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
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: 2000 0.13 2010 0.42 2020 1.1 13 Energy concept of the Federal Government, Germany, 2010 Jürgensen et al., Biomass and Bioenergy, 2014, 66, 126-132 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, 2013 2
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 / 6 2.5 / 4 4 / 8 12 / 15 Intervall % P N 40-90 50-90 40-90 40-90 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 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 Challenge for lignite-fired power plants: Reducing minimal load to avoid lifetime-consuming start-up, shutdown processes 8 th International Freiberg Conference, 12 16 June 2016
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 2 150 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
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 - 150 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 1 500 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 8 th International Freiberg Conference, 12 16 June 2016 5
Modelling results Efficiency and CO 2 emission 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 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 = 443 617 930 1609 377 276 80-156 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
Modelling results Efficiency and CO 2 emission 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 CCCC + 22HH 22 CCHH 33 OOOO CCCC 22 + 33HH 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 = 443 617 930 1609 377 276 80-156 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
Cost estimation Equipment Costs 2.500 Bare Erected Costs (2015) in /kw(th,meoh) 2.000 1.500 1.000 500 0-27 % 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 CTX1 1200 - Annex1 1200 - Annex2 1480 150 Annex3 2740 780 Annex2 1480 150 PTX2 270 150 PTX2 123 150 2660 Concept Methanol production in t/d Electrolysis capacity in MW(el) Full load hours Electrolysis in h/a 8 th International Freiberg Conference, 12 16 June 2016 8
Cost estimation Methanol Costs Levelized Methanol cost (2015) in /t MeOH 1.200 1.000 800 600 400 200 0-18 % 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 150-525 /t Source: Methanex, Methanol Prices, 2006-2016 CTX1 1200 - Annex1 1200 - Annex2 1480 150 Annex3 2740 780 Annex2 1480 150 PTX2 270 150 PTX2 123 150 2660 Concept Methanol production in t/d Electrolysis capacity in MW(el) Full load hours Electrolysis in h/a 8 th International Freiberg Conference, 12 16 June 2016 9
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
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, 12 16 June 2016 11
Acknowledgement 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. 8 th International Freiberg Conference, 12 16 June 2016 12
THANK YOU FOR YOUR ATTENTION! For enquiries or further questions, please contact: Christian Wolfersdorf Email: Christian.Wolfersdorf@iec.tu-freiberg.de Phone: +49-(0)3731-394512 Fax: +49-(0)3731-394555 Website: www.iec.tu-freiberg.de 8 th International Freiberg Conference, 12 16 June 2016 13
Backup Coal Analysis 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 C fix 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 8 th International Freiberg Conference, 12 16 June 2016 14
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
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 30 20 niedriger Preis: Ø = 28,85 /MWh 10 0 0 50 100 150 Tag 200 250 257 300 350 365 400 8 th International -10 Freiberg Conference, 12 16 June 2016 17
Electricity prices for green Methanol (renewable electricity) 60 geordnete Jahresganglinie der Strompreise 2014 (EEX Spot Auktion) 50 40 hoher Preis: Ø = 37,46 /MWh Strompreis in /MWh 30 20 niedriger Preis: Ø = 23,73 /MWh 10 0 0 50 100 150 Tag 200 250 257 300 350 365 400 8 th International -10 Freiberg Conference, 12 16 June 2016 18