The Latest Clean Technologies in Japan November 4, 2011 Yoshikazu IKAI Japan Energy Center 1
Contents 1. JCOAL/CCT Roadmap 2. Development of -fired Power Generation 3. CCS(Carbon Capture and Storage) 4. ECO Town 2
Global environmental protection Securing coal resources Domestic circumstances of coal technology R&D Combustion & Gasification Low rank coal CCS gas Steel making JCOAL/CCT Roadmap 2010 2020 2030 2040 2050 Reduction ratio:25% Reduction ratio:80 % High efficient and hybrid generation A-USC(700 ) Lignite Drying Gasification (TIGAR,ECOPRO) *HWT *Post Combustion *Oxyfuel (Callide) *Pre-Combustion CMM ECBM ECMM Tightness of coking coal Tightness of bituminous coal An era of low rank coal Low carbon generation UA-USC(760 ) CO2 Capture IGCC Poly-Generation Lignite Gasification +CCS Ad-Post Combustion Ad-Pre-Combustion Ad-Oxyfuel (Ad: Membrane Separation) Chemical looping ECBM COURSE50 (Hydrogen Reduction, Coke treatment) Step up for development in 2010-2020 1Demo Test: A-USC, COURSE50 TIGAR, ECOP RO 2PP Test: ECBM, Lignite Drying 3Element Test: Chemical Looping Changes of Electric power demand Zero-emission generation IGFC+CCS A-IGCC+CCS Hydrogen Production Tightness of oil and natural gas Replacement of existing coal fired power station Co-combustion of biomass and coal Commercialization of CCS <Technology Diffusion> Sustainability generation A-IGFC+CCS Carbon Recycling System International Markets for Japan s CCT USA-USC, IGCC Canada-CCS EU-USC, IGCC China-Eco- Town, ECBM Indonesia-UBC Vietnam-USC(SC), CFBC India-High Ash Use, Ash Use Mongolia-Lignite Gasification, Coke Making <Demo for Int. Australia-Lignite Gasification + CCS Coop.> Indonesia-TIGAR, HWT, Coke Making from Lignite <Modification> India-High Ash Use The point of allow means commercialization * means government support projects 3
2. Development of -fired Power Generation USC (A-USC) IGCC Oxy-Fuel 4
Roadmap for high-efficiency power generation technology Power Generating Efficiency (HHV) (%) Natural gas-cc Improved combustion CC (1500 class) (1700 class) IGCC with concomitant hydrogen formation (700 class) Natural gas Status of capture type system? has an efficiency approx. 10% lower than natural gas (600 class) IGCC demonstration equipment Fiscal Year 5
Towards higher thermal efficiency development of coal-fired power generation Pulverized Pulverized -Fired -Fired System System (PCF): (PCF): Efficiency Efficiency upgrade upgrade by by increasing increasing steam steam temperature temperature and and pressure; pressure; A-USC A-USC (Advanced (Advanced USC, USC, 700 700 class) class) is is under under development development Integrated Integrated Gasification Gasification Combined Combined Cycle Cycle System System (IGCC): (IGCC): Combined Combined Gas Gas turbine turbine (GT) (GT) and and steam steam turbine turbine (ST) (ST) cycle; cycle; Higher Higher thermal thermal efficiency efficiency than than PCF; PCF; Increasing Increasing the the GT GT inlet inlet gas gas temperature temperature is is necessary necessary for for efficiency efficiency upgrade upgrade Integrated Integrated Gasification Gasification Fuel Fuel Cell Cell Combined Combined Cycle Cycle System System (IGFC): (IGFC): Triple Triple combined combined cycle cycle (GT+ST+FC); (GT+ST+FC); Higher Higher thermal thermal efficiency efficiency than than IGCC IGCC 1 PCF 2 IGCC(1500 class) 3 IGFC Latest PCF (USC) 700 class (A-USC) Boiler ST Boiler ST Gasifier GT ST Gasifier FC GT ST Gross:42~43% (HHV) Net : 41%(HHV) (Basis) Gross:48% Net : 46% reduction: approx. 11% Gross:51~53% Net :46~48% reduction: approx. 13% Gross:60%~ Net :55%~ reduction: approx. 25%~ 6
NetEficiency (%) CO2Emisio nrate(%) 5 450 3540 Ave rageinjapan 60 7080 9010 46 38 40 4241 (197) PCPC(USC) PFBC 1095 93 90 IGC ) C(150 83 Efficiency of Japan s coal-fired power plants and formation ratio Net Thermal Efficiency (%) Emission Ratio (%) 55 50 45 40 35 60 70 80 90 100 38 Average for Japan (1997) 100 42 40 PC (Pulverized coalfired thermal power) 41 PC(USC) 93 PFBC 90 95 Development completed 46 IGCC(1500 ) 83 54 IGFC 70 Under development 7
Item Gasification technology of the western industrialized countries GE-TEXACO (USA) Slurry Oxygen Oxygen Cooling water SHELL (Netherlands ) Syngas GSP (CARBO-VCR Furnace ) (Germany ) Burner insert LURGI (Germany ) Syngas Gasifier Syngas Oxygen Steam Steam Water Oxygen Steam Oxygen Steam Slag Slag Slag Ash Process flow Oxygen Water Slurry Tank Recycle Slag Sump Slurry Pump Lock Hopper Burner Texaco Gasifer Quenched Syngas Clarifier Solids-Free Syngas Scrubber Purge water To recycle Solids to Disposal Raw coal Mill and dry feeding 1 2 3 4 Quench gas Gasifier 900 1500 Slag HP steam Syngas Cooler MP steam Dry ash removal Fly ash system Ash Cold Quench 115 Hot Quench 235 Wet scrubbing Product gas Oxygen Steam GSP Gasifier Water Slag Shift conversion COS hydrolysis Quench Low pressure Water steam Cooler Effluent treatment Cooling Product gas H 2 S Fraction Oxydant Steam Lock Dressy Tar Quench Condensate Separator Gas Cooler Ash Cooled Gas Hydrocarbon Liquids Main Specifications Type: Pressurized entrained bed gasification Feed: Slurry feed (fed from single nozzle mounted in furnace top) Merits (Strong points): Compact. Large pressure range. Demerits (Weak points): Cool gas efficiency is somewhat low. (High oxygen consumption) Limited range of the grades of coal that can be used Furnace materials and nozzle have a poor (short) service life. Capacity of a single unit is low. Type: Pressurized entrained bed gasification Feed: Dry feed (fed from oppositely arranged multiple nozzles) Merits (Strong points): High cool gas efficiency. High Syngas yield. Few limitations on the grades of coal that can be used. Capacity of single unit is large. Demerits (Weak points): Long retention time (in furnace). Furnace needs to have a large capacity (volume). A large amount of equipment is required for heat recovery and gas purification. Type: Pressurized entrained bed gasification Feed: Dry feed (fed from single nozzle mounted in furnace top) Merits (Strong points): Long nozzle service life. Gasification results from actual plants using feed materials such as lignite, biomass, and wastes have been acquired. Type: Pressurized fixed bed gasification. Feed: Lump coal dry feed (fed from rock hopper mounted in furnace top) Merits (Strong points): Preliminary coal treatment is easy. Low oxygen consumption. Demerits (Weak points): Poor syngas yield. (Large amounts of CH4 and tar.) High wastewater treatment costs. Significant limitations on grades of coal that can be used.
Concept of Japanese gasification Generated gases + Chars Carrier gas Carrier gas Air Chars Chars Reductor ->Volatile components + chars Volatile components Chars Combustor Volatile components +Chars Pressure vessel Chars Carrier gas When pulverized coal is injected into a high-temperature and high-pressure gasifier synthesis gas is formed from the volatile and the char components. Synthesis gas or Syngas is a mixture of carbon monoxide (CO) and water (H 2 O). From the synthesis gas, which is formed in the coal gasification process, it is possible to synthesize various chemical products such as hydrocarbon fuels (gasoline/light oil) and methanol and ammonia. Molten slag Slag tapping hole Source: CRIEPI Review No.44 (CRIEPI: Central Research Institute of Electric Power Industry 9
Schematic Overview of Nakoso IGCC Plant 10
250MW Nakoso IGCC plant in Japan Air blow type feed: 1700t/d Operation: 2007.9~ Efficiency: 48%(LHV) 46%(HHV) (Gross) SOx : 8ppm(0.06 lb/mmbtu) (16%O 2 ) NOx : 5ppm(0.03 lb/mmbtu) (16%O 2 ) Dust : 4mg/m 3 N(0.006 lb/mmbtu) (16%O 2 ) 11
The world s major IGCC Projects Spain Holland USA USA JAPAN 250MW Nakoso DEMO PLANT 12 12
Capture from coal-fired power plant 1. Capture from coal gasification (C,H,O,N,S,Ash) Gasifier Air (N 2 O 2 ) N 2 Gas purification CO shift capture H 2 GT HRSG 3. Oxy-firing Air (N 2 O 2 ) ASU (C,H,O,N,S,Ash) Boiler N 2 O 2 CO, H 2, H 2 2. Chemical Absorbtion from Pulverized -fired Thermal Power Boiler Flue gas treatment sequestration (C,H,O,N,S,Ash) Air (N 2 O 2 ) Flue gas treatment Compression/Cooling N 2,H 2 O,O 2 Compression/Cooling Storage N 2,O 2 Storage Storage Oxygen production O 2 Exhaust gas recirculation (, ) H 2 O,SO 2 Compression/Cooling 13
Installed capital cost for 550MW net generation The global status of CCS 2010 (GCCSI) 14
Japan-Australia Callide-A Oxy-fuel Project Demonstration of 30MWe coal fired power plant with CCS by Oxy-fuel technology Callide-A: 4 x 30 MWe (Use one unit) Evaporation: 123 t/h steam 4.1 MPa/460 o C Operation terminated 2002 Flue gas treatment / Fabric filter (without DeNOx / DeSOx) Partners CS Energy, Xstrata, Schlumberger JPOWER,IHI, Mitsui & Co, JCOAL CO2 storage site area (app.300km far east from Callide-A) Callide-A Power Plant 15
Demonstration of Diversified CCT Models, with Gasification as the Core 16
Flash Partial Hydropyrolysis Technology (ECOPRO) Flash Partial Hydopyrolysis Technology is a technology which causes rapid reaction to pulverized coal under high pressure (2-3Mpa) and in a moderate hydrogen atmosphere to highly efficiently obtain, from one reactor, synthetic gas easy to be evolved such as into Integrated Gasification Combined-Cycle (IGCC) power generation, indirect liquefaction (GTL), and chemicals while co-producing light oil as chemicals and fuel. The realization of a coal-based cross-industrial composite project (led by electric power/ chemistry/ steel) with this technology as its core will hopefully bring a dramatic improvement to total energy utilization efficiency. Basic partial hydropyrolysis test (1996-1999, 1kg/d) using a small-scale test unit PDU test (2000-2003, 1t/d, *NSC in-house research) using a reforming/partial oxidation-integrated PDU test unit Pilot plant test (2003-2008, 20t/d) Test are conducted, using a PP having its thermally self-supportable reactor together with other ancillary process units, to have forecasts for a demonstration unit (up to 1,000t/d) as the next step. 17
3. CCS (Carbon Capture and Storage) 18
Image View of Development of Underground Storage Technology Sequestration Capture Storage Transport Injection Injection from surface facilities Pipeline transport Sequestration Capture Storage facilities Tanker transport Injection from sea-based facilities Structural Cap Rock (impervious bed) Large-scale CO2 emission source Pipeline transport Microscope photo of water bearing stratum The layer is a stratum including brine formed by porous sandrock with a high porosity. Land zone Underground water bearing stratum <Trial calculation of storage stratum> Porosity: 20% Sweep efficiency: 50% dissolution rate: 47kg/m 3 Storage capacity Structural Cap Rock (impervious bed) Storage stratum thickness Storage stratum diameter 10,000 t- 10m 260m 1 million t- 50m 1.2km Sea zone Underground water bearing stratum 19
Underground Storage Projects in the World Japan Project Nagaoka Norway Sleipner Canada Weyburn Implemented by RITE Statoil Co. Canadia Petroleum Research (RTCR) Place Water bearing strata on gas fields Land zone (complicated geological strata) Depth: 1.1km Water bearing strata on gas fields Sea zone Depth: 1.0km Oil stratum (EOR) Land zone (Continental geological strata) Depth: 1.0km Time of commencement July 2003 (Injection time: 1.5 years) October 1996 (Injection time: 20 years) September 2000 (Injection time: 20 years) Scale Rate: 6,700t- /year Total amount: 10,000t- supply source: Commercially available EOR:Enhanced Oil Recovery Rate: 1 million t- /year Total amount: 20 million t- Source:Accompanying natural gas (Environmental tax 55$/t- ) Rate: 1 million t- /year Total amount: 20 million t- supply source: gasifier 20
Enhanced Oil Oil Recovery (EOR) Outline Comparison of Storage Technologies (IEZ-GHG, JCOAL) gas and water injection well Miscible zone Water gas Oil well oil oil gas gas and water injection well Water Storage in in aquifer Injection Well Water bearing stratum Enhanced Bed Bed Methane (ECBM) Transport Capture Injection CO equipment 2 Decarbonization CH 4 technology CH 4 capture Production well Injection well Natural gas Production well Power Plant CH 4 utilization CH 4 fixation NG stratum seam Sleipner 21
Yubari ECBM Project injection trial (from 2004 ) 夕張市 三菱マテリアル鉱山事務所 15 シューハ ロ IW-1 0 2.5 5km 22
4. ECO Town 23
What s a ECO town? To propose the master plan to realize the production of highly value added products from brown coal and bituminous coal in ECT. To propose the master plan and to conduct basic feasibility study based on optimum integration of Japanese Clean Technologies (CCT) including engineering and operation system. To show the procedure to realize ECT in conjunction with needs from enterprises and construction plan for infrastructures in the coal producing country. 24
排ガス O2 O 濃度計 燃料ガスカロリー計 流量自動調節弁 炭化室排出ガス管温度測定用熱電対 燃焼室温度測定用熱電対 炭化室排出ガス管温度を自動で測定採取し監視 分析することにより 火落ち時刻を判定し 最小限のエネルギーでコークス化できるように調整していく 燃焼室温度を連続的に測定採取し 最適な温度設定値を自動的に算出し 自動で燃料ガスを調整する Gas Engine for CMM Technology provided from Japan toward ECT implementation Energy Supply CMM Concentration CDQ Coke-related COG Desulfurization Automatic control system of coke oven heating コークス炉自動燃焼制御 燃焼室 炭化室 導入後 煙突ガス本管燃料 Cコー OKE クス炉燃料ガス流量設定値煙値 コークス炉ガス集気本管 各燃焼室発生ガス温度 各炭化室排出ガス温度 炉団 火落時刻判定 炉団温度制御 < 制御 運転室 > G/T combined cycle power plant (COG/BFG) CMC COG reformingwithout catalyst N2 ECMM refuse Power Plant Chemistry Recycling UBC High Efficiency Gasification Desert Greening by using Ash Water Treatment Methanol Anmmonia DME CTL SNG refuse Power Plant Waste Heat Recovery in cement plant 25
ECO- Town in INDONESIA ECO- Town in Indonesia 26
Thank you for your attention! 27