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Linde-KCA-Dresden GmbH 1 PCCC1, Abu Dhabi, 17th-19th May 2011
Torsten Stoffregen (Linde-KCA-Dresden)
Abu Dhabi, May 19, 2011
New results from the PCC pilot plant Niederaussem
Linde-KCA-Dresden GmbH 2 PCCC1, Abu Dhabi, 17th-19th May 2011
Cooperation of RWE – Linde – BASFjoint development of a PCC technology
The interdisciplinary approach – key to success:
BASF – ”The Chemical Company“: development of new solvents and optimized process design
Linde – “Engineering company”: engineering and construction of the pilot plant, system optimization, scale up
RWE Power – “Power producer and utility”: plant integration, interface optimization, operation
CO2-Capture
Linde-KCA-Dresden GmbH 3 PCCC1, Abu Dhabi, 17th-19th May 2011
1st phase of the new solvent testingis finished successfully
2007 20092008 2010
Working Group “PCC-Demo”■ Optimization of the PCC concept
■ Scale up for a full-scale plant
■ Designing of the demo plant
Solvent Development BASF■ Screening
■ Miniplant performance tests
CO2 Capture Pilot Plant■ Engineering, Procurement
■ Construction
■ Operation MEA
■ Operation 2 new solventsNew solvents
MEA
Linde-KCA-Dresden GmbH 4 PCCC1, Abu Dhabi, 17th-19th May 2011
Pilot Plant Niederaussem Process
Drain
Cooling water
CO2
Desorber
Flue gas(after FGD)
Absorber
Prescrubber
NaOHsolutiontank
Booster fan
Condenser
Filter
Cooling water
Cooling water
Cooling water
ReboilerSteam generator
Solvent tank
SolventNaOH
CO2-lean flue gas
Make-up water
Make-up water
Make up water
Solvent regeneration
CO2-capture Flue gas cooling and SO2-pre scrubbing
Cooling water
Drain
Linde-KCA-Dresden GmbH 5 PCCC1, Abu Dhabi, 17th-19th May 2011
Pilot plant NiederaussemTechnical facts
Type Pilot plant
lignite
Flue gas 1552 Nm3/h
Product 159 Nm³/h CO2; 7.2 t/d CO2
Source lignite-fired power plant
Start-up June 2009
Design 6 Skids, 2 Container
Skid 1 4 x 4 x 41 m; weight: 80 t
Instrumentation 240
MOC tests at 15 different locations
Linde-KCA-Dresden GmbH 6 PCCC1, Abu Dhabi, 17th-19th May 2011
0
200
400
600
800
1000
1200
1400
1600
1800
2000
operating hours
capt
ured
CO
2 [t]
pow
er p
lant
out
put [
MW
]Operation time
captured CO2
solvent flowrate
pel
solv
ent f
low
rate
[-]
MEA Gustav 200 Ludwig 540
Operation key figures within1.5 years of operation
10000 hours operation
2500 t CO2 captured
Linde-KCA-Dresden GmbH 7 PCCC1, Abu Dhabi, 17th-19th May 2011
Specific energy consumption for the 3 tested solvents
2400
2600
2800
3000
3200
3400
3600
3800
4000
Solvent circulation rate
Spec
ific
ener
gy c
onsu
mpt
ion
[MJ/
t CO
2]
MEA
Ludwig540
Gustav200
Comparison of MEA with the
2 tested new solvents
Gustav and Ludwig have a 20% lower specific energy consumption
Gustav and Ludwig have a significant lower solvent circulation rate
Linde-KCA-Dresden GmbH 8 PCCC1, Abu Dhabi, 17th-19th May 2011
2600
2800
3000
3200
3400
3600
3800
Solvent circulation rate
Spec
ific
ener
gy c
onsu
mpt
ion
[MJ/
tCO
2]
Without interstagecooling
30°C
40°C
Impact of interstage coolingExample: Gustav 200
Impact of Interstage Cooling
no cooling leads to higher specific energy requirement for regeneration
Implementation of interstage cooler is economically
Linde-KCA-Dresden GmbH 9 PCCC1, Abu Dhabi, 17th-19th May 2011
Impact of CO2 recovery rateMEA and Gustav 200
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
Solvent circulation rate
Spec
ific
ener
gy c
onsu
mpt
ion
[MJ/
t CO
2] 80% 95%90%
95%90%80%
MEA
Gustav200
Impact of CO2 recovery rate
solvent circulation rate can be reduced
impact on minimum achievable specific energy consumption is minor
Linde-KCA-Dresden GmbH 10 PCCC1, Abu Dhabi, 17th-19th May 2011
duration of operation
tota
l con
tent
of o
rgan
ic a
cids
(HSS
)
MEA
Gustav200
Degradation: heat stable salts (HSS)MEA and Gustav200
Comparison of MEA with Gustav200
building of HSS for Gustav200 is significantly lower
no reclaiming required for Gustav200 after 4000 operating hours
Linde-KCA-Dresden GmbH 11 PCCC1, Abu Dhabi, 17th-19th May 2011
Material testingLocation and type of Samples
A2
B1
B2
B6
B3
B4
B5
B7
B8
A3
A1 A5
A4
A6
A1, A3 – A6:Flanges, tubes, gaskets
A2:Concrete module
B1 – B7:Coupons
Pre-scrubber
AbsorberDesorber
Causticsoda
Drain
Make-up waterCO2-leanflue gas
CO2 fromregeneration
Drain
Solvent
Flue gas
Linde-KCA-Dresden GmbH 12 PCCC1, Abu Dhabi, 17th-19th May 2011
Material tests for MEA
material specification typesteel 1.4541 coupon + flange-tube-flange
1.4571 coupon 1.4462 coupon 2.4548 coupon
polypropylene PP-H couponFRP vinyl ester flange-tube-flange
epoxy ester flange-tube-flangegasket EPDM
NBRPTFE
concrete modul with PP-H inliner
Tensile test specimensof PP-H
Metal couponswith welding seam
Cut concrete module with PP-H inliner
Linde-KCA-Dresden GmbH 13 PCCC1, Abu Dhabi, 17th-19th May 2011
Material Tests for MEAExamination + Results for steel
Examination
— based on DIN 50905 and ASTM G31-72
— Determination of linear corrosion rate
— Visual inspection of local corrosion (pitting, crevice corrosion, stress corrosion cracking)
Results
— Corrosion rate < 0,001 mm/year for all type of tested steel grades
— No local corrosion attack
Conclusion
— All tested steel types are resistant to corrosion.
Flange-tube-flange modul (1.4571)
Coupons 1.4571
Linde-KCA-Dresden GmbH 14 PCCC1, Abu Dhabi, 17th-19th May 2011
Demo Plant as Intermediate Step from Pilot Plant to Commercial Application
*Timeline depends on development progress and especially project boundary conditions (e.g. permitting).
Demo Plant1 train
app. 250 MWel, equiv.
≈1.3 million t/a CO2
Commercial PCC Plant2 trains for a 1,100 MW power plant
app. 550 MWel, equiv. per train
≈3 million t/a CO2 per train
Operation Design, Construction, Commissioning Design, Construction, Commissioning
2011 * 2016* 2020*Today
No CO2 Storage CO2 Transportation and Storage - Design, Construction, Commissioning
Scale-up
factor
500
Scale-up
factor
2
Pilot PlantNiederaußem
app. 0,5 MWel, equiv.
≈2,500 t/a CO2
Linde-KCA-Dresden GmbH 15 PCCC1, Abu Dhabi, 17th-19th May 2011
Outlook
Second phase of Niederaussem test program - Cooperation will proceed until 2013
New tests scheduled
— 2 long term tests (with conventional FGD and with high performance FGD)
— long term test of materials, degradation and emission
Modification of pilot plant
— installation of high-performance column internals
— improved emission control system at top of Absorber
— additional online gas analysis equipment
Your Questions?
Dr. Iven Clausen
BASF SE
E-CZA/ML – G 200
67056 Ludwigshafen
Phone: +49.621.60-99232
www.basf.com
Torsten Stoffregen
LINDE-KCA-DRESDEN GMBH
Bodenbacher Str. 80
01277 Dresden
Phone: +49.351.250-3538
www.linde-kca.com
Dr. Peter Moser
RWE Power AG
Huyssenallee 2
45128 Essen
Phone: +49.201.12-28562
www.rwe.com
