June 2016
Process description
4
Annex – Coal to Methanol
Coal preparation PCPP
Gasification Gas cleanup Synthesis &
product upgrading
Elektrolysis & gas storage
Excess Steam Pth Waste water Waste gases Carbonaceous
residues etc.
Electricity Pel Steam Pth
Flue gas
ASU
H2
O2
Further coal preparation
Lignite
Air WaterO2
MeOH
500 MW(th, LHV) 1,450 °C, 40 bar
ca. 2,260 MW(th, LHV)
PTX – CO2 to Methanol
Coal preparation PCPP
Methanol synthesis
Product upgrading
Steam Pth Waste water Waste gases etc.
Electricity Pel Steam Pth Flue gas
Flue gas
Electrolysis & gas storage
H2
CO2Post combustion capture unit
Lignite
Water
O2
MeOH
ca. 2,260 MW(th, LHV)
Flue gas
MEA
Clean gas
150 MW(el)
→ Flexibility improvement of lignite-fired power plant:→ Annex, PTX = power sink → Reduction of net power output, Electricity storage
→ Cost reduction by sharing infrastructure and auxiliary equipment
0 / 150 MW(el) / MAX
Process description
• Case study for different configurations with Methanol production,• Analysed with flow-sheet simulation tools (Aspen Plus) regarding:
− Power consumption, steam integration, flexibility improvements, part load operation of PCPP,− Efficiency, CO2 emissions, CAPEX, OPEX
5
Annex & PTX concept configuration
8th International Freiberg Conference, 12 – 16 June 2016
concepts loads for electricity prices (cases)
Unit Annex 1 Annex 2 PTX 2 Annex 3 Low price (LEP)² High price (HEP)³
Water Electrolysis - 150 MW(el) 150 MW(el) > 150 MW(el) Nominal load Minimal load
PCPP1 2,260 MW(th) 2,260 MW(th) 2,260 MW(th) 2,260 MW(th) Minimal load Nominal load
Gasifier1 500 MW(th) 500 MW(th) - 500 MW(th) Nominal load Nominal load
ASU x x - - Minimal load Nominal load
CO-Shift x x - - Nominal load Nominal load
Synthesis x x x x Nominal load Nominal load 1 LHV-based thermal power input; ²Reference: 6570 h/a; ³Reference: 2190 h/a
→
Modelling results
6
Efficiency and CO2 emission
𝜼𝜼𝑪𝑪𝑹𝑹,𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨 = �̇�𝑨𝑪𝑪,𝑴𝑴𝑨𝑨𝑴𝑴𝑴𝑴
�̇�𝑨𝑪𝑪,𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪,𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨
PCPP
Annex unit
Pth,steam Pth,(el,aux)
Pth,MeOH
Pel,PCPPPth,Coal,PCPP
Pth,Coal,Annex
(Pel,ren,excess)
𝜼𝜼�𝒕𝒕𝒕𝒕 = 𝑷𝑷�𝒕𝒕𝒕𝒕,𝑴𝑴𝑨𝑨𝑴𝑴𝑴𝑴
𝑷𝑷�𝒕𝒕𝒕𝒕,𝒄𝒄𝑪𝑪𝑪𝑪𝑪𝑪,𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨 + 𝑷𝑷�𝒕𝒕𝒕𝒕,𝑨𝑨𝑪𝑪,𝑪𝑪𝒂𝒂𝑨𝑨 − 𝑷𝑷�𝒕𝒕𝒕𝒕,𝒔𝒔𝒕𝒕𝑨𝑨𝑪𝑪𝒔𝒔
Annex 1 Annex 2 Annex 3 PTX 2
Electrolysis capacity in MW(el) - 150 780 150
Thermal Input Coal in MW(th) *1 500 500 500 -
Methanol Output in t/d 1200 1480 2740 270
Net Power Output (LEP) in % Reference PCPP Minimal load 50 % 46 32 -26 36
Thermal efficiency in % *² 56,6 45,2 33,7 20,4
Carbon retention MeOH in % 39,0*³ 48,0*³ 88,2*³ 92,0*4
CO2 emissions in g/kWh(th,MeOH) electricity from PCPP, 978 g/kWh(el) 443 617 930 1609
CO2 emissions in g/kWh(th,MeOH) renewable electricity, 53 g/kWh(el) 377 276 80 -156
*1 LHV-based*² Electrolyzer efficiency 67 % (LHV)*³ based on coal*4 based on CO2
Modelling results
7
Efficiency and CO2 emission
𝜼𝜼𝑪𝑪𝑹𝑹,𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨 = �̇�𝑨𝑪𝑪,𝑴𝑴𝑨𝑨𝑴𝑴𝑴𝑴
�̇�𝑨𝑪𝑪,𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪,𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨 𝜼𝜼𝑪𝑪𝑹𝑹,𝑷𝑷𝑷𝑷𝑷𝑷 =
�̇�𝑨𝑪𝑪,𝑴𝑴𝑨𝑨𝑴𝑴𝑴𝑴
�̇�𝑨𝑪𝑪,𝑪𝑪𝑴𝑴𝟐𝟐𝜼𝜼�𝒕𝒕𝒕𝒕 =
𝑷𝑷�𝒕𝒕𝒕𝒕,𝑴𝑴𝑨𝑨𝑴𝑴𝑴𝑴
𝑷𝑷�𝒕𝒕𝒕𝒕,𝒄𝒄𝑪𝑪𝑪𝑪𝑪𝑪,𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨𝑨 + 𝑷𝑷�𝒕𝒕𝒕𝒕,𝑨𝑨𝑪𝑪,𝑪𝑪𝒂𝒂𝑨𝑨 − 𝑷𝑷�𝒕𝒕𝒕𝒕,𝒔𝒔𝒕𝒕𝑨𝑨𝑪𝑪𝒔𝒔
PCPP
Annex / PTX unit
Pth,steam Pth,(el,aux)
Pth,MeOH
Pel,PCPPPth,Coal,PCPP
Pth,Coal,Annex
(Pel,ren,excess)
𝑪𝑪𝑴𝑴 + 𝟐𝟐𝑴𝑴𝟐𝟐 ⇄ 𝑪𝑪𝑴𝑴𝟑𝟑𝑴𝑴𝑴𝑴
𝑪𝑪𝑴𝑴𝟐𝟐 + 𝟑𝟑𝑴𝑴𝟐𝟐 ⇄ 𝑪𝑪𝑴𝑴𝟑𝟑𝑴𝑴𝑴𝑴+ 𝑴𝑴𝟐𝟐𝑴𝑴
Annex 1 Annex 2 Annex 3 PTX 2
Electrolysis capacity in MW(el) - 150 780 150
Thermal Input Coal in MW(th) *1 500 500 500 -
Methanol Output in t/d 1200 1480 2740 270
Net Power Output (LEP) in % Reference PCPP Minimal load 50 % 46 32 -26 36
Thermal efficiency in % *² 56,6 45,2 33,7 20,4
Carbon retention MeOH in % 39,0*³ 48,0*³ 88,2*³ 92,0*4
CO2 emissions in g/kWh(th,MeOH) electricity from PCPP, 978 g/kWh(el) 443 617 930 1609
CO2 emissions in g/kWh(th,MeOH) renewable electricity, 53 g/kWh(el) 377 276 80 -156
*1 LHV-based*² Electrolyzer efficiency 67 % (LHV)*³ based on coal*4 based on CO2
54% 69%53%
26%53%
20% 28%
23%
15%
23%
24%
22%
57%
22%
70%
0
500
1.000
1.500
2.000
2.500
16%
80%
Cost estimation
8
Concept Methanol production in t/d Electrolysis capacity in MW(el) Full load hours Electrolysis in h/a
CTX1 1200
- 5830
Annex1 1200
- 5830
Annex2 1480 150
5830
Annex3 2740 780
5830
Annex2 1480 150
5830
PTX2 270 150
5830
PTX2 123 150
2660
Bar
e Er
ecte
d C
osts
(201
5)
in €
/kW
(th,M
eOH
)
Equipment Costs
8th International Freiberg Conference, 12 – 16 June 2016
Infrastructure and auxiliary equipment
Electrolysis unit and gas storage
Gas cleanup, synthesis and upgrading
Coal handling, gasification and ASU
-27 % +89 %
0
200
400
600
800
1.000
1.200
24 €/MWh(el)
19,6 €/MWh(el)
Cost estimation
9
Methanol price range 150-525 €/t
Concept Methanol production in t/d Electrolysis capacity in MW(el) Full load hours Electrolysis in h/a
Leve
lized
Met
hano
l cos
t (2
015)
in €
/t M
eOH
Source: Methanex, Methanol Prices, 2006-2016
Methanol Costs
CTX1 1200
- 5830
Annex1 1200
- 5830
Annex2 1480 150
5830
Annex3 2740 780
5830
Annex2 1480 150
5830
PTX2 270 150
5830
PTX2 123 150
2660
8th International Freiberg Conference, 12 – 16 June 2016
PTX2 270 150
5830
Electricity and fuel in €/t MeOH
CAPEX and other OPEX in €/t MeOH
0 €/MWh(el)
-18 %
70% 80% 90% 100% 110% 120% 130% 140%
Cost estimation
10
Methanol Costs – Sensitivity
(1 – availability) 11,3 %
construction time 3 years
interest rate 10 %
methanol capacity 268 t/d
electricity price LEP 23,86 €/MWh(el) HEP 34,86 €/MWh(el)
Parameter Reference value Reference PTX2
- 50 %
- 50 %
- 50 %
+ 50 %
- 50 %
+ 50 %
+ 50 %
+ 50 %
- 50 %
+ 50 %
Methanol cost (2015)
Summary
11 8th International Freiberg Conference, 12 – 16 June 2016
Annex and PTX concepts improve flexibility of electricity generation from lignite: • Power sink → net power output reduction from 50 % (PCPP) to 32 / 36 % (Annex 2 / PTX 2)
without lifetime-consuming start-up/Shut-down processes• Electrolysis unit needs high availability for cost reduction
Electrolysis capacity (Annex) ↑ • Power sink ↑, 𝜂𝜂𝐶𝐶𝐶𝐶 ↑• Specific CAPEX ↓• Total investment costs ↑• �̅�𝜂𝑡𝑡𝑡 ↓
Annex 2 (1480 t/d) ↔ PTX 2 (268 t/d) 150 MW(el) electrolysis unit • CAPEX → ± 0 % • OPEX ↓ - 45 %• Methanol costs ↓ - 20 %
Future investigations: • Different gasification technologies and synthesis concepts• Higher value chemical products (MTO, MTG, FT)• Dynamic modeling
Annex 1 ↔ CTX 1 (1200 t/d) without electrolysis unit • CAPEX ↓ - 27 %• OPEX ↓ - 8 %• Methanol costs ↓ - 18 %
Acknowledgement
12 8th International Freiberg Conference, 12 – 16 June 2016
Project HotVeGasII: Project number 0327773G • Participating companies
− EnBW Kraftwerke AG− RWE Power AG, Forschung und Entwicklung− Vattenfall Europe Generation AG− AIR LIQUIDE Forschung und Entwicklung GmbH− Siemens Fuel Gasification Technology GmbH & Co. KG
• Participating research partners:− TU München, Institute for Energy Systems− TU Bergakademie Freiberg, Institute of Energy Process Engineering and Chemical Engineering− Forschungszentrum Jülich GmbH, Institute of Energy and Climate Research (IEK-2)− GTT-Technologies, Gesellschaft für Technische Thermochemie und –physik mbH
Project CODY: Project number 03ET7063 • Participating companies
− E.ON Technologies GmbH / Uniper Technologies GmbH− Linde AG (Linde Engineering)
• Participating research partners:− TU Bergakademie Freiberg, Institute of Energy Process Engineering and Chemical Engineering, altogether 5 chairs
The results presented in this presentation solely represent the authors view.
For enquiries or further questions, please contact:
Christian Wolfersdorf Email: [email protected] Phone: +49-(0)3731-394512Fax: +49-(0)3731-394555
Website: www.iec.tu-freiberg.de
13
THANK YOU FOR YOUR ATTENTION!
8th International Freiberg Conference, 12 – 16 June 2016
Backup
14
Coal Analysis
8th International Freiberg Conference, 12 – 16 June 2016
Ultimate analysis Heating Value analysis Ash wt.-% (dry) 10.769 HHV MJ/kg (dry) 23.691 Carbon wt.-% (dry) 60.000 Hydrogen wt.-% (dry) 4.396 Proximate analysis Nitrogen wt.-% (dry) 0.879 Moisture wt.-% 12.000 Chlorine wt.-% (dry) 0.022 Cfix wt.-% (dry) 38.242 Sulfur wt.-% (dry) 1.319 VM wt.-% (dry) 50.989 Oxygen wt.-% (dry) 22.615 Ash wt.-% (dry) 10.769 Sum wt.-% (dry) 100.000 Sum wt.-% (dry) 100.000
0 $/bbl
20 $/bbl
40 $/bbl
60 $/bbl
80 $/bbl
100 $/bbl
120 $/bbl
140 $/bbl
0 €/t MeOH
100 €/t MeOH
200 €/t MeOH
300 €/t MeOH
400 €/t MeOH
500 €/t MeOH
600 €/t MeOH
Jan-
02Ju
l-02
Jan-
03Ju
l-03
Jan-
04Ju
l-04
Jan-
05Ju
l-05
Jan-
06Ju
l-06
Jan-
07Ju
l-07
Jan-
08Ju
l-08
Jan-
09Ju
l-09
Jan-
10Ju
l-10
Jan-
11Ju
l-11
Jan-
12Ju
l-12
Jan-
13Ju
l-13
Jan-
14Ju
l-14
Jan-
15Ju
l-15
Jan-
16
Rohö
lpre
is B
rent
in $
/bbl
Met
hano
lpre
is (E
urop
a, M
etha
nex)
in €
/tBack-up
16
Electricity prices for „grey Methanol“ (power plant electricity)
17 8th International Freiberg Conference, 12 – 16 June 2016-10
0
10
20
30
40
50
60
0 50 100 150 200 250 300 350 400
Stro
mpr
eis
in €
/MW
h
Tag
geordnete Jahresganglinie der Strompreise 2014 (EEX Spot Auktion)
365257
niedriger Preis: Ø = 28,85 €/MWh
hoher Preis:Ø = 42,08 €/MWh
Electricity prices for „green Methanol“ (renewable electricity)
18 8th International Freiberg Conference, 12 – 16 June 2016-10
0
10
20
30
40
50
60
0 50 100 150 200 250 300 350 400
Stro
mpr
eis
in €
/MW
h
Tag
geordnete Jahresganglinie der Strompreise 2014 (EEX Spot Auktion)
365257
niedriger Preis: Ø = 23,73 €/MWh
hoher Preis: Ø = 37,46 €/MWh
