Improvement of power plant flexibility by coupling of ... · Improvements by coupling of power...
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11th ECCRIAUniversity of Sheffield
Improvement of power plant flexibilityby coupling of power generation
with syngas-based chemical synthesiswith syngas based chemical synthesis
Clemens Forman, Matthias Gootz, Christian Wolfersdorf, Bernd MeyerInstitute of Energy Process Engineering and Chemical Engineering, TU Bergakademie Freiberg6th September 2016, Sheffield, UK
Improvements by coupling of power generation with syngas-based chemical synthesis
1 B k d d ti ti
OUTLINE
1. Background and motivation
2 Power generation cases2. Power generation cases
3. Coupling interfaces
4. Modeling results
5. Summary
211th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
1. BACKGROUND AND MOTIVATION
lignite-fired power plant650‒1 100 MW(el) electric renewable
energy
lignite
650‒1,100 MW(el)
coalcombustion steam cycle
flue gas path flue gas, ash, gypsum
grid energysources
electric energyy
dryingresidual
gas
Annex plant auxiliaries
waterelectrolysis50 MW(el)
gy
Fischer Tropsch synthesis wax diesel200
carbonresidue
sourgas
steam
H2
coalgasifier
waterscrubbing CO-shift CO2/H2S
scrubbing MeOHsynthesis
MtG synthesis
MtO synthesis
Fischer Tropsch synthesis wax, diesel
gasoline
olefinsentrained-flow (EFG)
MW(th)
311th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
( )fluidized-bed (FBG) small-scale chemical synthesiswaste water pretreatment CO2O2
Improvements by coupling of power generation with syngas-based chemical synthesis
1. BACKGROUND AND MOTIVATION
MIN MAX MIN MAXAnnex plant servesas a power sink:
RES RES RES RESas a power sink:
▪ load elasticity ofpower plant rises▪ incorporation of
‒ auxiliary power
electricgrid
electricgrid
electricgrid
electricgrid
psurplus RES ► improved
power plantflexibilitygrid grid
or
MA
X
MIN tdow
n
grid grid
INAX ‒ auxiliary power ‒ auxiliary power
M M
shut
power plant +power
plant +
M
Annex plant
Annex plant
power plant
MA
power plant
411th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
plant plant plant plantplantplant
Improvements by coupling of power generation with syngas-based chemical synthesis
Existing power plant Design data Future power plant
2. POWER GENERATION CASES
built in 1970s to be built 2020+1,725 MW rated thermal input* 2 x 1,155 MW (30 % dry lignite)
672 t/h coal demand 2 x 450 t/h650 MW gross electric output 1,100 MW607 MW net electric output 1,046 MW
37.7 % gross efficiency* 47.6 %35.2 % net efficiency* 45.3 %
1,853 t/h live steam generation 2 x 1,387 t/h170 bar; 530 °C live steam parameter 285 bar; 605 °C
34/30 bar; 300/540 °C cold/hot reheat steam 56/51 bar; 340/620 °C66 mbar condenser pressure 35 mbar
wet cooling tower cooling system hybrid cooling tower(natural draft) (forced draft)
511th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
* thermal input / efficiencies based on LHV
Improvements by coupling of power generation with syngas-based chemical synthesis
Power plant modeling: steady-state simulation ► part load performance
2. POWER GENERATION CASES
sliding
pressuredrops
efficiency102
EPP: existing power plant | FPP: future power plant
pressure curves
96
98
100
effic
ienc
y(%
)
EPP
steamcycle
flue gas path
plantmodeling
90
92
94
ve n
etpl
ant e
BRACHTHÄUSER 1998 CHALMERS 2007
LINNENBERG 2009 ELSNER 2011
FPP
heatl
auxiliarypower
boilercurves
86
88
90
40 45 50 55 60 65 70 75 80 85 90 95 100
rela
tiv
ZIEMS 2012 ROEDER 2014
HANAK 2015 RUPPRECHT 2016
611th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
losses 40 45 50 55 60 65 70 75 80 85 90 95 100
boiler capacity (%)
Improvements by coupling of power generation with syngas-based chemical synthesis
Key performance data: net plant efficiency; specific auxiliary power
2. POWER GENERATION CASES
6,0
6,5
7,0
-0,75
-0,25
0,25
er (%
)
%-p
oint
s)
0.25
-0.75
-0.25
7.0
6.0
6.57,5
8,0
-0,25
0,25
(%)
%-p
oint
s)
0.25
-0.25
8.0
7.5
4,5
5,0
5,5
-2,25
-1,75
-1,25
xilia
ry p
owe
ncy
chan
ge (%
-2.25
-1.75
-1.25
4.5
5.0
5.5
6 0
6,5
7,0
-1 75
-1,25
-0,75
xilia
ry p
ower
ncy
chan
ge (% -0.75
-1.25
-1 75
7.0
6.5
6 0
3 0
3,5
4,0
,
-3 75
-3,25
-2,75
,
spec
ific
aux
et p
lant
eff
icie
net efficiency change
specific auxiliary power-3.75
-3.25
-2.75
3.0
3.5
4.0
5,0
5,5
6,0
-2,75
-2,25
1,75
spec
ific
aux
et p
lant
eff
icie
net efficiency change
specific auxiliary power
1.75
-2.25
-2.75
6.0
5.5
5.0
2,5
3,0
-4,25
3,75
40 45 50 55 60 65 70 75 80 85 90 95 100ne
boiler capacity (%)
specific auxiliary power
-4.25
3.75
2.5
3.0
4,5-3,2550 55 60 65 70 75 80 85 90 95 100
ne
boiler capacity (%)
specific auxiliary power
-3.25 4.5
existing power plant: 50‒100 % load future power plant: 40‒100 % load in DUO block operation (―)
711th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 201645‒100 % load in MONO block operation (- -)
Improvements by coupling of power generation with syngas-based chemical synthesis
Existing power plant
3. COUPLING INTERFACESECO
Target: coupling interfacesrequire little constructionaleffort only
~HP LP
SHT
RHTIP
50 Hz
1
CAPH
effort only
► MP steam: injection intothe cold reheat pipeline
HPFWH
SHT
EVAP
ESP
2
air
► LP steam: installation ofan additional feedwaterheater bypassing the existingLP feedwater heating section lignite
FWH
BFWP
FGD1
2
DMIDF
LP feedwater heating section
► Carbon residue & gases:combustion / thermal treatmentin the after burning section of the furnace
FWT
CT
FGD
clean gas LPFWH
ANNEX
residue& gases
in the after-burning section of the furnace
811th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
CP C
CWP
Improvements by coupling of power generation with syngas-based chemical synthesis
Future power plant
3. COUPLING INTERFACESECO 1clean gas air
Target: adjustment dueto load-dependentoperation conditions
~HP LP
SHT
RHTIP
50 HzFGD
I
CAPH
operation conditions
► MP steam: injection intofeed line of BFWT/FWHand cold reheat pipeline
SHT
EVAP
HPFWH
FGTS
I
II
2and cold reheat pipeline
► LP steam: feedwaterheating and injectioninto feed line of FBD
lignite
BFWP2
DM
FWH
C
FBD1
BFWT
3
IDF
2 x
residue& gasesinto feed line of FBD
► Carbon residue & gases:after-burning section(one/both blocks)
FWT
CT
LPFWH
HP-ABEco ANNEXESP CAPH
& gases
(one/both blocks)
911th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
CP C
CWP
2LP-ABEco
3
II
Improvements by coupling of power generation with syngas-based chemical synthesis
Residual & sour gases: positive pressure; ~30 °C; major components (at STP)
3. COUPLING INTERFACES
Sour gas: 54 … 58 vol.-% CO238 … 43 vol.-% H2S1.1 … 2.6 vol.-% COS
MeOH synthesis: purge gas 66 … 76 vol.-% H21 … 14 vol.-% CH4
light ends 36 … 49 vol.-% H2
► FG: 0.5 … 4 vol.-%
► SO2: +10 % at FGD21 … 22 vol.-% CH3OH
MtG synthesis: off gas ~ 92 vol.-% C1-C4
2
► CO2: up to 27 g/kWh
Carbon residue (FBG only): 1 atm; ~100 °C
34 wt.-% carbon; 66 wt.-% ash14 8 MW thermal input (11 5 MJ/kg LHV)14.8 MW thermal input (11.5 MJ/kg LHV)
1011th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Total heat input: steam; gases; carbon residue
3. COUPLING INTERFACES
FBG
MTGs
MP steam LP steam Residue & gases
FBG
MTGs
Energy Exergy
FBG
EFG
MTO
M
tion
sce
nari
os
FBG
EFG
MTO
M
tion
sce
nari
os
FBG
EFG
FTM
Ann
ex in
tegr
a
FBG
EFG
FTM
Ann
ex in
tegr
a
0 10 20 30 40 50 60 70 80 90
EFG
thermal rating (MW)
A
0 10 20 30 40 50 60 70 80 90
EFG
thermal rating (MW)A
1111th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Annex integration: mass and heat balancing
3. COUPLING INTERFACES
Power plant efficiency stand-alone (LHV)
el: electric | aux: auxiliaries
power plant
Power plant efficiency with Annex integration
Annex plant
C: coal | S: steam | W: feedwaterG: gases | R: carbon residue | P: product(s)
Annex plant
1211th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Net plant efficiency: reference case vs. Annex integration
4. MODELING RESULTS
-1 5
-1,0
-0,5
0,0
%-p
oint
s)
0.0
-1 5
-1.0
-0.5
-1 5
-1,0
-0,5
0,0
%-p
oint
s)
0.0
-1 5
-1.0
-0.5
3 5
-3,0
-2,5
-2,0
1,5
ency
cha
nge
(%
3 5
-3.0
-2.5
-2.0
1.5
3 5
-3,0
-2,5
-2,0
1,5
ency
cha
nge
(%
3 5
-3.0
-2.5
-2.0
1.5
-5,0
-4,5
-4,0
-3,5
et p
lant
eff
icie
EFG-MTG FBG-MTG
EFG-MTO FBG-MTO
EFG-FT FBG-FT
reference (existing plant)
-4.0
-3.5
-4.5
-5.0
5 5
-5,0
-4,5
-4,0
-3,5
et p
lant
eff
icie
EFG-MTG FBG-MTG
EFG-MTO FBG-MTO
EFG-FT FBG-FT
reference (future plant)
-4.0
-3.5
-4.5
-5.0
5 5
-6,0
-5,5
50 55 60 65 70 75 80 85 90 95 100
ne
boiler capacity (%)
reference (existing plant)
-6.0
-5.5
-6,0
-5,5
40 45 50 55 60 65 70 75 80 85 90 95 100ne
boiler capacity (%)
reference (future plant)
-6.0
-5.5
1311th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Net plant efficiency: reference case vs. Annex integration
4. MODELING RESULTS
-1 5
-1,0
-0,5
0,0
%-p
oint
s)
0.0
-1 5
-1.0
-0.5
-1 5
-1,0
-0,5
0,0
%-p
oint
s)
0.0
-1 5
-1.0
-0.5
3 5
-3,0
-2,5
-2,0
1,5
ency
cha
nge
(%
3 5
-3.0
-2.5
-2.0
1.5
3 5
-3,0
-2,5
-2,0
1,5
ency
cha
nge
(%
3 5
-3.0
-2.5
-2.0
1.5
-5,0
-4,5
-4,0
-3,5
et p
lant
eff
icie
EFG-MTG FBG-FT
reference (future plant)
-4.0
-3.5
-4.5
-5.0
5 5
-5,0
-4,5
-4,0
-3,5
et p
lant
eff
icie
EFG-MTG FBG-FT
reference (existing plant)
-4.0
-3.5
-4.5
-5.0
5 5
-6,0
-5,5
40 45 50 55 60 65 70 75 80 85 90 95 100ne
boiler capacity (%)
reference (future plant)
-6.0
-5.5
-6,0
-5,5
50 55 60 65 70 75 80 85 90 95 100
ne
boiler capacity (%)
reference (existing plant)
-6.0
-5.5
existing power plant: -0.2 … -0.5 (100 %) | -0.1 … -0.6 (50 %) future power plant: -0.5 … -0.6 (100 %) | -0.8 … -1.1 (40 %)
1411th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Coal savings: heat input by Annex integration results in less coal demand (and CO2 emissions)
4. MODELING RESULTS
6
7
8
eren
ce (%
)
EFG-MTG EFG-MTO EFG-FT
FBG-MTG FBG-MTO FBG-FT7
8
eren
ce (%
)
EFG-MTG EFG-MTO EFG-FT
FBG-MTG FBG-MTO FBG-FT
4
5
6
mpa
red
to re
fe
4
5
6
mpa
red
to re
fe
1
2
3
al s
avin
gs c
om
2
3
4
al s
avin
gs c
om
040 45 50 55 60 65 70 75 80 85 90 95 100
coa
boiler capacity (%)
future power plant
150 55 60 65 70 75 80 85 90 95 100
coa
boiler capacity (%)
existing power plant
existing power plant: -30 … -93 g CO2 / kWh(el) future power plant: -11 … -44 g CO2 / kWh(el)
1511th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Coal savings: heat input by Annex integration results in less coal demand (and CO2 emissions)
4. MODELING RESULTS
6
7
8
eren
ce (%
)
EFG-MTG EFG-MTO EFG-FT
FBG-MTG FBG-MTO FBG-FT10
12
eren
ce (%
)
EFG-MTG EFG-MTO EFG-FT
FBG-MTG FBG-MTO FBG-FT
4
5
6
mpa
red
to re
fe
6
8
mpa
red
to re
fe
1
2
3
al s
avin
gs c
om
2
4
al s
avin
gs c
om
040 45 50 55 60 65 70 75 80 85 90 95 100
coa
boiler capacity (%)
future power plant: DUO operation
045 50 55 60 65 70 75 80 85 90 95 100
coa
boiler capacity (%)
future power plant: MONO operation
future power plant: -24 … -83 g CO2 / kWh(el) [MONO] future power plant: -11 … -44 g CO2 / kWh(el) [DUO]
1611th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Load elasticity: coupling enables lowering of minimum power plant load
4. MODELING RESULTS
reference
Annex integration
100
97
91
100
98
94
100
on (%
)
g
Annex integration including electrolysis
Note: Annex integration averaged amongst all scenarios
4
60
80
city
gen
erat
io
54
51
44
39 37
34
249 48
4420
40
ve n
et e
lect
ric
22 20
16
0
0
existing power plant SINGLE future power plant DUO future power plant MONO
rela
tiv
existing powerplant SINGLE
future powerplant DUO
future powerplant MONO
1711th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Overall evaluation: SWOT analysis from power plant point of view
5. SUMMARY
Strengths: Annex integration results in coal savings (and less CO2 emissions)
Weaknesses: slight efficiency loss compared to reference plant cases
Opportunities: improvement of flexibility respectively load elasticity via Annex integration
Threats: possible limitations for coupling interfaces towards minimal boiler capacity
1811th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
Project „Concept studies of coal-based Polygeneration-Annex-plants” (03ET7042A)
ACKNOWLEDGEMENT
Supported by: Participating companies:
RWE Power AGForschung und Entwicklung
1911th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
For enquiries or further questions, please contact:
THANK YOU FOR YOUR ATTENTION!
Clemens FormanEmail: [email protected]: +49 (0) 3731 39 4806Fax: +49 (0) 3731 39 4555Website: www.iec.tu-freiberg.de
2011th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016
Improvements by coupling of power generation with syngas-based chemical synthesis
References
APPENDIX
Nomenclature (power plant)C. Wolfersdorf, K. Boblenz, R. Pardemann, B. Meyer; Syngas-based annex concepts for chemical energy storage and improvingflexibility of pulverized coal combustion power plants; AppliedEnergy 156 (2015) 618-627; doi:10.1016/j.apenergy.2015.07.039
M. Gootz, C. Forman, B. Meyer; Coal-to-Liquids: An attractivet it f i d l t it tili ti ? 8th
ABEco air bypass economizerBFWP boiler feed water pumpBFWT boiler feed water turbineC condenser
FBD fluidized-bed dryingFGD flue gas desulfurizationFGTS flue gas transfer systemFPP future power plant
opportunity for improved power plant capacity utilization?; 8thInternational Freiberg Conference on IGCC & XtL Technologies –Innovative Coal Value Chains, Cologne, Germany, 12.-16.06.2016
C. Forman, R. Pardemann, B. Meyer; Differentiated evaluation ofthe part load performance of an industrial CHP; COAL-GENConference 2015, Las Vegas, Nevada/USA, 08.-10.12.2015
CAPH combustion air preheaterCP condensate pumpCT cooling towerCWP cooling water pump
FWH feed water heatingFWT feed water tankHP high pressureIDF induced draft fan
, g , ,
Nomenclature (Annex plant)
EFG Entrained-flow gasifierFBG Fl idi d b d ifi
DM drying millsECO economizerEPP existing power plantESP electrostatic precipitatorEVAP evaporator
IP intermediate pressureLP low pressureMP medium pressureRHT reheaterSHT superheaterFBG Fluidized-bed gasifier
FT Fischer Tropsch synthesisMTG Methanol-to-Gasoline synthesisMTO Methanol-to-Olefins synthesis
EVAP evaporator SHT superheater
2111th European Conference on Coal Research and Its Applications, Sheffield, UK, 5–7 September 2016