Syngas-based Annex concepts in comparison with CO 2 -based Power-to-X concepts within pulverized coal combustion power plants

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1 Syngas-based Annex concepts in comparison with CO 2 -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

2 Background Electricity generation Example Germany Installed capacity in GW(el,net) Electricity generation in TWh(el) Excess Electricity in TWh(el) Pumped Hydro Renewables Oil NG SC NG CC Hard Coal Sources: Energy concept of the Federal Government, Germany, 2010 Jürgensen et al., Biomass and Bioenergy, 2014, 66, Challenges: Lignite Nuclear Flexibility improvement of fossil-fueled power plants Concepts for excess electricity storage in countries with high Renewables share Wünsch et al., Maßnahmen zur nachhaltigen Integration von Systemen zur gekoppelten Stromund Wärmebereitstellung in das neue Energieversorgungssystem, Prognos AG,

3 Background Flexibility Flexibility and part load capability of existing fossil fueled power plants (significant remaining lifetime) are limited PC Hard Coal PC Lignite CC Natural Gas SC Natural Gas Load gradients % P N / min 4 / / 4 4 / 8 12 / 15 Intervall % P N Source: Feldmüller, Siemens Energy, Flexibility of today s power plants from perspective of manufacturers, Germany, 2013 Information: State of the Art / Optimization potential Minimal load % P N 25 / / / / 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 Challenge for lignite-fired power plants: Reducing minimal load to avoid lifetime-consuming start-up, shutdown processes 8 th International Freiberg Conference, June 2016

4 Process description Annex Coal to Methanol ca. 2,260 MW(th, LHV) PTX CO 2 to Methanol ca. 2,260 MW(th, LHV) Lignite Coal preparation PCPP Flue gas Lignite Coal preparation PCPP Flue gas Excess Steam P th Waste water Waste gases Carbonaceous residues etc. Electricity P el Steam P th Steam P th Waste water Waste gases etc. Electricity P el Steam P th Flue gas 500 MW(th, LHV) 1,450 C, 40 bar Flue gas Further coal preparation Gasification Gas cleanup Synthesis & product upgrading MeOH MEA Post combustion capture unit CO 2 Methanol synthesis Product upgrading MeOH 0 / 150 MW(el) / MAX H MW(el) Air ASU O 2 O 2 Elektrolysis & gas storage Water Clean gas H 2 Electrolysis & gas storage Water O 2 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 4

5 Process description Annex & PTX concept configuration 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, CO 2 emissions, CAPEX, OPEX 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 MW(el) 150 MW(el) > 150 MW(el) Nominal load Minimal load PCPP 1 2,260 MW(th) 2,260 MW(th) 2,260 MW(th) 2,260 MW(th) Minimal load Nominal load Gasifier MW(th) 500 MW(th) 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 8 th International Freiberg Conference, June

6 Modelling results Efficiency and CO 2 emission Annex 1 Annex 2 Annex 3 PTX 2 Electrolysis capacity in MW(el) Thermal Input Coal in MW(th) * Methanol Output in t/d Net Power Output (LEP) in % Reference PCPP Minimal load 50 % P th,coal,pcpp PCPP P el,pcpp 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 CO 2 emissions in g/kwh(th,meoh) electricity from PCPP, 978 g/kwh(el) CO 2 emissions in g/kwh(th,meoh) renewable electricity, 53 g/kwh(el) * 1 LHV-based *² Electrolyzer efficiency 67 % (LHV) *³ based on coal * 4 based on CO 2 ηη tttt = PP tttt,mmmmmmmm PP tttt,cccccccc,aaaaaaaaaa + PP tttt,eeee,aaaaaa PP tttt,ssssssssss P th,coal,annex (P el,ren,excess ) P th,(el,aux) ηη CCRR,AAAAAAAAAA = Annex unit P th,steam nn CC,MMMMMMMM nn CC,CCCCCCCC,AAAAAAAAAA P th,meoh 6

7 Modelling results Efficiency and CO 2 emission Annex 1 Annex 2 Annex 3 PTX 2 Electrolysis capacity in MW(el) Thermal Input Coal in MW(th) * Methanol Output in t/d Net Power Output (LEP) in % Reference PCPP Minimal load 50 % Thermal efficiency in % *² 56,6 45,2 33,7 20,4 CCCC + 22HH 22 CCHH 33 OOOO CCCC HH 22 CCHH 33 OOOO+ HH 22 OO P th,coal,pcpp PCPP P el,pcpp Carbon retention MeOH in % 39,0*³ 48,0*³ 88,2*³ 92,0* 4 CO 2 emissions in g/kwh(th,meoh) electricity from PCPP, 978 g/kwh(el) CO 2 emissions in g/kwh(th,meoh) renewable electricity, 53 g/kwh(el) * 1 LHV-based *² Electrolyzer efficiency 67 % (LHV) *³ based on coal * 4 based on CO 2 ηη tttt = PP tttt,mmmmmmmm PP tttt,cccccccc,aaaaaaaaaa + PP tttt,eeee,aaaaaa PP tttt,ssssssssss P th,coal,annex (P el,ren,excess ) ηη CCRR,AAAAAAAAAA = nn CC,MMMMMMMM P th,(el,aux) nn CC,CCCCCCCC,AAAAAAAAAA Annex / PTX unit P th,steam P th,meoh ηη CCRR,PPPPPP = nn CC,MMMMMMMM nn CC,CCCC 22 7

8 Cost estimation Equipment Costs Bare Erected Costs (2015) in /kw(th,meoh) % 20% 28% 54% 69% 22% 23% 53% 57% 15% 26% 22% 23% 53% +89 % 70% 24% 80% 16% Infrastructure and auxiliary equipment Electrolysis unit and gas storage Gas cleanup, synthesis and upgrading Coal handling, gasification and ASU CTX Annex Annex Annex Annex PTX PTX Concept Methanol production in t/d Electrolysis capacity in MW(el) Full load hours Electrolysis in h/a 8 th International Freiberg Conference, June

9 Cost estimation Methanol Costs Levelized Methanol cost (2015) in /t MeOH % 24 /MWh(el) 19,6 /MWh(el) 0 /MWh(el) Electricity and fuel in /t MeOH CAPEX and other OPEX in /t MeOH Methanol price range /t Source: Methanex, Methanol Prices, CTX Annex Annex Annex Annex PTX PTX Concept Methanol production in t/d Electrolysis capacity in MW(el) Full load hours Electrolysis in h/a 8 th International Freiberg Conference, June

10 Cost estimation Methanol Costs Sensitivity Parameter Reference value Reference PTX2 (1 availability) 11,3 % - 50 % + 50 % construction time 3 years - 50 % + 50 % interest rate 10 % - 50 % + 50 % methanol capacity 268 t/d electricity price LEP 23,86 /MWh(el) HEP 34,86 /MWh(el) + 50 % - 50 % - 50 % + 50 % 70% 80% 90% 100% 110% 120% 130% 140% Methanol cost (2015) 10

11 Summary 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 Annex 1 CTX 1 (1200 t/d) without electrolysis unit CAPEX - 27 % OPEX - 8 % Methanol costs - 18 % Annex 2 (1480 t/d) PTX 2 (268 t/d) 150 MW(el) electrolysis unit CAPEX ± 0 % OPEX - 45 % Methanol costs - 20 % Electrolysis capacity (Annex) Power sink, ηη CCCC Specific CAPEX Total investment costs ηη ttt Future investigations: Different gasification technologies and synthesis concepts Higher value chemical products (MTO, MTG, FT) Dynamic modeling 8 th International Freiberg Conference, June

12 Acknowledgement Project HotVeGasII: Project number G 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. 8 th International Freiberg Conference, June

13 THANK YOU FOR YOUR ATTENTION! For enquiries or further questions, please contact: Christian Wolfersdorf Phone: +49-(0) Fax: +49-(0) Website: 8 th International Freiberg Conference, June

14 Backup Coal Analysis Ultimate analysis Heating Value analysis Ash wt.-% (dry) HHV MJ/kg (dry) Carbon wt.-% (dry) Hydrogen wt.-% (dry) Proximate analysis Nitrogen wt.-% (dry) Moisture wt.-% Chlorine wt.-% (dry) C fix wt.-% (dry) Sulfur wt.-% (dry) VM wt.-% (dry) Oxygen wt.-% (dry) Ash wt.-% (dry) Sum wt.-% (dry) Sum wt.-% (dry) th International Freiberg Conference, June

15 Back-up 600 /t MeOH 140 $/bbl Methanolpreis (Europa, Methanex) in /t 500 /t MeOH 400 /t MeOH 300 /t MeOH 200 /t MeOH 100 /t MeOH 120 $/bbl 100 $/bbl 80 $/bbl 60 $/bbl 40 $/bbl 20 $/bbl Rohölpreis Brent in $/bbl 0 /t MeOH 0 $/bbl Jan-02 Jul-02 Jan-03 Jul-03 Jan-04 Jul-04 Jan-05 Jul-05 Jan-06 Jul-06 Jan-07 Jul-07 Jan-08 Jul-08 Jan-09 Jul-09 Jan-10 Jul-10 Jan-11 Jul-11 Jan-12 Jul-12 Jan-13 Jul-13 Jan-14 Jul-14 Jan-15 Jul-15 Jan-16 16

16 Electricity prices for grey Methanol (power plant electricity) 60 geordnete Jahresganglinie der Strompreise 2014 (EEX Spot Auktion) 50 hoher Preis: Ø = 42,08 /MWh 40 Strompreis in /MWh niedriger Preis: Ø = 28,85 /MWh Tag th International -10 Freiberg Conference, June

17 Electricity prices for green Methanol (renewable electricity) 60 geordnete Jahresganglinie der Strompreise 2014 (EEX Spot Auktion) hoher Preis: Ø = 37,46 /MWh Strompreis in /MWh niedriger Preis: Ø = 23,73 /MWh Tag th International -10 Freiberg Conference, June

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