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New Energy and Industrial Technology Development Organization
Clean Coal Technology for the futureClean Coal Technology for the futureNEDONEDO’’ss ChallengeChallenge
Shunichi YANAI
7-8 September 2006 Horizon Hotel, Bandung, Indonesia
Environment Technology Development Department
New Energy and Industrial Technology Development Organization(NEDO)
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New Energy and Industrial Technology Development Organization
Presentation Outline
1. Japan’s New Coal Policy- C3 Initiative Towards the Establishment of a Clean Coal Cycle
2. Concept of NEDO’s fossil fuel processing strategy 3. NEDO’s Projects in Progress
(1) Coal Gasification Technology- EAGLE Project- BRAIN-C Program (Entrained Flow coal gasification Simulator ,etc.)
(Basic Research Associate for INnovated Coal Utilization Program)
(2) Coal Refining Technology - Hyper coal (ash-less coal) Production Project
(3) Reforming Technology for Hot-COG(4) Coal Liquefaction Technology
- Development in Japan- BCL Project - International Collaboration
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New Energy and Industrial Technology Development Organization
Basic Concept of the New Coal Policyin Japan (1/3)
The following three perspectives are considered to form the basic concept based on the recent structural changes in the energy situation
(1)Measures to facilitate a stable supply of energy and environmental protection in the whole of Asia
(2)Medium- to long-term outlook with a focus on 2030
(3)Deploying a comprehensive measure from upstream to downstream
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New Energy and Industrial Technology Development Organization
Basic Concept of the New Coal Policyin Japan (2/3)
3 policy targets for new coal policy
5 basic directionsof the new coal policy
Promotion of high-efficient utilization
Reduction/utilization of harmful products
Cultivation of new utilization possibilities
Expansion of supply potential
Establishment of efficient procurement environment
Reduction of environment load
Diversification of energy supply
Securing stable supply C
3 In
itia
tive
(7
acti
on p
lans
)
Clean Coal Cycle (C3)
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New Energy and Industrial Technology Development Organization
Basic Concept of the New Coal Policyin Japan (3/3)
Clean Coal Cycle (C3) Initiative (7 Action Plans)
Construction of infrastructure for policy implementationConstruction of infrastructure for policy implementation
Improvement of environment for preserving stable low prices of cImprovement of environment for preserving stable low prices of coaloal
Promotion of CCT for overcoming the environmental loadPromotion of CCT for overcoming the environmental load
Construction of a pan-Asian coal network
System efficiency improvement,thoroughness of policy evaluation and
reinforcement of public relations
Construction of a flexible and robust Coal supply and demand structure
Establishment of diversified Risk management methods
Promotion of innovative
CCT development
Demonstration of diversified CCT
models
Promotion of CCT diffusion domestically
and abroad
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New Energy and Industrial Technology Development Organization
Concept of NEDO’s fossil fuel processing strategy
Gasificationsimulator project
Hyper coal project
ATL project
CO+H2
Coal refining
Hydrogenation(coal and heavy oil)
FT synthesis
H2 (for chemicals, fuel cells and fuels)
Electricity
Iron
Reduction
gas turbine andfuel cell
Hydrogen production
Semi-reduced iron ore
Hyper Coal
Coal Petroleum
Biomass
Liquidfuels
EAGLE project
Gasification
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New Energy and Industrial Technology Development Organization
Coal Gasification TechnologyEAGLE Project (1/4)
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
FS/ Component Test
Operation
'02.3 Charging coal
'03.3 Start of operationBasic design/Detail DesignFabrication/Construction
EAGLE (Coal Energy Application for Gas, Liquid & Electricity)
Present
(1) Development of an advanced coal gasifier- innovative oxygen-blown, entrained-flow gasifier with two-stage
spiral flows in the gasification chamber(2) Establishment of high-efficiency coal gasification
technology(3) Establishment of gas clean-up system for purification
of produced gas to the acceptable level for fuelsynthesis and fuel cell
Objectives & Schedule of the EAGLE ProjectObjectives & Schedule of the EAGLE Project- Multi-purpose coal gasification technology development -
(Fiscal year)
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New Energy and Industrial Technology Development Organization
Coal Gasification Technology EAGLE Project (2/4)
LowerBurners (4)
Temp. (°C)1200 1600
Upper:O2 LeanCoal→ CharChar+CO2+H2O→CO+H2
Down : O2 rich Char+O2→CO2+H2O
Slag
H2COCO2
H2O
gas
CO2
O2
Coal
UpperBurners (4)
Image of Gasification FurnaceImage of Gasification Furnace
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New Energy and Industrial Technology Development Organization
Coal Gasification Technology EAGLE Project (3/4)
150t/d Pilot Plant located in Wakamatsu laboratory of J-Power
N
Air Separation Facilities
Incinerator
Gasifier 150t/dGas Clean-up
GT House (8MW)Sulfur Recovery
Facilities
Photograph of EAGLE Pilot Plant (150 t/d)Photograph of EAGLE Pilot Plant (150 t/d)
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New Energy and Industrial Technology Development Organization
Coal Gasification Technology EAGLE Project (4/4)
Project Targets and ResultsProject Targets and Results
Total Operation Time : 4,338 hrs (as of June, 2006)Total Coal Consumption: 21,000 ton
Item Targets ResultsCarbon Conversion Efficiency >98 %= >99 %
Cold Gas Efficiency >78 % 81 %Calorific Value (HHV) 10,000 kJ/m3N >10,100 kJ/m3N
Continuous Operation Time 1,000 hrs 852 hrsKinds of Coal 5 kinds 3 kinds
Sulfide Compounds <1 ppm <1 ppm Halogenated Compounds <1 ppm <1 ppm
Ammonia <1 ppm <1 ppmParticulate Matter <1 mg/m3N <1 mg/m3N
in Clean Syngas
=
==
====
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New Energy and Industrial Technology Development Organization
Coal Gasification TechnologyBRAIN-C Program (1/6)
- Kyushu University- Waseda University- Kansai University- Gifu University- Kyoto University- Gunma University- Akita University- Niigata University- Seikei University- Osaka University
- Osaka University- Chubu University- Tokyo Institute of Technology- Tokyo University of
Agriculture and Technology- Tohoku University- Toyohashi University of Technology- Kitami Institute of Technology- Nagoya University- Kagoshima University
- Toray Research Center, Inc.- Hitachi, Ltd.- Mitsubishi Heavy Industries,Ltd.- Babcock-Hitachi K.K., - Idemitsu Kosan Co., Ltd.
- Kawasaki Heavy Industries, Ltd.- Ube Industries, Ltd.- Sumitomo Coal Mining Co., Ltd.- Tokyo Electric Power Co., Inc.- Delight Co., Ltd.
- Japan Coal Energy Center (JCOAL) - National Institute of Advanced Industrial Science and Technology (AIST)- Central Research Institute of Electric Power Industry (CRIEPI)- SRI International, NEA (Niksa Energy Associates)
Academic (University)
Private company
Government agency & Foundation, Others< Participants >
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
Phase I
Phase II
(Fiscal year)
1. Development of simulator for pressurized entrained-flow coal gasification
2. Coal Data Base & Standard Coal Sample Bank
“Basic Coal Utilization Technology Development”BRAIN-C Program
(Basic Research Associate for INnovated Coal Utilization Program)
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New Energy and Industrial Technology Development Organization
Coal Gasification TechnologyBRAIN-C Program (3/6)
Objectives of Coal Gasification Simulator ProjectObjectives of Coal Gasification Simulator Project
Establishment of a database to make use of data on physical properties and reaction of each type of coalPhysic property/reaction data:
100 kinds of coal (in total)
3. Establishment of acomprehensive database
Development and verification of a simulator that can provide design support, optimize operating conditions, and evaluate types of coal
- Estimated accuracyat gasifier outlet :Temp. within ±20℃
- Gas composition within ±2%- Reaction efficiency of coal within ±2%
2. Verifying/upgrading the accuracy of simulator
Development and upgrading of models necessary to develop a highly accurate simulation compatible with different kinds of coal and suitable for practical use
1. Upgrading simulation model(1) Reaction model(2) Ash deposition model(3) Heat transfer model
Development TargetItem
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New Energy and Industrial Technology Development Organization
Coal Gasification TechnologyBRAIN-C Program (2/6)
1. Design of Gasification Furnace2. Influence on Gasification Efficiency and Thermal Efficiency3. Long-term and Stable Operation4. Gas Cleanup and Environmental Characteristic
Gasifi-cation
Furnace
HeatRecovery
Unit
Liquid Slag
Reaction Gas + Char
Coal
Oxygen
Char
1. Temperature Distributions3. Composition of Reaction Gas5. Particle Trajectories
Heat Transfer ModelsFluid Dynamic Models
Reaction Models
2. Carbon Conversion4. Gas Flow Patterns6. Ash Behavior
Simulated Aspects
Integrated Simulation Models
1.Devolatilization Models2.Char Reaction Models
3.Ash Behavior Models4.N, S, Alkalies, Halogen, Detrimental, Trace Elements, etc
Coal +Char → Volatile + CharChar + O2 →CO2 , Char + CO2 → CO Char + H2O →H2,COAsh Generation, Adhesion, Deposition
Development of Reaction Models
Contribution to Commercialization of Highly Efficient Coal Gasification Technology
Development of Gasification Simulation ModelDevelopment of Gasification Simulation Model
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New Energy and Industrial Technology Development Organization
Coal Gasification TechnologyBRAIN-C Program (4/6)
Example of Analysis of Entrained-Flow Coal GasifierExample of Analysis of Entrained-Flow Coal Gasifier
Gasifi-cation
Furnace
HeatRecovery
Unit
Liquid Slag
Reaction Gas + Char
Coal
Oxygen
Char
Gas Flow Rate Distribution
Coal ParticleOrbiting
COConcentration
DistributionTemperatureDistribution
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New Energy and Industrial Technology Development Organization
Coal Gasification TechnologyBRAIN-C Program (5/6)
Objectives of Coal Gasification Simulator ProjectObjectives of Coal Gasification Simulator ProjectCoal Data Base & Standard Coal Sample BankCoal Data Base & Standard Coal Sample Bank
Storage Conditions for Standard Coal Sample(AIST)
Standard Coal Sample(for distribution)
(1) Establishment of a database to make use of data on physical properties and reaction of each type of coal.
(2) Physic property/reaction data: 100 kinds of coal (in total)
1. Establishment of a comprehensive database
2. Standard Coal Sample Bank
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New Energy and Industrial Technology Development Organization
Coal Gasification TechnologyBRAIN-C Program (6/6)
Summary of Decade’s Results in Basic Coal UtilizationSummary of Decade’s Results in Basic Coal Utilization
Two Coal gasification simulators (RESORT & FLUENT base) were developed to analyze and predict thermal, chemical, and physical phenomena in pressurized entrained-flow coal gasifiers.
These solutions were then compared with the data acquired from measurements at 2 t/d and 50 t/d (HYCOL) entrained flow coal gasification pilot plants.
The simulator can predict the both temperature profiles and ash deposition profiles fairly accurately.
These gasification simulators are now being used in the national coal gasification project in Japan.
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New Energy and Industrial Technology Development Organization
Coal Refining TechnologyHyper Coal Production Project (1/6)
Objectives of the Hyper Coal projectObjectives of the Hyper Coal project
• Development of ash less coal (less than 200ppm ash in coal) production technology
• Investigation of utilization technology for ash less coal– Carbon material for iron or nonferrous metal smelting– Blending coal for coke formation– Fuel for pulverized coal firing– Fuel for gas turbine etc.
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New Energy and Industrial Technology Development Organization
Coal Refining TechnologyHyper Coal Production Project (2/6)
Schedule of Hyper Coal ProjectSchedule of Hyper Coal Project
ProductionStage
Iron or non-ferrous metal smelting(Substitute of coking coal & Slag reduction)
Applicationof Hyper Coal
Pulverized coal-fired power(Coal ash reduction, CO2 reduction
( ~10%))
Gas turbine c/c power generationResearch & Development Commercialization(Coal ash reduction, CO2 reduction(~20%))
2000 2005 2010 2015 2020Demonstration Commercialization
100 t/d 5000t/d
Establishment of Production Tech.
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New Energy and Industrial Technology Development Organization
Coal Refining TechnologyHyper Coal Production Project (3/6)
Hyper coal technology can produce ash less coal (less than 200ppm)Hyper coal technology can produce ash less coal (less than 200ppm)
isd and dissolving
coal structure
The image of HyperCoal productionThe image of HyperCoal production
Coal and organic solvent are mixed.
Coal structure is relaxed, and then organic parts of coal are extracted by the solvent.
After the extraction, the solubles (Hyper Coal) and residue (insolubles +ash) are separated.
Heating
SolventCoal
Solid/Liquid separation
Solvent recovery
Hyper Coal
Insoluble Coal
AshInsoluble matter
Soluble matter
(Byproduct)
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New Energy and Industrial Technology Development Organization
Coal Refining TechnologyHyper Coal Production Project (4/6)
Hyper Coal Bench-Scale Uunit (0.1 t/d BSU)Hyper Coal Bench-Scale Uunit (0.1 t/d BSU)
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New Energy and Industrial Technology Development Organization
Coal Refining TechnologyHyper Coal Production Project (5/6)
HyperCoal
250 300 350 400 450Extraction Temp. [oC]
01020304050607080
Hyp
er C
oal E
xtra
ctio
n Yi
eld
[wt%
daf
]
Solvent :
1-Methylnaphthalene
CH3
~70%!!StratfordYanzhauNantunUpper FreeportIllinois #6Pittsburgh
Coal solvent extraction (deashing) characteristics Coal solvent extraction (deashing) characteristics
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New Energy and Industrial Technology Development Organization
Coal Refining TechnologyHyper Coal Production Project (6/6)
Production and Utilization Flow of Hyper CoalProduction and Utilization Flow of Hyper Coal
Coal
Insoluble Coal
Solvent
1MPa
Mine-Mouth Power Plant
Extract
Byproduct
Utilizationin Japan
Coal producing country Japan
Solvent Extraction
(De-Ashing)
Ion Exchange
(De-Alkalization)
360 380~ ℃
Hyper Coal
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New Energy and Industrial Technology Development Organization
Reforming Technology for Hot-COG- CLEAN FUEL from “Hot-COG” - (1/2)
In coke ovens, coke oven gas (COG) is generated during coking as a by-product. To avoid the unfavorable deposition of tar, the COG’s high-temperature heat energy is not effectively used.
(1) Tar in “Hot COG” is converted to synthetic gas with high thermal efficiency.(2) Clean fuel such as Hydrogen, Methanol and DME is produced from the gas.(3) This technology contributes to reduction CO2 emission and energy saving.
Cokes
Dry Main
COGTankFuel for Coke Oven
CokeOven
80℃ COG
This research and development aims at developing technologies toproduce synthesis gas that can be converted to clean liquid fuels, such as methanol or DME , by reforming the high-temperature COG with tar from coke ovens, thereby making use of the heat energy of the gas.
< This project is started in 2006 FY >
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New Energy and Industrial Technology Development Organization
Reforming Technology for Hot-COG- CLEAN FUEL from “Hot-COG” - (2/2)
Existing or Newly Developed Process
In-house Use
Dust
Cokes
Hot Collecting Main
Dry Main
COGTankFuel for Coke Oven
CokeOven
Coal
COGPurification Separation
CO
GR
efor
mer
Process for Liquid Fuel
Existing Process
DME
COG
Tar,Diesel Oil
Liquid AmmoniaH2SO4
Des
ulfu
rizat
ion
Met
hano
lC
onve
ter
MethanolPurification
Off Gas
Methanol
Hydrogen
HydrogenSeparation
(PSA)
COG ReformingTechnology
Existing Facilities
DMEConversion600 ~~ 700℃
80℃
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyDevelopment in Japan(1/3)
• Production of large amount of liquid fuels from coal that is evenly distributed in the world
• Energy security by diversifying energy source
• Contribution to environmental issue• Contribution to development of industries• Effective use of unused resources
Significance of Coal LiquefactionSignificance of Coal Liquefaction
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyDevelopment in Japan(2/3)
Coal
RecycleSolvent
H2
Liquefaction
Heavy Oil
Separation&
Fractionation
ProductsCatalyst
Temperature Pressure
Diesel
Gasoline
Principle of Direct Coal LiquefactionPrinciple of Direct Coal Liquefaction
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyDevelopment in Japan(3/3)
Liquefaction Development in New Sunshine Program of METI
Bituminous Coal Liquefaction (NEDOL)Bituminous Coal Liquefaction (NEDOL)
Up-grading
International Collaboration
NEDOL process
BCL Process
Fundamental Research
1980 1985 1990 1995 2000 2005
Process, Material, Equipment, CatalystProcess, Material, Equipment, Catalyst
OperationDesign & Construction
Design & Construction Operation
1 t/d PSU etc.
ImprovementOperationConstruction50t/d Pilot Plant
BCL process Improvement
Supporting Research
150 t/d Pilot Plant
F/S
F/S
Indonesia
China
Brown Coal Liquefaction (BCL)Brown Coal Liquefaction (BCL)
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyBCL Project (1/3)
- Experience of 50t/d PP at Australia- High reactivity catalyst with low cost- New idea introduced from research results of Takasago Research Laboratory
Bottom recycle operation for
increasing distillate yield
In-line hydrotreating unit for
increasing product quality
Feature of Improved BCL processFeature of Improved BCL process
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyBCL Project (2/3)
Feature of Improved BCL processFeature of Improved BCL process
Achievement- Demonstration of brown coal liquefa-ction concept Oil yield of 52wt%
- Continuous operationof 1,700hrs
- Demonstration of highefficiency de-wateringprocess
- Demonstration of solvent de-ashingprocess in high de-ashing ratio
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyBCL Project (3/3)
Solvent Recycle
Recycle Gas
Separator Light OilLight Oil
Recycle GasCompressor
Fixed BedHydrotreater
HydrogenationInline
Hydrotreatment
Solvent De-ashing
Middle OilMiddle Oil
SludgeCLB Recycle
Removed Water
Evaporator
Reactor
Fractionator
SlurryDe-watering
Settler
H2
CLB Separator
CLB Run Down
Catalyst
Preheater
PressureReducing
SeparatorSeparator
DAO Recycle
SlurryMaking
H2S Rich Gas
Off GasPurification
Slurry Feed Pump
Purge Gas(Fuel Gas)
H2
H2
H2
Improved BCL Process FlowImproved BCL Process Flow
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyUp-grading
40 bbl/d PDU plant
> 95Octane Number(Gasoline)
> 1,000 hContinuous Operation hrs
Satisfy JIS N,S in Oil
> 35(>50 after blended)
Cetane Number(Diesel )
Objectives
Upgrading of Coal Liquefaction Oil Upgrading of Coal Liquefaction Oil
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyInternational Collaboration(1/2)
2001
Invitation and Training of Indonesian Engineers
Research Cooperation for Coal Liquefaction Technology
Feasibility Study of Coal Liquefaction Commercial Plant
Collection of Engineering Data by 0.1 t/d BSU
Evaluation of Indonesian Coal
MOU between BPPT and NEDO
20022000199919981997199619951994Fiscal Year
Content
2nd1st 3rd
Collaboration between Indonesia and NEDOCollaboration between Indonesia and NEDO
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New Energy and Industrial Technology Development Organization
Coal Liquefaction TechnologyInternational Collaboration(2/2)
DCF(Discount Cash Flow)MethodFinancial Analysis
Coal Gasification ProcessProduction of Hydrogen
Limonite Ore in IndonesiaCatalyst
Raw Materialsfor Transportation Fuels Product Oil
Berau, Mulia & Banko coalsRaw Coal
Kalimanta & South SumatraPlant Location
3,000t/d (1-unit), 6,000t/d(1-unit),12,000t/d (2-unit), 30,000t/d(5-unit)Plant Scale
Improved BCL ProcessProcess
Basic Conditions of F/S for a Commercial Coal Liquefaction PlantBasic Conditions of F/S for a Commercial Coal Liquefaction Plant