25_B13_Ube Industries_Ube Machinery Corporation_Mizuho Information &...

7/28/2019 25_B13_Ube Industries_Ube Machinery Corporation_Mizuho Information & Research_IndonesiaFSReportingMeeting99

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Program organization research of

Low-rank coal fuel waste heat drying

project in a cement factory

22nd February, 2013

Ube Industries

Ube Machinery Corporation

Mizuho Information & Research Institute


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Contents

1. Project Outline

2. Low-rank Coal Utilization Expansion

3. Waste Heat Coal Drying Technology

4. Reference Scenario setting

5. Emission Reduction Calculation

6. Estimated Potential of CO2 Reduction

7. Conclusions

NEDOs Feasibility Studies with the Aim of Developing a Joint Crediting Mechanism(JCM) SectorCement

2


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1. Project Outline

The effect of adoption the low-temperature waste heat recovery system for

low-rank coal fuel drying into the existing cement plant will be evaluated in

respect of utilization expansion of low-rank coal and its energy cost saving,

and estimated the CO2 reduction potential.

Survey in Summary

PT Semen Padang Indonesia, West Sumatra

Advancing on low-rank coal utilization expansion to meet increase of

domestic coal demand, propagation ofwaste heat recovery system for coal

drying to the existing cement plant aimed at both low-rank coal utilization

and CO2 reduction can be achieved large reduction potential.

Partner / Site

Objective


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1. Project Outline


4

Possible Problems by Shifting from High(mid)-rank coal to Low-rank coal:Increase of CO2 emissions

Decrease in energy utilization efficiency or production efficiency (quantity)

Low-rankCoal Dryingprocess with employed

Low-temperature Waste Heat Recovery is

Effective for Low-carbon Economic Growth.

Current Circumstances of Indonesian coal

Indonesian economic growth has been significantly developing and will continue in the

future:(1) Indonesia will be needed to meet coal demands by foreign countries, while responding to

sharply increase of domestic coal demands with its economic growth.(2) Indonesian government positions the domestic use of low-rank coal which has large

reserve, as an economic growth measure.(3) In general, economic growth tends to lead to increase of CO2 emissions. It increases also by

conversion into low-rank coal as the same.

(4) However, the Indonesian government is trying as much as possible to suppress an increaseof CO2 emissions with it's economic growth.(5) Low-rank coal utilization technology to realize the Low-Carbon Economic Growth" has

been expected.


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Minable years of coal reserves in Indonesia

Coal RankCV (air dry basis)

[kcal/kg]Probable Reserve (A) [Mt]

Actual Production 2011 (B)

[Mt]Minable years (A/B) [y]

Low Calorie 7,100 182 - -

Total 13,448 327 (41)


0

20

40

60

80

100

120

2011 2012 2013 2014 2015

AnnualConsum

ption

[Mt/y]

High

Medium

Low

Coal Consumption for each Coal rank by PLN

0

100

200

300

400

500

600

2007 2008 2009 2010 2015 2020 2025 2030 2050

Coal[Mt]

Production

Domestic Sales

Export

Coal production and domestic sales and export

5Source: Ministries of Energy and Mineral Resources

2. Low-rank coal Utilization ExpansionCurrent Circumstances and Projection of Indonesian coal

1. Only by medium-high-rank coal used as currently, both coal demand of domestic and export cannot be satisfied.

2. Especially to correspond to the drastic growth of domestic coal demand, low-rank coal with abundant reserve is required to beutilized.

3. The superiority oflow-rank coal price merit is invariable. (See next.)

4. Projection planning of electricity sector which takes 65% of domestic demands also appropriates an increased part by low-rank coal.

Low-rank coal ratio taken in the amount of the coal used plan to increase from 26% in 2011 to 54% in 2015. Cement sector seems to

be most similar situation. And ratio of low-rank coal taken in the amount of coal used increases, and the coal rank conversion to

Low from Medium + High proceeds also in existing plant.


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0

20

40

60

80

100

120

140

Jan

-09

Mar

-09

May

-09

Jul-09

Sep

-09

Nov

-09

Jan

-10

Mar

-10

May

-10

Jul-10

Sep

-10

Nov

-10

Jan

-11

Mar

-11

May

-11

Jul-11

Sep

-11

Nov

-11

Jan

-12

Mar

-12

May

-12

Jul-12

Sep

-12

Nov

-12

ICIprice[U$/t]

Month - Year

ICI-1 ICI-2 ICI-3 ICI-4 ICI-5

2. Low-rank coal Utilization Expansion

Coal Price Index (2009-2012)

50

60

70

80

90

100

0 10 20 30 40 50I

ndexofcalorieunitprice

ratio(ICI-1=100)[-]

Total Moisture (%)

ICI2

ICI3

ICI5

ICI4

ICI1


6

Caloric Unit Price Merit depend on TM (2012)

Current circumstances ofIndonesian coal market trend

Waste Heat

Drying

2012 average

EconomicalMerit

The superiority oflow-rank coal price merit is invariable


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SP Waste Gas

Limestone

Mill

NSP Tower

Suspension

Pre-heater

Rotary Kiln

Raw

Materials Cooler Fan

Clinker Silo

EP

Coal

Coal Mill

Stack

Conditioner

Air

(1) Coal Dryer

(1) Coal dryer" is installed on the coal supply line of the existing cementplant. ( = Paddle type dryer of UMC original development )

(2) Heat Recovery of unused waste-heat from clinker cooler is connected.

(2) Heat

Recovery

Cement Production Process

3. Waste Heat Coal Drying TechnologyNEDOs Feasibility Studies with the Aim of Developing a Joint Crediting Mechanism(JCM) SectorCement

Scope of facilities to be extended

Fuel Conversion to low rank coal is realized

7

Concept of Waste heat coal drying system


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Concept ofUBE coal dryer


By drying low-rank coal through recovering unutilized low temperature waste heat (especially 70-200 deg.C)before feeding to the plant, a calorific value of the low-rank coal will be as much as that of high grade coal.

Promoting low-rank coal utilization necessary to meet increase of domestic coal demand

Abundant reserves of low-rank coal is advantageous for both stable supply and a price merit

(1) Concept of proposed technology is:- Use waste heat from Industrial plant and/or own coal fired power plant

- Reduce moisture content of lignite to as low level as sub-bituminous coal (ex. TM:50% (x1/2) 25%)- Taking advantage of existing plant

- Without large-scale modification, the cheaper equipment cost is achieved

(2) Benefit ofUbe's drying process: Suitable drier forlow-temperature waste heat recovery system

- Recover unused waste heat at low temperature even in atmosphere composition gas

- Dry coal at high drying efficiency under the considered safety operating condition

- Ordinary sized coal in bulk fed directly to the coal dryer by existing coal handling systems.

Low-rank Coal

Paddle type Dryer

Dried Coal

Waste Heat

8

3. Waste Heat Coal Drying Technology


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(*) Dry coal capacity = 487 k-t/y

3. Waste Heat Coal Drying TechnologyNEDOs Feasibility Studies with the Aim of Developing a Joint Crediting Mechanism(JCM) SectorCement

9

Concept of waste heat coal drying and energy recovery process

t/h (3 x 30.8t/h)

%-TM

High-moisture Coal(From Existing Coal Conveyer)

185 260 50

Clinker Cooler Exshaust Gas

Waste Heate

t/h

%-TM

Air Dry Coal (To Existing Coal Mill)

92.345.0

65.5

22.5

(3 x 21.8t/h)

Coal

Dryer

Bag

Filter

(1) Coal Dryer(2) Heat Recovery

Plot Plan

Area = 1,300m2 (48 x 28m)


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The essence of proposed methodology is same to CDM methodology ACM0012 but proposed one include coal dryer in the boundary.

And to evaluate the drying system, the simple and practical indirect monitoring is proposed.

Reference ScenarioRS Project ScenarioPJ

Raw coal Coal Dryer Dry coal

Heat

Generator

Fossil Fuel Waste Heat

Raw coal Coal Dryer Dry coal

Heat

Recovery

10


4. Reference Scenario setting

ReferenceScenario options

Screeningresults

Explanation

1. Without

Drying

Coal is directly input to a process.

Based on the projection of Indonesian coal and its policy, the coal used will become lower rank coal.

But using lower rank coal directly cause the reduction of production capacity.

While economic growth will increase demand for cement sector, the choice of production by direct

supply of low-rank coal is unlikely.

2. Fossil fuel

Drying

Reference

Scenario

Coal is input to a process after drying with coal(coal is selected because of economic attractive).

It is consistent with the Indonesian measure to promote the use of low-rank coal.

The coal drying technique is mature and feasible. This scenario is most feasible if this project doesnt exist.

3. Waste heat

Drying

Project

Scenario

Coal is input to a process after pre-drying with low-temperature waste heat.

This will become feasible only by using the technique to be installed this time.

This scenario can realize the Indonesian policy to promote low-rank coal, with less CO2 emissions.

Based on the sustainable Indonesian economic growth with in a view ofsufficient coal supply-and-demand

circumstances as a background, the scenario settling with aiming to achieve low-carbon growth was performed

with considering to the expansion of low-rank coal utilization

CO2

Elec.CO2 CO2

CO2

Elec.


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5. Emission Reductions Calculation


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REy (Reference Emissions) PEy (Project Emissions)

Fossilfuel-derived

REfuel,y = HGPJRF EFCO2,fuel PEfuel,y = 0REfuel,y

The reference CO2 emissions (fromfossil fuel combustion)

t-CO2/y PEfuel,yProject Emissions(fossil fuel)

t-CO2/y

HGPJ

The amount of heat which is converted

to product dry coal for the coal dryer

by the project activity :Using PT

monitoring value

Mcal/y

RF

The efficiency of heat generator and

dryer in the reference scenario (1(heatgenerated/fossil fuel used)2(increased heatamount of coal/heat input to dryer))

:Estimated value

-

EFCO2,fuelThe CO2 emission factor of fossil fuel

which is used for the coal dryer facility

in the reference scenario :Default value

t-CO2/Mcal

Electricity-derived

REelec,y = PRF,y TPJ,y EFCO2,elec,y 1,000 PE elec,y = ECPJ,y EFCO2,elec,y

REelec,yThe reference CO2 emissions (from

electricity consumption)t-CO2/y PEelec,y

The project CO2 emissions (from

electricity consumption)t-CO2/y

PRF,y

The rated power consumption of the

coal dryer facility in the reference

scenario :Estimated value

kW

ECPJ,y

The electricity consumption of the

coal dryer facilities by the project

activity :Monitoring value

MWh/y

TPJ,yThe operating hours of the facility by

the project activity :Monitoring valueh/y EFCO2,elec,y

The CO2 emission factor of

electricity :Default value

t-CO2/MWh

EFCO2,elec,yThe CO2 emission factor of

electricity :Default value

t-CO2/MWh

ERy (Emission Reduction) = REy - PEy = (REfuel,y + REelec,y) - PEelec,y


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12

Process

Heat

Recovery

Coal

dryerCoal

Heat receiving stream

Waste heat stream (air composition)Monitoring parameter (1)Electricity consumption

measured by power meter

PEelec,y

Monitoring parameter (2A. Direct measurement method

Conceptual diagram of monitoring method

5. Emission Reductions Calculation

Air

( W1H1 ) ( W2H2 )

Monitoring parameter (2B. Indirect measurement method

Measuring feed rate and analysis value

(property) ofcoal, which were measured both atthe inlet and the outlet of the coal dryer.

Then calculating the W(Weight of coal) & H(Heat

value of coal). HGPJ is calculated by HGPJ =

(W2H2) -( W1H1 )

Measuring flow rate, temperature and relative humidity of the gasboth at

the inlet and outlet of the coal dryer, then calculating the difference of water vaporamount contained in the gas by using those measured values. (The calculation result

is equal to water amount drawn from the input coal.) By using the value of the

water amount drawn from the input coal, finally calculating the increased heat

amount from comparing the coal before/after drying.

Difficult to monitor continuouslyEasy and highly accurate measurement method

(simple and practical )


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Symbol Explanation Determination wayPa

rameterssetbefore

startofthisproject

RFThe efficiency of heat generator and dryer

(=1(RS)2(RS)) in the reference scenario

Designed value of assumed coal drier facilities that wouldbe used in the reference scenario

EFCO2,fuelThe CO2 emission factor of fossil fuel which

is used for the coal dryer facility in the

reference scenario

Estimating that the fossil fuel to be input is coal, andanalyzing the input coal on a regular basis

PRF,yThe rated power consumption of the coal

dryer facility in the reference scenario

Designed value of assumed coal drier facilities that would beused in the reference scenario

EFCO2,elec,y The CO2 emission factor of electricity Using of the emission factor of a grid, or the emission factor

of a power plant in the case where no grid is used To be upgraded as necessary.

M

onitoring

pa

rameter

HGPJThe amount of heat which is converted toproduct dry coal for the coal dryer by the

project activity during the year

Continuous and automatic measuring and recording, byusing temperature and flow rate data

TPJ,y Project operating time Continuous and automatic measuring and recording

ECPJ,yThe electricity consumption of the coaldryer facility by the project activityduring the year

Continuous and automatic measuring and recording, byusing electricity meter

5. Emission Reduction Calculation


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REy (Reference Emissions) PEy (Project Emissions)

Fossil fuel-

derived

REfuel,y = HGPJRF EFCO2,fuel=119,662[Gcal/y]0.8[-]0.451[t-CO2/Gcal]

=67,310[t-CO2/y]

PEfuel,y = 0

Electricity-

derived

REelec,y = PRF,y TPJ,y EFCO2,elec,y 1,000=0 [t-CO2/y]

PEelec,y = ECPJ,y EFCO2,elec,y=28,270[MWh/y] 0.743[t-CO2/MWh]

=21,000[t-CO2/y]

ERy (Emission Reduction) = REy - PEy = (REfuel,y + REelec,y) - PEelec,y= ( 67,310 + 0) - ( 0 + 21,000 ) = 46,310 [tCO2/y]


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0.77 0.850.94

1.03 1.14 1.25

1.381.52

1.681.85

2.042.25

2.47

2.72

0.080.17

0.270.37

0.490.62

0.760.91

1.091.27

1.48

1.71

1.96

0

1

2

3

0

10

20

30

40

50

60

2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

Estimated

CO2Reduction

[Mt]

AnnualCoalC

onsumption[Mt]

Annual Coal Consumption of Indonesian Cement sector

Possible CO2 Reduction Potential

Estimated CO2 Reduction Potential based on Increase coal demand from 2012

6. Estimated Potential of CO2 Reduction

Coal ConsumptionBefore drying (TM=45%) 92.3 t/h

After drying (TM=22.5%) 65.5 t/h

Annual Coal RequirementBefore drying (TM=45%) 0.687 Mt/y Coal Price merit

= USD11.3M/y(Based on current coal market)After drying (TM=22.5%) 0.487 Mt/y

CO2 Reduction 46,310 t-CO2/y

CO2 Reduction Potential Factor on Coal consumption 0.0950 t-CO2/t-coal after drying

Calculation results of the Indonesian CO2 reduction potential of cement sector


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Estimated and Possible Potential of CO2 reduction of Indonesian cement sector

Low-rank coal


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7. Conclusions

Simple and Practical MRV for Indonesian Low-Carbon Growth

In order to effectively address the issue of climate change, eachcountry will be needed to achieve low-carbon growth byutilizing technologies, markets, and finance.

Based on the circumstances and the future orientations of Indonesia, and by adopting simple and practical MRVmethodology that has been currently considered, the JCM will

promote transfer of technology from Japan to Indonesia, and willenable to realize a economic growth with less CO2 emissions inIndonesia.

Estimated and Possible Potential of CO2 reduction of Indonesiancement sector was calculated;

Estimated CO2 reduction effect using the methodology in the

project case of coal feed rate of92.3 t-low-rank coal/h is approx.46,310t-CO2/y

Reduction potential of the CO2 in Indonesian Cement sector is setto 0.77Mt-CO2/y currently in maximum, and 1.96 2.72 Mt-CO2/y around 2025 is expected.


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Thank you for your attention.

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