Steag Power Plants in the Rhine - EnergieRegion.NRW

Projects in
NRW
Development of Power plant
technology at the Ruhr area
using the example of
Evonik Steag
Dr. Wolfgang A. Benesch
Director Energy Technologies
EVONIK Energy Services, Germany

Our Background
Adjustment of RAG Group starting in 2005
Dr. Benesch 3 / 2010
RAG Aktiengesellschaft
Sales: ~ 22 billion € Employees: ~ 98.000 (each in 2005)
Energy Chemicals Real Estate Mining
STEAG
Power Generation
Gas Distribution
Decentralized
Energy Supplies
Coal Trading
Degussa
Technology
Specialties
Consumer
Solutions
Specialty Materials
RAG Immobilien
Residential Real
Estate
Land Development /
Commercial Real
Estate
Real Estate
Services
Deutsche
Steinkohle
Production of
Coal
Production of
Coke
RAG Coal
International
Mining
Technology
Tar Refining

Evonik Today
Business Areas
Dr. Benesch 3 / 2010
Chemicals Energy Real Estate
• Focus: specialty chemicals
• A global leader
• 2009 sales: €10.0 billion
• Leading market positions in over 80%
of sales
• Market-driven R&D and modern
innovation management
• Over 100 production facilities
in some 30 countries
• Focus: hard coal-fired power plants and
renewable energies
• A technology leader in planning,
building and operating power plants
• 2009 sales: €2.6 billion
Power Renewable District
Energies
Heating
• Grid-independent power producer with
around 9,500 MW installed global cap.
• Strong position in the fields of biomass
and geothermal energy in Germany
Energy
Services
Immobilien
3%
Trading
• Focus: residential property
• One of the largest private residential
property companies in Germany
• Manages about 60,000 own
residential units plus a 50% stake in
THS with more than 75,000 units
• 2009 sales: €0.4 billion
• Active property owner with strong
regional focus
Power
Minerals

STEAG History at the Ruhr area
Some Milestones
1937 Steag had been founded in Essen, main background was
the use of the waste coal of the local mines for power
generation
1940 Commissioning of the first power plant in Lünen
(4x45MW)
1957 commissioning of 1st unit in Walsum with 68MW capacity
1962 150MW units in in Lünen and Herne
1969 Test of FGD process in Lünen
1970/71 350MW units in West
1981/82 710MW /747MW units in Voerde / Bergkamen
1988 retrofit of FGD and following DENOx in all units
1989 500MW supercritical unit in Herne
2006 commissioning of biomass pp Lünen
2010 750MW Walsum 10 supercritical, highest efficiency under
comparable conditions
Dr. Benesch 3 / 2010

Steag Power Plants in the Rhine -
Ruhr Region
Voerde
2.120 MW i
Walsum
600 MW i
Dr. Benesch 3 / 2010
Voerde
2,120 MW
Rhine
Walsum
600 MW
Duisburg
Essen
Herne
950 MW i
Lippe
Wesel-
Datteln Canal
Lünen
500 MW
Herne
950 MW
Ruhr
Lünen
500 MW i
Dortmund-
Ems Canal
Dortmund
Bergkamen
747 MW
Datteln-
Hamm Canal
Bergkamen
747 MW i

Dr. Benesch 3 / 2010
Platzhalter Bild
Environmental friendly
power plants in a green
surrounding

Lünen pp
Dr. Benesch 3 / 2010
� roots of Steag 1937
� slag tap boiler technology
� development of ESP, FGD,
DENOX technology
� coal dust ignition system
� 170MW IGCC
� railway electricity generator
1938 - 42 Commissioning of 4 x 45 MW
1954 Commissioning of 50 MW unit
1962 Commissioning of 150 MW unit 3
1968 Initial test fd activated carbon FGD
1969 Commissioning of 350 MW unit
1973 Commissioning of 170 MW IGCC
1974 Pilot plant for lime stone FGD
1988 Commissioning of FGD
1989 Commissioning of DENOX
2003 District heat supply

Herne pp
Dr. Benesch 3 / 2010
� 1st supercritical unit of
Steag commissioned 1989
� considerable amount of
district heating
� operating as flare for coke
oven plant
� fuel staging for primary NOx
reduction
� extensive SNCR testing
� co combustion
1962/63 Commissioning of units 1 and 2
with 150 MW each
1966 Commissioning of unit 3 with 300
MW
1989 Commissioning of unit 4 (500 MW)

Evonik Herne IV supercritical power station
Single air flue gas path
Burner size 106 MW th
Burners 12
Fuel high ash content hard
coal (up to 35% of ash)
from Ruhr area
Dr. Benesch 3 / 2010

Co combustion of bone meal and sewage
sludge in Evonik Power plant Herne 3
Dr. Benesch 3 / 2010

Voerde pp
Dr. Benesch 3 / 2010
� biggest Steag site
� Voerde unit A+B together with
RWE
� after 20 years of FGD operation
retrofit of 2nd generation FGD
� flexible operation pf big units
1970/71 Commissioning of units 1 and 2 of the power
plant West, 350 MW each
1982/85 Commissioning of unit A+B of the Voerde
power plant (710 MW) with FGD
1987 Retrofitting of the power plant West with a
flue gas desulfurization system
1989 Retrofitting of both power plants with nitrogen
oxide reduction systems
2005 Partial modernization of flue gas
desulfurization system,
with capacity increase (2 x 51 MW)
2006 Retrofitting of the power plant West with
capacity increase (2 x 6 MW)

Voerde pp
Boiler types
Dr. Benesch 3 / 2010

Typical load profile Evonik STEAG
350MW power plant
kWh
400000
350000
300000
250000
200000
150000
100000
50000
Dr. Benesch 3 / 2010
0
9.5.05 0:00
9.5.05 12:00
10.5.05 0:00
10.5.05 12:00
11.5.05 0:00
11.5.05 12:00
12.5.05 0:00
12.5.05 12:00
13.5.05 0:00
13.5.05 12:00
14.5.05 0:00
14.5.05 12:00
15.5.05 0:00
15.5.05 12:00
16.5.05 0:00
16.5.05 12:00
17.5.05 0:00
17.5.05 12:00
18.5.05 0:00
18.5.05 12:00
19.5.05 0:00
19.5.05 12:00
20.5.05 0:00

Flexibility in dynamic behavior
Load fluctuations during heavy wind periods
source: VGB Kongress 2007, Lambertz
Increase of fluctuating renewable energy sources as well as
economical requests ask for higher flexibility of modern fossil fired
steam power plants.
Dr. Benesch 3 / 2010

Walsum pp
Dr. Benesch 3 / 2010
� start as a typical mine mouth
power station
� highest reliable steam supply
for the neighboring paper mill
� reuse of CO 2 in a small scale
for paper industry (Precipitated
Calcium Carbonate)
� currently commissioning of the
most modern hard coal fired
power station in the world for
cooling tower operation
1928-50 Erection of first generators for the mine
1957 Commissioning of the first classical single
unit 6 with 68 MW capacity
1959/60 Commission of units 7 and 8 with 150 MW
1988 Commissioning of unit 9 (410 MW),
decommissioning of units 6 and 8, refitting
of the power plant with FGD and DENOX
2010 Commissioning of 790 MW unit (CCEC)

Biomass pp Lünen
Dr. Benesch 3 / 2010
� biggest of 11 Steag biomass
power plants
� Steag is gathering broad
experience in single and cocombustion
of biomass
2006 Commissioning of the 20MW el unit
main fuel: different kinds of wood

Evonik Energo Mineral Sp. Zo.o.
based in Katowice, Poland
• Founded 2001; start of the operative
business in 2002.
• Long-term contracts for the disposal
of by-products from 9 power stations
all over Poland.
• Strategic investments in infrastructure
and silo installations at the power
stations are planned to support the
marketing of fly ash.
Dr. 20.06.2010 Benesch | Evonik 3 / 2010 Power Minerals Seite 17

Evonik New Energies in Poland
Heat and Electricity supply of industrial
customers, use of mine gas
Dr. 20.06.2010 Benesch | Evonik 3 / 2010 Power Minerals Seite 18

Conclusion
� The Rhine Ruhr area had been dominated over
decades by mine and steel industry
� Based on this boundary conditions local power
plant technology developed mainly based on
local, high ash content hard coal
� In the last 30 years the image is changing
� Coming from small mine mouth power plants to
big stand alone units (economy of scale)
� Slag tap and dry bottom ash boiler technology
for high ash content coals had been developed
� Switch from local to imported coal
� Environmental friendliness had been insured by
installation of high sophisticated ESP, FGD and
DENOX technology
� IGCC as well as CO2 reuse had been tested
� Use of biomass as a fuel is helpful to reduce
CO2 emissions, this is done e.g. successfully in
Lünen biomass pp
Dr. Benesch 5 / 2010

Dr. Benesch 5 / 2010