current status and perspective of research and development
TRANSCRIPT
Current Status and Perspective of Research and Development on Coal Utilization Technology in Japan
20th Annual International Pittsburgh Coal Conference September 15-19, 2003
Ikuo SaitoInstitute for Energy Utilization
National Institute of Advanced Industrial Science and Technology (AIST)
Presentation planCongratulations on the 20th anniversary
Japan’s Energy Situation
Japan’s Energy Policy
Current Status and Perspective of Research and Development on Coal Utilization Technology
Summary
Acknowledgement
Japan US France Germany UKPrimary energy supply(million tons of oilequivalent) 515 2270 255 337 230Coal 17 24 6 24 15Oil 52 39 35 40 36Natural gas 12 23 14 21 36Nuclear 16 9 40 13 11Hydro 1.4 1.1 2.4 0.5 0.2Renewable energy, etc. 2 4 5 1 1
Self-supply rates (%) 20.2 74.4 50 39.4 122.5
Source: IEA “Energy Balances of OECD Countries 1998-1999”
Table 1 Primary energy supply in major countries (1999)
JapanJapan’’s Energy Situation Compared with the Worlds Energy Situation Compared with the World
The energy self-supply rate of Japan is still very low, at about 20%, compared with other major countries
Weakness of energy self-supply in Japan
Fig. 1 Change in the final energy consumption by sectors
0
50
100
150
200
250
300
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00
Fiscal year
Index (FY1973 level = 100)
Source: Comprehensive Energy Statistics
Passenger vehicletransportation sector
Residential sectorTransportation sectorCommercial/residentialsectorCommercial sector
Freight & publictransportation sector
Industrial sector
268
225209207189
150
107
(%)
FY1973 FY1990 FY2000 FY2010Primary energysupply (million kl ofcrude oil equivalent) 414 526 604
Targetcase602
Oil 77 58 52 about 45Coal 15 17 18 about 19Natural gas 2 10 13 about 14Nuclear 1 9 12 about 15Hydro 4 4 3 about 3Geothermal 0 0.1 0.2 about 0.2New energy 1 1 1 about 3
Table 2 Change in primary energy supply
Source: Comprehensive Energy Statistics
Target value of oil dependency rate is about 45% by FY 2010
· Energy conservation / new energy measures
· Implementation of Keidanren’s independent action plan
· Promotion of nuclear power policy, etc.
Energy conservation: - 6 million t-C
New energy: - 9 million t-C
Fuel change, etc.: - 5 million t-C
Total: - 20 million t-C
Fig.2 Reduction of Energy-Originating CO2
250
270
290
310
330
350
1990 1995 2000 2005 2010 (Fiscal year)
Energy-originating CO
2emissions
When measures for 1998 and thereafter are not takenWhen measures decided so far are takenTarget
Impl
emen
tatio
nof
exi
stin
gm
easu
res
Actual level in FY1990:287 million t-C
Actual level in FY2000:316 million t-C
307million t-C
287million t-C
20million t-C：+ 7％ A
dditi
onal
mea
sure
s
(million t-C) 347million t-C
29million t-C：10%
+
++
Japan’s Energy Policy(1)
Japan’s Energy Policy(2)! Energy Conservation
• In addition to measures currently being implemented (approx. 50 million kl), further measures are to be implemented (approx. 7 million kl) focusing on items such as in the Residential Sector including passenger cars and the Commercial Sector including the Service Sector.
• Approximately 6 million t-C is expected to decrease.
Japan’s Energy Policy(3)! New Energy
• The target for the implementation of new energy is set at 19.1 million kl for FY2010.
• Moves for the approval of "the Law concerning Special Measures for Promotion of New Energy by General electricity supplier" with measures such as obligating General electricity supplier to use a minimum predetermined level of New Energy.
• Measures to reduce the burden on the person implementing New Energy (Household Sun Rooms/Advanced Household Solar Systems, Clean- Energy Motor Vehicles)
• Pushing the public sector to take the lead in implementing equipment and machinery using new energy.
• Advancement of technological development and verification tests for fuel cells.
• Increasing the range of new energy (biomass energy, cool energy)
• Approximately 9 million t-C is expected to decrease.
490 494
58101
14
552
134
439
118
Fig. Actual Result of Introducing New Energy and Targets of IFig. Actual Result of Introducing New Energy and Targets of Introduction for FY 2010ntroduction for FY 2010
Waste power generation
Unused energy
Black liquid, waste material, etc.
Wind power Wind power generationgeneration
Solar thermal Solar thermal utilizationutilization
Photovoltaic Photovoltaic power generationpower generation
Biomass (power generation + thermal)
Overall new energy
7,220,000 7,220,000 klkl
19,100,000 19,100,000 klkl
Actual result in FY2000 Target for FY2010
About 3 times
About the same
1.2% of the total primary energy supply
3% of the total primary energy supply
Black liquid, waste material, etc.
Photovoltaic power generationSolar thermal utilizationWind power generation, etc.
Thermal utilization of waste
Japan’s Energy Policy(4)
! Fuel Switching• Replace out-dated coal generated power stations with highly effective
LNG Combined Cycle power generation• Industrial boilers using coal will be converted to using natural gas.
• Approximately 5 million t-C is expected to decrease.
! Adding up the figures obtained by these measures, 20 million t-C is expected to decrease.
Revision of revenue structure! Revision of oil tax ( Oil and Coal tax)
• Rearrangement of tax burden structure• New tax on coal, increase in tax of LNG and LPG
! Further promotion of energy conservation and new energy development (Reviewing expenditure program of special accounts for energy)
Oil (yen/kl) LNG (yen/t) LPG (yen/t) Coal (yen/t) *
Present 2,040 720 670
2003.10- 2,040 840 800 230
2005.4- 2,040 960 940 460
2007.4- 2,040 1,080 1,080 700
•Coal for steel manufacturing, coke making and cement making and coal for power generation in Okinawa prefecture is exempted from tax.
Japan’s Energy Policy(5)
Natural energy Solar, Wind
Renewable energy Biomass
New Energy Introduction Technology
Wind turbine Gasification of Biomass
Waste/Municipal waste Plastics waste
Coal Ultra heavy oil
Gas hydrate
Natural gas
Oil
Green Technology Suppression of Dioxine Hydrogen production Coal GT-CC power generation Deep desulfurization
Zero emission
Stability for energy supply
Env
ironm
enta
l pre
serv
atio
nCompatibility between Environmental Preservation and Stability for Energy Supply
Basic Research (funded by Ministry of Education, Culture, Sports, Science and Technology) related to coal
Specific Area Research (B) “Coal Utilization Technology Development Aiming for Solution of Global Environmental Problems from GlobalPerspective”
Professor K. Miura (Kyoto University) : Principal Investigator
Selected 12 research subjects out of 59 proposals from universities 1999.4 – 2003.3 (4years), about 440 million yen in total 1) Development of new pretreatment method 2) Development of in-situ treatment technology3) Basic research supporting enhanced flue gas treatment technology
Fig. 3 Technology Development Strategy related to Coal for the 21st Century (related to METI)
CO2 Reduction Rate
203020201990 2000
10%
High Efficiency1st Generation
10 - 20%
High Efficiency2nd Generation
2010
20 - 30%
HighEfficiency
Hybrid Generation
30 - 40%
Zero Emission
Generation
PFBC,USC
IGCC,SCOPE21,
DIOS
IGFC,Hypr-RingHyperCoal
H2 production Technology from Coal
Promotion structure of the program related to METI
METI
NEDO
CCUJ
Private sector, universities, etc.
AIST
Joint research project
Project Funding
METI:Ministry of Economy, Trade and Industry
NEDO:New Energy and Industrial Technology Development Organization
AIST:National Institute of Advanced Industrial Science Technology
CCUJ:Center for Coal Utilization, Japan
CCT RD&D in Japan (1)
Power Generation Technology
Integrated Coal Gasification Combined Cycle Power Generation System (IGCC)
Super Coke Oven for Productivity and Environmental enhancement toward 21st Century (SCOPE21)
High Efficiency Combustion Technology
Advanced Pressurized Fluidized Bed Combustion Technology (A-PFBC)
HyperCoal Power Generation System
Integrated Coal Gasification Fuel Cell Combined Cycle Power Generation System (IGFC)
Industrial Technology
CCT RD&D in Japan (2)
Substitute Oil Production Technology
Dimethyl Ether Production Technology
Multi Purpose Coal Utilization Technology
Coal Liquefaction Technology (BCL, NEDOL)
Substitute Natural Gas Production Technology
Technology of Hydrogen Production from Coal with CO2 Recovery System (Hyper-RING)
PFBC! Bubbling type PFBC has been commercialized
! RD&D71 MW as a national project at Wakamatsu Coal Utilization Technical Center
of J-power (Electric Power Development Co., Ltd.) (started its operation in Sep. 1994) Gross thermal efficiency: 37.5%
! Commercialized85MW Tomato-Atsuma Power Plant No. 3 Unit of the Hokkaido Electric
Power Co., Inc. (started its operation in March 1998) 40.1%250MW Ohsaki Power Plant No. 1 Unit of the Chugoku Electric Power Co.,
Ltd. (started its operation in Dec. 2000) 41.5%360 MW Karita New No. 1 Unit of Kyushu Electric Power Co., Ltd.
(started its operation in July 2001) 42.8%
Fig. 4 Super Coke Oven for Productivity and Environmental enhancement toward 21st Century (SCOPE21)Fine coal
350～400
Coarse coal
Hot briquetting machine
Emission free transporting system
Emission free charging system
Closedtransportingsystem
CDQ withreheating system
Coke150～200
RegeneratorDryer
Fuel
Hot gas generatorWaste gas
350～400℃ ℃
℃
Coal
Rapid heatingpreheater Emission gas
free pusher 1000℃Coke oven
Tightly sealed door750～850℃
Advanced Coke Making Process (SCOPE21)
Pilot Plant Test
FundamentalTechnologyDevelopment
Basic Research
1994
Bench Scale Tests
Construction
Test Operation
19951993 19971996 1998 1999 20012000 2002
Fig. 5 Schedule of SCOPE21 Project
Fig. 6 SCOPE21 Pilot Plant
IGCC
! Based on the test results by a pilot plant using an air-blown pressurized two-stage entrained gasification furnace with a coal processing amount of 200 t/d from 1991 through 1996
! Demonstration Plant (Nakoso, Iwaki City, Fukushima Prefecture, about 200 km north of Tokyo)
Capacity 250 MW（1600 ton/day）Gasifier air-blown, entrained flow gasifier/ 2.5MPaGas clean-up Cold gas clean-up using MDEA Gas turbine 1200 C
1999 20062000 20052004 2009200320022001 2007 2008Fiscal year
Preparatory verification tests
Demonstration plant tests
DesignOperation
testsConstruction
Environmental impact assessment
Fig. 7 Schedule of IGCC Demonstration Plant Program
Fig. 8 Integrated Coal Gasification Combined Cycle Power Generation System (IGCC)
Conceptual Drawing of IGCC Demonstration Plant
GasifierGas Turbine
Gas Clean Up1,200 OCGas Turbine
MDEA,Lime stone
Gas clean up
Air blown,entrained
flow gasifier
Gasifier
40.5%Net Efficiency
250MW(1,600t/d)Capacity
Specifications
IGFC (EAGLE Project)
! Integrated coal Gasification Fuel Cell combined cycle (IGFC)
! Coal Energy Application for Gas, Liquids and Electricity
! Pilot Plant (Wakamatsu, Fukuoka Prefecture in Kyushu)Coal feed 150 ton/dayGasifier oxygen-blown entrained flow gasifier (two-stage
tangential flow type in a single chamber) /2.5MPaGas clean-up Cold gas clean-up using MDEA
Sulfur compound <1 ppm, Halogen compound <1 ppmAmmonia compound <1 ppm, Dust <1 mg/m3N
Flow Diagram of the EAGLE Pilot Plant
GComp. GT
Gas Clean Gas Clean -- Up UnitUp UnitCoal Gasification UnitCoal Gasification Unit
PulverizedCoal
Gasifier Syngas Cooler Precise Desulfurizer
COS Converter
Water Scrubber MDEA
Absorber
MDEA Regenerator
Acid Gas Furnace
Limestone Absorber
Incinerator HRSGStack
Gas Turbine UnitGas Turbine UnitAir Separation UnitAir Separation Unit
Filter
GGH
CharSlag
Nitrogen
Oxygen
AirRectifier
Air Compressor
Fig. 9 Integrated Coal Gasification Fuel Cell Combined Cycle Power Generation System (IGFC)
(Fiscal year)1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
FS/ Component Test
Operational Studies
'02.3 Charging coal
'03.3 Start of operationBasic design/Detail Design
Fabrication/Construction
Schedule of EAGLE Project
Fig. 10 View of EAGLE Plant (IGFC) in Fukuoka
Specification
Coal Feed
Pressure
Coal Gasifica-
tion
150 t/d
2.5MPa
Oxygen-Blown
EntrainedFlow
Gasification
CoalCoal
ResidueResidue(organic+ash)(organic+ash)
Minerals Minerals (ash)(ash)
Extract Extract (organic matter)(organic matter)
Feedstock forFeedstock for
Gas Gas TurbineTurbine
HyperCoalHyperCoal(ashless coal)(ashless coal)
> 60%> 60%
OrganicOrganicsolvent solvent extractionextraction
High Net Power OutputHigh Net Power Output
COCO22 Emission ReductionEmission Reduction
Net : 48%Net : 48%
HyperCoalHyperCoal power generation systempower generation system
Net thermal Net thermal efficiencyefficiency：：4848％％ (HHV)(HHV)
(350(350ooC, C, 1.5MPa)1.5MPa)
5050ooCC
130130ooCC
StackStack
NN22
1.5 1.5 MPaMPaBurnerBurner
Combusted gas Combusted gas ((13501350ooC)C)
AirAir
GasGasturbineturbine
CombustorCombustor(1350(1350ooC)C)AirAir
Temp < 90Temp < 90ooC C
De-SOxunit．
DeDe--SOSOxxunitunit．．
ExhaustExhaust(180(180--200200ooC)C)
Heat exchangeHeat exchange
CompressorCompressor
HyperCoalfeeder
Ash Ash < 200ppm< 200ppm
HyperCoalHyperCoal firing power firing power generationgeneration systemsystem
Particle Particle --7474µµm (m (>95>95％％))
GG
Steam turbineSteam turbineGG
Heat recoveryHeat recovery
HyPr-Ring•H2 production process from coal with high efficiency•Integration of water carbon reaction, water gas shift reaction and CO2 absorbing reaction in a single reactor
•Temperature : 650C, reaction pressure : 6MPa or more •Absorption of CO2 using calcium oxide (CaO)•Existence of absorbent moves equilibrium of shift reaction and internally gives the energy into water gas reaction.
•Cold gas efficiency : over 75%, S contents in gas : <1 ppm•CO2 emission : same level as natural gas
Water
Hydrogen
CO2HyPr-RING
Heat
Coal (Biomass, Heavy oil)
Fig. 11 Outline of Hypr-RING process flow
Coal
Water
Hydrogen rich clean gas
CO2
Reactor
SeparatorRecycle water
Calcination furnaceof CaCO3
CaO
CaCO3Ash
Summary! Japan’s energy situation and energy policy were
introduced. To clear COP3 agreement, necessity of further effort of energy conservation and new energy development were emphasized.
! Current status of research and development on coal utilization technology in Japan were presented. Environment around coal is getting worse from the point of view of environmental preservation, but it is emphasized that coal energy is still very important and development of highly efficient coal utilization technology should be sustained.
Acknowledgement! New and Renewable Energy Division, Agency of Natural Resources
and Energy (ANRE), METI! Coal Division, ANRE, METI! Environmental Industry Office, Industrial Science Technology Policy
and Environment Bureau, METI! New Energy and Industrial Technology Development Organization
(NEDO)! Center for Coal Utilization, Japan (CCUJ)! Japan Coal Energy Center (JCOAL)! J-Power (EPDC)! Mr. Yusuke Tadakuma (NEDO)! Dr. Koji Ukegawa (AIST)! Dr. Hiroyuki Hatano (AIST)! Mr. Kenji Kato (Nippon Steel Corporation)
! Professor Masakatsu Nomura (Osaka University)
Thank you for your attention
Basic Research Grant Fundamental Research Project
METI
NEDO
RITE
Private sector, universities, etc.
Seeds discovery
METI
RITE, etc
Global environment conservation related to industrial technological development promotion project (seeds discovery)
Leading research project on global environment industrial technology
Program-based development of CO2 fixation and effective utilization technologies
Research and development for geological storage technologies of CO2
Study of Technology for Environmental Assessment in CO2 Ocean Sequestration to mitigate the Climate Change
Research and Development of efficient energy utilization and CO2 fixation technologies for effective reuse of paper wastes
Development of CO2 recovery and utilization technology using coal and natural gas
Development of large-scale carbon dioxide fixation technology
Promotion Scheme based on National Support System(1)
１１
Practical Application
METI
NEDO
RITE and Private organizations
Support of technological development for practicalapplication
Technological development for practical application of CO2 fixation and effective utilization
Industrial technological developmentpromotion project for achieving the Kyoto Protocol targets
Promotion Scheme based on National Support System(2)
１１
Achievement of the Kyoto Protocol targets
International Cooperation
METI
NEDO
RITE and Private organizations, etc.
Support of international cooperation and collaborativeresearch on the global environment
Global environment international research promotion project
Energy environment international collaborativeresearch support project
Global environment international cooperation promotion project
International research onthe global environment
Selection of site and targeted layer for injectionFukasawa-cho, Nagaoka City, Niigata Prefecture, Japan
Drilling of injection wellDrilling of observation wellThree observation wells have been drilled for monitoring the behavior of injected carbon
dioxide, such as migration, in the aquiferConstruction of injection facilityInjection and observation experimentThe injection of carbon dioxide : from early July 2003, 10,000 tones in total over 18 months Injection rate : 20 tones/day.
Research and development for geological storage technologies of CO2
Study of Technology for Environmental Assessment in CO2 Ocean Sequestration to mitigate the
Climate Change (SEA-COSMIC)
! Clarification of behaviors of liquid CO2-seawater at injection
! Research on technologies of CO2 transport to intermediate depths of the ocean and dilution
! Laboratory experiment on CO2 impacts on marine organisms
! Development of models to assess environmental impacts near the area of CO2 injection
! International joint research of CO2 injection at the open ocean site as one of the CTI activities
! Supporting survey • Study on the research trends concerning CO2 ocean sequestration in Japan and
abroad
• Study on the optimization of the total system
Expected CCT for 21st Century (1)
High Efficiency 1st Generation (1990-2000)
Pressurized Fluidized Bed Combustion (PFBC)
Supercritical Steam Power Generation System (USC)
High Efficiency 1st Generation (2000- 2010)
Integrated Coal Gasification Combined Cycle Power Generation System (IGCC)
Super Coke Oven for Productivity and Environmental enhancement toward 21st Century (SCOPE21)
Direct Iron Ore Smelting Technology (DIOS)
Expected CCT for 21st Century (2)
Zero Emission Generation (2020- )
Hydrogen Production from Coal with CO2 Recovery System (Hyper-RING)
Technology to support Integration of Power Generation, Steel Making and Chemical Industry
High Efficiency Hybrid Generation (2010-2020)
Integrated Coal Gasification Fuel Cell Combined Cycle Power Generation System (IGFC)
Hydrogen Production Technology from Coal to support CO2 Free Energy
Co-production Technology with Power and Chemical Raw Materials
Dimethyl Ether ProductionTechnology (DME)
Design and Evaluation of Commercial Plant
Back-up Study
100t/d Pilot PlantOperation
100t/d Pilot PlantConstruction
20032002 2004 2005 2006
Schedule of DME SynthesisPlant Construction and Operation
Dimethyl Ether Production Technology (DME)
View of Pilot Plant (5 t/d) in Hokkaido
Compressor HouseCompressor House
DME Storage TankDME Storage Tank
Pump HousePump House
Synthesis Gas ProductionSynthesis Gas Production
Solvent Tank, OthersSolvent Tank, Others
Thermal Oil UnitThermal Oil UnitCO2 RemovalDME SynthesisDME Separation
/ Purification
Grand FlareGrand Flare
Advanced Pressurized Fluidized Bed Combustion Technology (A-PFBC)
Basic Plan
Elementary Test / FS
Design
Manufacturing
Installation
Test Run / Evaluation
1996 1997 1998 1999 2000 2001 2002
Test Project Schedule A-PFBC PDU
Advanced Pressurized Fluidized Bed Combustion Technology (A-PFBC) PDU of A-PFBC
PartialGasifier
Desulfurizer
Oxidizer
Variation of ash content in HyperCoalVariation of ash content in HyperCoal
Target Level Target Level 0.02%0.02%
(200ppm)(200ppm)