advanced industrial technologies for energy conservation …€¦ · · 2008-08-29advanced...
TRANSCRIPT
ADVANCED INDUSTRIAL TECHNOLOGIES FOR ENERGY CONSERVATION IN JAPAN
November, 2007
JAPAN EXTERNAL TRADE ORGANIZATION JAPAN CONSULTING INSTITUTE
Source: UNFCCC HP
1. Importance of Energy Conservation / CO2 Emission Reduction (1) For Suppression / Mitigation of Global Warming
In order to prevent / mitigate climate change (global warming), CO2 in the atmosphere must be reduced to the level before the industrial revolution. In case that CO2 increases at the present rate, the environment of the earth will be disastrous within the century.
(2) Preservation of Energy Resources
World primary energy demand by fuel in the reference scenario Data source: IEA 2004
Recoverable Fuel Resources
Fuel Oil Natural gas
Coal Uranium
Recoverable reserve
1.15 trillion barrels
176 trillion m3
984 billion tons
4.6 million tons
Annual production
28 billion barrels
2.6 trillion m3
5.1 billion tons
54 k tons
Recoverable years
41 67 192 85
Source of data
BP Statistics 2004 OECD/NEA, IAEA
URANIUM (year 2003)
(3) Reduction of Product Cost The cost of products which consume more energy for production will be higher due to higher cost of energy which will soar. In order to lower the manufacturing cost, therefore, it will be essential to reduce the energy consumed for the production. Thus, to survive in the market, the energy consumption must be reduced to the minimum from the view point of lowering production cost emission and CO2.
(4) Effect of CO2 Emission on Commercial Value of Products in the future From the viewpoints of global warming problem and exhaustion of fuel resources, the commercial value of products which consumes more energy accompanying more CO2 emission for production will be lowered resulting in the forfeiture of the market. It is expected that trade barriers may be set against commodities based on their CO2 emission during the production in the countries such as EU.
Energy consumption Higher production cost
Energy consumption
CO2emission
Lower commercial value of productMay become a trade barrier in near future
2. Advantage of CDM (UNFCCC Clean Development Mechanism) Those manufacturing / production technology which produces less GHG (CO2) than the baseline technology (most commercially plausible technology) can take advantage of CERs (Certified Emission Reductions) of CDM which is salable further lowering the production cost while contributing to suppression of global warming. CDM, therefore, is very effective both for improvement of project economics and suppression of global warming.
Example of power generation with 500 MW unit (20 years operation at plant load factor of 75%)
Power generated 500,000 kW×8,760h/y×20y×0.75 = 65.7×109 kWh Primary energy Renewable energy Coal Fuel consumption None 65.7×109 kWh / 0.36×3,600 kJ/kWh = 657×1012 kJ
657×1012 kJ / (24.49×109 kJ/103 ton) = 26.8×106 ton Fuel cost None 26.8×106 ton ×US$ 50/ ton-coal = US$1.34×109 CO2 emission None 25.8 ton-c/109 kJ (Source: IPCC)
657×1012 kJ×25.8 ton-c/109 kJ×44/12=62×106 ton-CO2 CO2 emission credit (Equivalent value)
62×106 ton-CO2 =62×106 ×US$20/ton-CO2
=US$ 1.24×109
Base
Presumption: Net plant efficiency = 36%, Net heat value of coal=24.49×109 kJ/103 ton (referring to IPCC) Carbon emission factor=25.8 ton-c/109 kJ (Source: IPCC), CO2 market price= US$20/ton-CO2
3. What shall be done to mitigate global warming? As the global warming is caused mostly by the accumulation of CO2 in the atmosphere which is caused by combustion of fossil fuels such as coal, oil and natural gas, the consumption of fossil fuels shall be reduced. This will be possible with the following measures:
(1) To adopt high energy efficient technology (system and equipment). (2) To recover and utilize waste energy/heat effectively, including cogeneration. (3) To use less carbon intensive fuels (less CO2 emission for same heat
generation).
Approximate comparison of CO2 emission by fuel Fuel Coal Oil Natural gas
For same amount of heat generation
100 80 60
For same amount of power generation
100 80 45 (Combined cycle plant)
(4) To use of renewable energy such as hydraulic power, solar energy, wind power, geothermal energy and biomass Note: Biomass and biomass derived fuel are considered carbon neutral.
4. Background for high energy efficient industrial technologies developed in Japan
(1) Three time Middle East Oil crises forced Japanese industry to make efforts
for developing high energy efficient industrial technologies in Japan Japan has been dependent on the import mostly from the Middle East of its demand for oil and have suffered oil crises (embargo on oil export by the Middle East oil producing countries) three times, which forced Japanese industry develop high energy efficient technologies.
(2) High energy efficiency industrial technologies developed in Japan High energy efficient industrial technologies have been developed vigorously by Japanese industry since the first oil crisis leading other industrialized nations.
The 1973 oil crisis: began in the wake of the fourth Middle East war. The 1979 oil crisis: occurred in the wake of the Iranian Revolution. The 1990 energy crisis: occurred as a result of the first Gulf War.
GDP and primary energy consumption of Japan
112
496
306
259
0
100
200
300
400
500
600
230
240
250
260
270
280
290
300
310
GDP
Primary energyconsumption
Con
sum
ptio
n (
10
00
kL)
GD
P (
trill
ion
yen)
112
496
306
259
0
100
200
300
400
500
600
1973 2004230
240
250
260
270
280
290
300
3101973 2004
GDP Trillion Yen
Primary EnergyConsumption 1000kLoe
year
Energy Consumption per GDP of Major Industrialized Countries
TOE / million US$
Canada
England USA
France
Japan German
Calculated based on 1995 US$ Source: ENERGY BALANCES OF OECD COUNTRIES 1999-2000,
Energy Consumption of Manufacturing Industries in Japan - 1/2 Thermal power generation (2003)
(Index : 1kWh power basis)
Japan Germany USA France China (Source: ECOFYS)
Manufacturing petroleum product (2002) (Index : 1kl of product basis)
Japan Industrialized Europe USA, Canada Asian countries (Source: Solomon associates)
Steel manufacturing (2003) (Index : 1ton of product basis)
Japan Korea EU China USA Russia (Source: the Japan I & S Federation)
Paper manufacturing (2003) (index : 1ton of product basis)
Japan Sweden Canada USA (Source: METI of Japan)
Base: 100 for Japan Base: 100 for Japan
Base: 100 for Japan Base: 100 for Japan
Energy Consumption of Manufacturing Industries in Japan - 2/2 Cement manufacturing (2000)
(Index : 1ton of clinker basis)
Japan Europe Korea M & South China USA Russia America (Source: Battelle Institute)
Manufacturing caustic soda by electrolysis (2003) (Index : 1ton of product basis)
Japan Korea China USA East E. West E. (Source: SRI Chemical Economics Handbook)
Copper manufacturing (Index : 1ton of product basis)
Japan Europe Asia N. America S. America (Source: Japan mining industry association)
Aluminum plate manufacturing (Index : 1ton of product basis)
Japan World (Source: International Aluminum Institute)
Base: 100 for Japan
Base: 100 for Japan
Base: 100 for Japan
Base: 100 for Japan
ADVANCED INDUSTRIAL TECHNOLOGIES
1. Power generation
2. Steel manufacturing
3. Cement manufacturing
4. Fertilizer and chemical manufacturing
5. Refinery
6. Food industryEnvironment
7. Energy & CO2
8. Heat pump
1. Ultra supercritical pressure coal–fired power generation system
1000MW High temperature ultra supercritical pressure coal–fired power plant
(Source: HP of Mitsubishi Heavy Industries)
2. Pressurized fluidized bed boiler combined cycle plant system
360MW Pressurized fluidized bed boiler combined cycle plant system
(Source: HP of Kyushu EPC)
Coal-fired Power Generation - 1
1ry & 2ry Cyclones Pressure vessel Electrostatic precipitator
Fluidized bed boiler
Coal bunker
DeNOx equipment
Exhaust gas feedwater heater
Gas turbine
Cal slurry pump
Steam turbine
(Source: HP of Toshiba Corporation)
(Source: Catalogue of IHI Corporation)
3. Integrated coal gasification combined cycle system
(Source: HP of Mitsubishi Heavy Industries)
250MW Integrated coal gasification combined cycle plant
(Source: HP of Mitsubishi Heavy Industries)
4. Coal gasification SOFC combined cycle
Coal gasification SOFC (Solid Oxide Fuel Cell) combined cycle (Source: HP of Mitsubishi Heavy Industries)
Coal gasification SOFC (Solid Oxide Fuel Cell) combined cycle plant
(Source: HP of Mitsubishi Heavy Industries)
Coal-fired Power Generation – 2 (for very near future use)
Pulverizer
Coal bunker
Coal gasifier Heat exchange
Oxygen/air
Slag Char
Filter
Sulfur removal device
Inverter Steam turbine
Condenser
Exhaust gas
Compressor
Gas turbine HRSG
Coal
Coal gasifier Filter
Gas turbine
Steam turbine
HRSGChimney
Coal gasifier
Coal feed system
Coal gas
Porous filter
Combustor
Gypsum Wet DeSOx
AirStack
N2
O2
Char
Air Air separating unit
Air compressor
Char
Air
1. Natural gas-fired combined cycle plant system
(Source: HP of Toshiba Corporation)
Gas turbine for 455MW single-shaft Natural gas-fired combined cycle plant
(Source: HP of Mitsubishi Heavy Industries)
2. SOFC-GT combined cycle (being developed)
(Source: HP of Mitsubishi Heavy Industries)
SOFC-gas turbine combined cycle package for DPHC
(Source: HP of Mitsubishi Heavy Industries)
Natural Gas-fired Power Generation
SOFC module SOFC cell tube
Recirculation device
Inverter
Combustor
Gas turbine
Heat exchanger
Fuel
Air
1. Diesel Engine power generation
(Model: Mitsubishi 18KU34)
2. Gas engine power generation
(Model: Mitsubishi Gas Engine)
3. Gas turbine cogeneration (heat/power ratio controllable type)
(Source: HP of Hitachi Zosen Corporation)
4. PEFC cogeneration
(Source: HP of Mitsubishi Heavy Industries)
Process steam
Feedwater
Fuel
Superheated t
Generator
Compressor
Turbine
Gas turbine
Power Air
Heat recovery boiler
Stack
Exhaust gas
Combustor
Distributed Power & Heat Cogeneration
Wind turbine power generation
(Model: Mitsubishi Heavy Industries MWT95/2.4)
Photovoltaic cell power generation
1,000kW Photovoltaic power generation plant
(Model: Mitsubishi Heavy Industries MA100)
Hydraulic power generation
412MW Pump turbine generator (Francis type pump turbine supplied by Mitsubishi Heavy Industries)
Refuse incineration power generation
132.6MW Refuse incineration power plant
(Singapore Tuas South incineration plant constructed by Mitsubishi Heavy Industries)
Renewable Energy Power Generation
1-1 Advanced Supercritical Pressure Coal-fired Power Plant Power generation Coal-firing Supercritical pressure plant
1. Function and features (1) High efficiency power generation
By applying high temperature supercritical steam condition such as 25MPa 600/600°C to steam cycle, much higher thermal efficiency of plant than subcritical pressure plant is obtainable. Applicable to 300MW and larger unit.
(2) High thermal efficiency over whole operating load range As the boiler is designed suitable for variable pressure operation, high plant efficiency over whole load range is obtainable owing to sliding pressure operation.
(3) Excellent dynamic performance Owing to once-through boiler design with less heat storage capacity of water and metal, excellent dynamic performance is obtained.
(4) Environmentally friendly operation Owing to state of the art combustion technology, environmentally friendly operation in addition to CO2 emission reduction is assured.
2. Plant system
Supercritical coal-fired power generation plant
Electrostatic precipitator
Low NOx burner
Boiler
Lime stone
Unloader Dust net
Coal carrier
Stacker
Reclaimer Coal conveyer
Electricity Transmission cable
Switch -gear Transformer
Generator
Building DeNOx reduction measures
Coalbunker
Steam turbine Catalytic DeNOx
Air preheater
Induced draft fan
Desulphurization plant
Stack 200m height
Flue gas analyzer
Gypsum
Coal ash
Useful ashAsh pond To DeSOx
Forced draft fanRaw water
Water purifier
Ocean
Pulvelizer
Steam
Boi
ler f
eedw
ater
pum
p
Feed
w
ater
Coo
ling
wat
er Ash
Circ
ulat
ing
wat
er p
ump
Indu
stria
l wat
er
Dis
char
ge w
ater
Coa
l
Conde -nser
3. Performance advantage
Steam Pressure & Temperature
0 25 50 75 100 107
SC Pressure MPa
SC Main steam temp °C
SC Reheat steam temp °C
Sub PressureMPa
Sub Mainsteam
Sub RH Steam temp °C
Unit load %
0
50
100
150
200
250
300
350
400
450
500
550
600
650SC steam temp.
Sub steam temp
SC steam pressure
Sub steam pressure
Tem
pera
ture
℃
30
25
20
15
10
5
Pre
ssur
e M
Pa
Improvement of plant efficiency
4. System and structure
(1) Boiler
The main difference of supercritical sliding pressure boiler from subcritical pressure drum type boiler with regard to structure is furnace water wall construction due to once-through flow in the former furnace water wall and recirculation flow in the latter.
High reliability of furnace water wall is assured with vertical tube structure with rifled tubes or spirally-wound structure with smooth or rifled tubes.
(2) Turbine generator
The structure of steam turbine for supercritical plant is basically same as that for subcritical plant except for the alteration material and physical dimensions.
(3) Plant
•Distributed Digital Control system is installed for better dynamic performance.
• Demineralizer is provided for better boiler feedwater quality control.
5. FWW mass velocity & FWW structure
Furnace water wall (FWW) flow Furnace water wall structure
Vertical tube wall with rifled tube Spirally-wound tube wall with smooth tubes
60deg. Inclined tube wall
Vertical tube wall
Critical mass velocity
0
500
1000
1500
2000
2500
3000
3500
0 25 50 75 100 107
Unit load %
Mas
s ve
loci
ty k
g/m
2 /s
Massvelocity(MV)in verticaltube kg/m2/s
MV in 60deginclinedtube kg/m2/s
Critical MVfor smoothtube kg/m2/s
Critical MVfor insiderifled tube kg/m2/s
6. Energy Saving /CO2 Emission Reduction
More than 5%~(8%) reduction of fuel consumption and CO2 emission are
achievable compared with the conventional plant with steam condition of
16.7MPa×538°C /538°C.
500MW coal-fired power plant (load factor 0.75)
Plant Conventional plant Supercritical plant
Coal consumption Base - 50,000~90,000 ton/year CO2 emission Base - 140,000~230,000 ton/year
1-2 Integrated Coal Gasification Combined Cycle Plant Power Generation Coal gasification IGCC 1. Function (1) Integrated coal gasification and power generation (2) High efficiency power generation with coal (3) Environmentally friendly coal-used power generation
2. Plant system
Integrated coal gasification combined cycle
Coal gasifier
Coal feed system
Coal gas
Porous filter
Combustor
GypsumWet DeSOx
AirStack
N2
O2
Char
Air Air separating unit
Air compressor
3. Features (1) High efficiency (~50% LHV base) power generation with coal is obtainable,
resulting in less coal consumption and less CO2 emission.
Presently 250MW air-blown IGCC is being demonstrated for performance and
operability.
(2) Wide range of coal can be used for fuel.
A wide range coal is gasified in gasifier, transforming into coal gas suitable for
combustor of gas turbine.
(3) Less emission of SOx, NOx and particulate emission per kWh.
In addition, SOx is recovered as gypsum with DeSOx equipment and NOx
formation is minimized by reducing atmosphere in gasifier and low NOx
combustor of gas turbine. Dust is removed with porous filter before entering
into combustor of gas turbine.
(4) Useful byproduct-slag
1-3 Gas Turbine Combined Cycle PlantPower generation Natural gas firing Gas turbine combined cycle (GT CC)
1. Function (1) Highest efficiency is obtainable among the natural gas-fired power generation
technologies commercially available at the present (ηHHV~52%). (2) Most environmentally friendly power generation using fossil fuel commercially
available at the present.CO2 emission is less than a half of coal fired plant. (3)Suitable for large output. The output of a single shaft type CC (gas turbine
combined cycle plant composed of a gas turbine with a steam turbine on one shaft) is ~ almost 500MW.
2. System
Single shaft type CC
LP steam turbine
HRSG
Stack
Gas turbine
HP/IP STturbine
Generator
1- 4 Distributed Power & Heat Generation (Cogeneration) Power Generation of
power and heat Gas turbine, Steam turbine, Diesel engine, Gas engine, Fuel Cell
1. Function
(1) Cogeneration (combined heat and power generation or CHP) means generation of not only electric power generation, but also heat (steam and/or hot water) using the energy of exhaust gas or low temperature steam from power generation plant.
(2) As for the engine, diesel engine, gas engine, gas turbine, gas turbine combined cycle, steam turbine plant and fuel cell are used depending on quality of available fuel, steam/hot water condition required, capacity and so on.
(3) Compared with power generation plant of which energy efficiency is about 20 - 52%, much higher energy efficiency up to 80 to 90% is obtainable, saving fuel and reducing GHG (CO2) to about a half. The heat (steam/hot water) is used for refrigerating system, factory, swimming pool, bath, home uses.
2. System The following cogeneration system is an example which uses gas engine. By installing HRSG (heat recovery steam generator) to produce steam with waste heat of exhaust gas and heat exchangers to produce hot/warm water with the heat of cooling water, energy efficiency is increased from 43.5% to 72.5% while maintaining power generation efficiency of 43.5%.
Power generation efficiency: 43.5% ⇒ Cogeneration efficiency : 72.5%
(Source: HP of Mitsubishi heavy ind)
Warm waterOil
l
Cooling water Lub.oil
OptionalOilcooler
Feedwater HRSG
Exhaust
Fuel 100%
STEAM
Power
Hot water
Engine
Optional
Generator
Air
1ry cooler
Air cooler
Warm water
3. Features (1) High energy efficiency while keeping high power generation efficiency. (2) Various kinds of engines are applicable as the main engine. (3) High energy efficiency results in reduced fuel consumption and CO2 emission.
4. Energy Saving/ CO2 Emission Reduction (1) Fuel consumption is much reduced to maximum about 50% by cogeneration
from exclusive power and independent heat generation (Example: Power generation efficiency of ηg=40% is possible to be raised to ηc=80% of cogeneration efficiency)
(2) CO2 emission is reduced at the rate of ηg /ηc
Comparison of energy efficiency
Plant Power generation only Cogeneration Energy efficiency 20~50 % ~80 % Fuel consumption Base 1/2 CO2 emission Base 1/2
1- 5 High Temperature Chemical Recovery Boiler Pulp/paper industry Chemical recovery & power
generation Chemical recovery boiler
1.Function Chemical recovery boiler burns black liquor as fuel for chemical recovery boiler for power generation and recovers chemicals contained in black liquor.
2. Features (1) Elevated Steam Conditions
Our highest steam condition of 13.3 MPa, 515 is the world record.
(2)Anti-Corrosion Measures for Furnace Tubes
As a countermeasure to corrosive black liquor, one of following furnace wall
protection is used.
- 25 Cr and 18 Cr overlay weld (for high pressure boilers)
- Stud +P.C.O. (for low - medium pressure boilers)
- Composite tube (optional)
High temperature chemical recovery boiler
High temperature high pressure steam above 500°C 9.8kPa
Steam drum Super heater
Evaporator
Economizer
Steam
Feedwater pump Deaerator
Exhaust gas temperature ˂ 130°C
3ry air
FD fan
FD fan
Furnace
2ry air
1ry air
Electrostatic precipitator
ID fun
Feedwater Exhaust feedwater heater
Stack
Indirect black liquor heater
Black liquor
Steam
1- 6 Geothermal Power plant Power generation Geothermal energy Steam turbine generator
1. Outline (1) Clean power generation without fuel
Geothermal energy takes the form of high temperature water or steam that comes from deep (300 to 3,000 meter deep production wells) in the earth where it has been heated by magma. This is a high efficiency source of ecologically friendly energy for electric power generation.
(2) No CO2 (GHG) emission Eligible for CDM In geothermal electric power generation, no fossil fuel is used for generation of power since the heat energy is contained in the hot water or steam from the underground so that basically no CO2 is emitted except for that accompanied (approx. 1/20 of fossil fuel-fired power generation).
(3) Effective utilization of geothermal energy High temperature water or steam under pressure gushes out passes through separator (High pressure fluid separator) and flusher (Low-pressure fluid separator) to separate steam from high-temperature water and to produce low pressure steam. The clean steam produced at these stages is sent to steam turbine which converts the geothermal heat energy to electric power.
2. Types of geothermal power plant cycle
(1) Dry steam cycle In case dry steam comes from geothermal reservoir, the steam is directly routed to turbine generator to produce power.
(2) Flash steam cycle Hot water usually at temperatures greater than 360° F (182° C) that is pumped under high pressure to the generation equipment at the surface. Upon reaching the generation equipment the pressure is suddenly reduced, flashing some of the hot water into steam. This steam is then used to power the turbine/generator units to produce electricity. The remaining hot water not flashed into steam, and the water condensed from the steam is generally pumped back into the reservoir.
(3) Binary cycle The water from the geothermal reservoir is used to heat another “working fluid” which is vaporized and used to turn the turbine/generator units. The geothermal water and the “working fluid” are each confined in separate circulating systems or “closed loops” and never come in contact with each other. The advantage of the Binary Cycle plant is that they can operate with lower temperature waters (225°F - 360°F), by using working fluids that have an even lower boiling point than water.
3. Energy saving / Reduction of GHG emission As no fossil fuel is burnt, fossil fuel required for the power generation equivalent to that generated with geothermal energy is saved.
Example: 300MW power generation with load factor 75%
Energy source Geothermal Coal firing Fuel required 0 690×103 ton/year
CO2 emission Approx. 90×103 ton/year
1,870×103 ton/year
Emission reduction 1,780×103 ton/year Base
Present worth of ERs for 20US$/ton CO2
35.6×106 US$/year Base
As shown in the table, geothermal power generation is a very effective means of power generation to reduce GHG emission. In case that the project (300MW geothermal power generation with load factor 75%) is registered as a CDM project, the CER will worth for approx. 17.8×106 US$/year as shown in the above table.
1- 7 Amorphous-Micro Crystal Si Thin Film Solar Cell Power generation Renewable energy Photovoltaic cell
1. Function (1) Clean power generation with sunlight (renewable clean energy) with no fuel
consumption and no CO2 emission (2) Suitable for distributed power generation which can be deployed anywhere where sun
shines. 2. Structure / System
It is a thin film tandem type PVC composed of amorphous silicon layer and crystal silicon PVC layers to absorb the wider range of wavelength of sun light.
3. Features (1) Much less material required
The quantity of raw material required for amorphous-microcrystalline Si
tandem type thin film photovoltaic cell is much less than crystalline Si PVC.
The thickness is approx. 1/100 of single crystalline PVC.
(2) Excellent performance at higher temperature
It is advantageous for hot/warm region because that amorphous-
microcrystalline Si PVC produces more electricity than crystalline Si and
polycrystalline Si PVC at higher temperature (>25℃).
(3) High quality Si is not required
It does not require high quality Si as required for crystalline/polycrystalline Si
PVC, requires much less Si and less energy for manufacturing, resulting in the
most environmentally friendly PVC of all types.
4. Energy Saving / CO2 Emission Reduction
Photovoltaic power generation is a typical renewable energy power generation
technology which does not consume any amount of fuel for power generation.
Therefore the quantity of fossil fuel required for the same amount of power
generation with thermal power is saved with photovoltaic power generation
resulting in no emission of CO2.
Example: 10 MW power generation
PVC power
generation
Coal-fired power generation
Fuel consumption None Approx. 3,500 kg coal/h
CO2 emission None Approx. 9,500 kgCO2/h
1- 8 Micro water turbine plant Power generation Renewable energy
(hydraulic power)Micro water turbine
1. Function (1) Clean power generation
Power generation utilizing hydraulic power (renewable clean energy), using no fossil fuel and producing no CO2 (GHG).
(2) Suitable for distributed power generation Electric power is generated utilizing water stream of small flow rate and head, such as small river, irrigation channel, sewage water, pressure reduction and other sources.
2. Feature (1) Installation at site is simple and easy owing to the package type design.
Type: horizontal shaft propeller type (2) Maintenance is easy due to the simplified structure. (3) Appropriate selection for the needs is possible.
Generation output: 3~250kW, Flow rate: 0.1~3m3/s, Net head; 2~20m
3. Structure
Horizontal shaft propeller type water turbine generator
Source: Fuji Electric Systems Co. Ltd.
4. Energy saving / CO2 emission reduction
Example: 100kW hydraulic plant Power plant Coal-fired plant Hydraulic plant
Coal consumption Approx. 35 kg/h 0 CO2 emission Approx. 95 kg CO2/h 0
1- 9 Wind Turbine Generator Power Generation Wind turbine
1. Function
(1) Clean power generation with wind (renewable clean energy) with no fuel consumption and no CO2 emission
(2) Suitable for distributed power generation deployed where wind is available.
2,400 kW wind turbine generator and major dimensions
( Model: Mitsubishi MWT95/2.4)
2. Structure
3. Features
(1) Excellent performance in moderate wind speed zone (IEC Class ⅡA)
(2) Variable pitch control for high efficiency over a wide range of wind speed and
for wind load reduction
(3) Smart Yaw technology indigenous to MHI’s wind turbine which increases
reliability for the frequent change of wind direction
4. Energy Saving / CO2 Emission Reduction
Power generation with wind turbine does not consume any amount of fuel.
Therefore the quantity of fossil fuel required for the same amount of power
generation with thermal power plant is saved with wind power generation,
resulting in no emission of CO2.
S-4 Sintering material supply equipment S-1 Blast furnace gas (BFG) firing
gas turbine combined cycle S-6 Direct current arc furnace with S-8 Hot slab direct transfer rolling S-9 Continuous annealing furnace
S-5 Pulverized coal injection into blast S-7 Continuous casting machine S-10 Wire-rod coil convection heat treatment
S-15 High efficient ignition equipment for S-2 Blast furnace top pressure
power generation equipment S-12 High frequency electric melting furnace S-11 Tube low-temperature forge-welding
S-16 Coke oven coal humidity conditioning S-13 Cast iron electric melting groove type S-21 Continuous Annealing Furnace
S-17 Cokes dry quenching equipment S-3 Ditto S-14 High energy efficiency type alloy refining
S-18 Heat recovery from sintering machine
cooler
S-22 Energy recovery from converter furnace
exhaust
S-19 Heat recovery from sintering furnace h
S-23 Heat recovery from converter exhaust gas
Blast furnace gas holder
Factory
Dust catcher Venturi scrubber Raw
coal Coke
Gas separating unit Generator
Oxygen, secondary raw material Scrap iron
Coke furnace Molten iron
Air heating furnace Blast furnace
Sintering machine
Powder coke
Coke furnace
Coke car Coke at 200°C
High pressure steam Low pressure
steam
Exhaust heat boiler
Exhaust duster
Turbine Generator Condenser
Belt conveyor Deaerator
Circulation blower Cyclone Pure water tank
Electric furnace
Scrap iron
Molten steel
Converter
Continuous casting equipment
Billet
Bloom
Slab
Heating furnace
Major products Rail Steel sheet pile Section steel Bar
Wire rod
Plank
Hot rolled coil Hot rolled plank
Cold rolled coil Cold rolled steel sheet Steel sheet for plating Welded steel pipe Pipe steel pipe
Seamless steel pie
Cast iron products Seamless steel pipe manufacturing equipment
Welded steel pipe manufacturing equipment
Cold strip mill
Hot strip mill
Plank mill
Rolling
Strip steel mill
Looping mill
Straightforward Rolling
Soaking pit Ingot making mill
Uniform heating furnace
◎Energy consumption ratio for each process (There are portions for which energy consumption can not be expressed by a numerical value, therefore the total of each process is not always 100%.)
◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
◎Electric power saving ratio by exhaust heat power generation
Petroleum fuel Non petroleum fuel Electric power Steam
2. Steel Manufacturing
2-1 Blast Furnace Gas Firing Combined Cycle Steel / iron manufacturing Waste heat recovery Power generation
1. Function
(1) Generating electricity using blast furnace gas as the fuel
(2) High power generation efficiency obtained by installing advanced BFG fired gas
turbine combined cycle
2. Features
(1) 1.5 times of electricity generation of that with conventional power plant
(2) Utilization of low calorific waste gas as the fuel. (Approx. 1000kcal/Nm3)
(3) High reliability is assured by more than 20 years of successful operation record
4. Energy Saving / CO2 Emission Reduction
(1) Technical Features Blast furnace gas generated as the by-product of steel mill is normally used in conventional boiler or discharged via flare stack. Additional electricity can be generated with application of combined cycle.
(2) Energy Saving/CO2 Emission Reduction
Power output comparison Plant BFG-fired combined
cycle plant BFG-fired conventional
plant Coal-fired plant
Power produced
985×106 kWh 700×106 kWh 985×106 kWh
Coal fired 0 (BFG) 0 (BFG) 700,000 ton/y
CO2 emission
0 (Base) 0 (Base) 200,000 ton/y
2-2 Blast Furnace Top-pressure Power Generation Turbine
Steel/iron manufacturing Energy Recovery Expansion Turbine 1. Function
(1) Waste energy(pressure) recovery system
(2) Blast furnace gas expansion
(3) Stable plant (blast furnace) operation
2. Features (1) Power generation without combustion of any kind of fuel
(2) About 30% of energy is recoverable as electricity
(3) Simplification of plant (blast furnace) operation
3. Top pressure turbine system
Power
(Improvement)
Blast furnace gas
Blast furnace
Duster
Gas cooling system
Dust bin
Screw conveyor
Top pressure turbine
Septum valve
New
Blast furnace gas pipe
Generator
Blas
t furn
ace g
as
Cooli
ng w
ater
Dry-type dust collector (Bag filter)
Existing
4. Energy Saving / CO2 Emission Reduction
(1) Technical Features High efficiency energy recovery system for blast furnace gas with expansion
turbine.
(2) Energy Saving and CO2 Emission Reduction Approx. 30% of the mechanical energy of BFG could be recovered as
electricity.
System does not use any fossil fuel, does not produce any CO2.
2- 3 Waste Heat Recovery Power Generation Power generation Heat recovery Steam turbine cogeneration
1. Function
(1) Heat recovery from exhaust (waste) gas of which temperature is higher than 250℃ with Heat Recovery Steam Generator (HRSG) to produce steam. Various kinds of hot gases are usable for the heat recovery and steam generation. Higher the gas temperature, higher efficiency is obtainable.
(2) The steam generated by the boiler is used as the driving media of the steam
turbine coupled with the boiler. Thus steam turbine generator is operated to generate the power. Unit capacity is 1,000kW and larger. Larger the unit capacity, better efficiency is obtainable.
(3) As the heat sources are exhaust gases, usually no addition of fossil fuel is
required. In case the gas temperature is low, supplemental firing is necessary.
2. System
Exhaust heat recovery power generation
Turbine generator Condenser
Low pressure steam Preheater
HRSG
Superheater
Exhaust gas Cooling tower
Vacuum pump
Cooling water
High pressure steam
Feed water
4. Energy Saving / CO2 Emission Reduction As the waste exhaust gasses are utilized, (1) Fuel consumption is basically zero. (2) CO2 emission is zero.
Comparison of power plant and cogeneration plant
Plant Power generation only Cogeneration Energy efficiency ~30 % ~80 % Fuel consumption 0 0 CO2 emission 0 0
2-4 Cokes Dry Quenching Equipment Steel/ Iron manufacturing Coke oven Fire extinguisher
1. Function After hot coke has been manufactured in the coke oven, this equipment (coke
dry quenching (CDQ)) cools it with inactive gas, i.e., ordinary exhaust gas, in an
airtight container so that inactive gas warmed by heat exchange will be
recovered and will be used for steam or for power generation with steam as the
heat source.
2. Features For general steelmaking plants, 7% to 8% of the energy consumption is
occupied by the area of coke. Approximately 45% of this consumption is
sensible heat of hot, or red heated, coke. This equipment recovers this sensible
heat. In the conventional method, fire of this hot coke is extinguished by watering
after being taken out from the coke oven, and the sensible heat generated at that
time was emitted into atmosphere. (The equipment is called water spray type
red-heated coke cooling equipment.)
The new equipment consists of (1) a coke cooling furnace, which contains a
spare and a cooling chamber, and (2) an exhaust gas boiler. The red-heated
coke (approximately 1,200℃) enters the spare chamber, blown there from the
top of the furnace, exchange heat with the circulating inactive gas. The inactive
gas that has become hot (800℃) converts water into steam while circulating in
the heat tube of the exhaust heat boiler. The temperature of the coke
temperature decreases to 200℃ at the output port of the furnace.
Energy Saving / CO2 Emission Reduction
When this equipment is installed, steam of 0.5 t-steam/t-coke can be recovered.
Steam of 0.5 t is equivalent to approximately 150 kWh (300 kWh/t-steam).
3. Structure/System
Cokes Dry Quenching system
Hoisting column
Hoist Charging equipment
Cyclon
Coke bucket
Coke car
Coke 200°C
Conveyor Quarrying equipment
Steam
Feed water
Gas circulating fan
Duster
Improved
2- 5 Regeneration Burner Steel/ Iron manufacturing Burner Regeneration burner
1. Function Regeneration burner is composed of minimum a pair of burners. When one
burner is in operation, the other works as heat storage type heat exchanger and
also as exhaust conduit. Thus they work as a burner and heat exchanger
interchangeably recovering the heat contained in exhaust gas.
2. Features (1) Heat is effectively recovered up to 50% contained in exhaust gas.
(2) Better combustion performance of burner
As the combustion air is heated by the heat stored in the storage body
(commonly ceramics) before combustion, stable complete combustion condition
is established.
(3) As the heat storage mass works as heat exchanger, system is simplified
3. Structure/System
Regeneration burner
Exhaust gas temperature 170°C
Exhaust gas 4 direction change valve
Heat storage mass (Honey cone ceramics type)
Heat storage burner Improvement
Abcd
Raw material crashing process
Lime stone
Clay
Quartzite
Blast furnace slag
Electrostatic precipitator
Raw material silo
Hard type raw material crashing mill
Boiler
Cooling tower
Sintering process
Blending silo
Turbine Generator
Cement exhaust gas SP tower Hard type lime stone crashing
Bag dust collector
Chimney
Chimney
Chimney
Cyclone Kiln
Clinker cooler Clinker
crasher
Electrostatic precipitator
Boiler
Finishing process
Clinker silo
Lime
Spare crasher
Air separator
Finishing mill
Bag packing and shipment
Cement silo
Cement bag packer Shipment by truck (bags)
Shipment by truck (bulk)
Shipment by cement only ship (bulk)
Cement silo
3. Cement Manufacturing Process
C-2 Vertical roller mill C-1 Waste heat recovery system for cement plant C-6 Pre-crusher
C-13 Vertical roller mill for slag grinding C-3 Suspension pre-heater C-7 Pre-Grinder
C-16 Coarse coal recirculation of vertical roller mill
C-4 NSP method (calciner) cement Kiln C-8 Highly efficient cement separator
C-5 Vertical roller mill C-12 Vertical roller mill for grinding clinker C-9 Highly efficient clinker cooler
C-10 NSP method cement Kiln – Fluidized bed pre-calcining
C-11 Shaft Type Cement Kiln
C-14 Utilization of town waste as material and fuel for cement
C-15 New type clinker cooler
C-17 5-stage cyclone suspension pre-Heater
C-18 Low pressure loss suspension pre-Heater
C-19 Utilization of used tires as fuel for calcinations
C-20 Power generation with waste heat
C-21 Utilization of Used Plastics as fuel for Calcinations
◎Energy consumption ratio for each process (There are portions for which energy consumption can not be expressed by a numerical value, therefore the total of each process is not always 100%.)
◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
◎Electric power saving ratio by exhaust heat power generation
Fuel Electric
(Power generation and others) (Power generation and others)
Fuel Electric
3-1 Power Generation utilizing waste heat from cement manufacturing plant
Turbine
Electric generator
Flow of steam or water Flow of gas
Pre
-hea
ter
Kiln
Boiler
Condenser
Calciner
Clinker cooler
Sintering process Product process
Chimney
Improvement
HP/LP flasher
Dust collector
Boiler
With 3,000t/d cement plant, approx. 6,500kWpower generation is possible.
Pre
heat
pro
cess
Material process
Primary reformer
◎Energy consumption ratio for each process
◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
Fuel Electric power
Fuel Electric power
Note: In case of CA-PE-7+, both steam and electric power are reduced by 100% because no reformer is necessary.
4. Fertilizer & Chemical Manufacturing Process - 1
F-2 Exhaust heat recovery heat exchanger type primary reformer
F-6 CO oxidizing reactor F-1 Urea production technology F-3 High conversion rate synthetic reactor
F-7 Ammonia manufacturing plant integrated with high-pressure coal gasification power plant
F-10 High-pressure water power recovery turbine
F-4 Low differential pressure synthetic reactor
F-8 Synthesized gas compressor outlet heat recovery system
F-11 Pre-reformer for ammonia-reforming process
F-9 Synthesized gas compressor outlet heat recovery system
F-12 Exhaust heat recovery system for primary reformer
F-13 Gas turbine-drivencompressor for ammonia plant
F-5 Isothermal CO conversion
reactor
Gasification (reforming) process
Raw material
Heating furnace
Steam Boiler feed water
Steam drum
Steam Air
Secondary reformer
Fuel
CO2 conversion tower
CO conversion process Gas refining process
CO2 absorbing tower
CO2 stripper
Methanator
Synthetic process
Ammonia synthetic tower
Purge
compressor
Flash gas
Separator
Product ammonia
F-15 Electrolyzer with ion-exchange membrane F-14 Quadruple effect-type concentration for electrolytic caustic soda with barrier membrane
F-16 Saline solution electrolyzer with ion-exchange membrane F-17 Brine preheater with salt water electrolytic heat recovery F-18 Active cathode for electrolysis with ion-exchange membrane
◎Energy consumption ratio for each process
◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
Steam Electric power
Steam Electric power
4. Fertilizer & Chemical Manufacturing Process - 2Caustic soda manufacturing process
Raw material salt refining process
Raw material salt
Raw material salt melting and refining
Saturated salt
Refining for ion exchange membrane
Chlorine
Anode liquid tank
Electrolytic process
Anode Cathode
Anode chamber Cathode chamber
Electrolytic vessel
Hydrogen
Concentration process
Cathode liquid tank
Steam
Caustic soda
Water
Evaporating system
Caustic soda
Cooling water
Condenser
4. Fertilizer & Chemical Manufacturing Process - 3
F-19 Packing for quench tower tray F-20 Turbo expander for methane tower top gas line F-21 Cold thermal energy recovery from methane-separating tower bottom liquid
◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
Fuel Steam Electric power
Naphtha decomposing manufacturing process
High pressure steam
Steam super heater
Naphtha★Steam
Decomposing furnace
Common stack
Heavy oil cracking tower
Cracked heavy oil refining tower
Cracked heavy oil
Light heavy oil refining tower
Separated gas
Alkali cleaningtower
Compressor (1 - 3 stages)
Light constituent separating tower
Water stripper
Decomposed gas water removing
tower
Four stages
Hydrogen Methane Off gas
Ethane removing tower
Acetylene
Water reaction tower
Methane removing tower (methane
decomposing tower)
Stripper propylene tower
Acetylene water reaction tower Propylene tower
Ethylene tower Green oil decomposing tower
Ethylene intermediate tank
Recycled ethane Propylene C3LPG
Propane removing tower
Pentane removing tower
C4 -C
5 separating tower
C4 Residue Separated gasoline Rerunning tower Separated kerosene
C5 residual Separated heavy oil
◎Energy consumption of consumption ratio for each energy
Fuel, Steam Electric power
Decomposed gas cooling tower (quench tower)
Steam★
4-1 Urea Production Plant Fertilizer industry Urea production Synthesis section
1. Function (1) Urea Production
2. Structure / System (1) A urea plant is composed of five sections such as urea synthesis, purification,
recovery, concentration and product forming section.
(2) Major feature of this technology is in the urea synthesis section which contains
a reactor, a stripper and a carbamate condenser.
(3) Liquid ammonia is fed to the reactor via the HP Carbamate Ejector which
provides the driving force for circulation in the synthesis loop. The reactor is
operated at an N/C ratio of 3.7, 182 °C and 152 bar.
(4) Urea synthesis solution leaving the reactor is fed to the stripper where
unconverted carbamate is thermally decomposed and excess ammonia and
CO2 are efficiently separated by CO2 stripping.
(5) The stripped off gas from the stripper is fed to the Vertical Submerged
Carbamate Condenser, operated at an N/C ratio of 3.0, 180°C and 152 bar.
(6) Ammonia and CO2 gas condense to form ammonium carbamate and
subsequently urea is formed by dehydration of the carbamate in the shell side.
(7) Reaction heat of carbamate formation is recovered to generate 5 bar steam in
the tube side. A packed bed is provided at the top of the Condenser to absorb
uncondensed ammonia and CO2 gas into a recycle carbamate solution from the
MP absorption stage. Inert gas from the top of the packed bed is sent to the
purification section
3. Features (1) Ground Level Reactor: The sophisticated two-stage synthesis concept
employing a Condenser and an HP ejector enables the HP equipment in the synthesis section to be laid-out very compactly in low elevation.
(2) Less Corrosion: TOYO and Sumitomo Metal Ind., Ltd. (SMI) have jointly developed new duplex stainless steel DP28W™ for urea plant. The biggest advantage of duplex stainless steel is the excellent corrosion resistance and passivation property in urea-carbamate solution.
(3) Clean Effluents: The liquid effluents from the urea plant contaminated with NH3, CO2 and urea are processed in the process condensate stripper-urea hydrolyzer system. The process condensate leaving the system is purified to 1 ppm of urea and 1 ppm of NH3. The exhaust air from the prilling tower (or granulator) is scrubbed through a packed bed scrubber to reduce the urea dust content to 30 mg/Nm3-air.
(4) Easily revamp a conventional urea plant: Existing urea reactor can be re-utilized for conventional solution recycle process or ammonia stripping process
4. Energy Saving/CO2 Emission Reduction
(1) Technical Features
The operation conditions of the synthesis section have been optimized under
lower operation pressure than in the previous process. As a result, a
remarkable reduction in energy consumption has been achieved.
(2) Energy Saving/CO2 Emission Reduction
This technology realizes 30% reduction of the energy consumption in a urea
plant compared with the total recycle process and 10-20% compared with the
conventional stripping technology. As one of example, the reduction of 550,000
kcal/ton of urea can be expected by modification of the total recycle urea plant
by this technology.
4-2 N2O (Nitrous oxide) Decomposition Plant Fertilizer industry
Decomposition of N2O (GHG) N2O decomposition plant
1. What is N2O and how much is its global warming potential? (1) Nitric acid (HNO3) is an important component for synthetic fertilizers such as
KNO3 and NaNO3. (2) N2O is undesired byproduct of HNO3 production. In order to produce nitric
acid, ammonia (NH3) is oxidized into NO with catalyst. NH3 + 2O2 → HNO3 + H2O 4NH3 + 5O2 → 4NO + 6H2O 4NH3 + 4O2 → 2N2O + 6H2O 2NH3 + 8 NO → 5N2O + 3H2O
(3) N2O is a GHG of which global warming potential is 310 times higher than CO2 which is the most popular GHG mostly produced by combustion of fossil fuel.
(4) Therefore it is effective for mitigating global warming to decompose it into non greenhouse effect gases such as N2 and O2
2. How is N2O decomposed? (1) Catalytic decomposition equipment is installed between HNO3 absorber and stack. (2) N2O is decomposed while it flows through the equipment.
N2O → N2 + (1/2)O2
Fig. 1
R-1 Pinch technology
R-2 WIN TRAY R-8 Waste heat boiler for sulfur recovery
◎Energy consumption ratio for oil refining entire process Fuel and steam: 88% Electric power: 12%
◎Energy consumption ratio for each process
◎ Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
Fuel, steam Electric power
Fuel, steam Electric power
Fig. 2
Street asphalt
Air cooler
Alkylation
MTBE
Oil refining entire process
Crude oil normal pressure distillation system process (Fig. 2)
Crude oil
Naphtha
Kerosene
Light oil
Gas oil
Atmo
sphe
ric di
stilat
ion
Hydrotreater L naphtha
H naphtha
Gas
LPG recovery
Naphtha
Gasolineconditioner Refomed
gasoline Kerosene
Diesel Light oil
Gas LPG
Regular gasoline Premium gasoline Jet fuel
Kerosene
Diesel light oil
Methanol
Light v gas oil Heavy v gas oil
FCC gasoline FCC light oil
Heavy oil B
Asphalt Asphalt conditioner
Sulphur
(Fig.4)
Hydrotreater
Vacuume distlation
Fluid catakytic cracker
Atmospheric bottomsr
Hydrogen Generator
Hydrotreater
Vacuume residuum
FCC feed hydrotreater
FCC feed hydrotreater
FCC feed hydrotreater
Desulphurized heavy oil
Desulphurized heavy oil
Heavy
oil
conditi
oner
Heavy oil A
Heavy oil C
Lubrication oil process Sulphur recovery plant
5. Refinery Process - 1
R-9 Distillation column with Intermediate reboiler
R-12 Cogeneration using gas turbine exhaust gas as
combustion air for heating furnace
R-13 Rotary Regenerative Burner System
R-3 Hydro-carbon vapor recovery system
R-4 Dense loading technology
R-10 Hydrogen membrane separator
◎Energy consumption ratio for each process
◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
Fuel Steam Electric power
Common equipments Oil refining annexed equipments Hydrogen manufacturing equipments
Fuel Steam Electric power
Crude oil normal pressure distillation system process
Crude oil
Primary side reflax
Secondary side reflax
Main distillation tower
Stripper
Stripping steam Stripping
steam
Naphtha stabilizer
Gas recovery
Naphtha splitter
Recirculation tank
Light naphtha
Reboiler
Reboiler
Naphtha hydrogen treatment refining facility
Heat exchanger Heavy naphtha
Kerosene
Light light oil
Heavy light oil
Atmospheric bottoms
Fig. 3 Fig. 4
Steam
Hydrogenation desulfurization system process
Crude oil
Stripper
Recirculated hydrogen
Hydrogen
Reactor
Heating furnace
Injection water
High press. tank
Low press. tank
Fuel gas
Receiving tank
Heating furnace
Light oil
Off gas rinse
Waste water Product oil
R-6 Power recovery of CO gas R-7 Power recovery system with mixed fluid condensing turbine R-11 Heat pump type PP separator
◎Energy consumption ratio for each energy
◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
Fuel Steam Electric
Fuel Steam Electric
5. Refinery Process - 2
◎Energy consumption ratio for each energy
◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)
Fuel Steam Electric
Fuel Steam Electric power
To oil separator
Flowing contact decomposing system process
Contact reforming system process
Reaction tower
Heating furnace Raw material naphtha
Combined feed heat exchanger
Hydrogen gas
Separator
Reformate
Stabilizer Off gas
R-5 Reduction in blown steam by column top t l
Reduced pressure distillation equipment process
Raw oil
Stripping steam
Heating furnace
Steam
Quench oil
RP residuals
Steam Flash tower by RP
Light RP oil
Wash oil Heavy RP oil
Slop oil tank
Slop oil
RP light oil
Steam generator
CO boiler
Air blower
Exhaust gas cooler Exhaust gas
treater
Raw oil
Gasoline
Main
distill
ation
towe
r Low pressure evaporator
18% recover Light oil
Heavy oil
High pressure evaporator
Medium, low pressure evaporator
6-1 Methane Fermentation System Utilization of
waste Methane fermentation
Power generation Fertilizer production
1. Function (1) Sanitary treatment of food waste and animal waste,
(2) Producing methane gas from waste to generate electricity,
(3) Producing liquid fertilizer and compost.
2. System (1) Waste is put into Methane fermentation tank through receiving facilities,
(2) Methane gas produced is supplied to gas engine to generate electricity.
(3) Digestive fluid discharged from the tank is utilized as liquid fertilizer.
(4) Waste dehydrated in receiving facilities is utilized as compost.
4. Energy Recovery & Methane/CO2 Emission Reduction
(1) From 85 ton/d of waste, 2000kWh/d electric power is produced, 35 ton/d
liquid fertilizer and 15 ton/d compost are obtained,
(2) Compared with direct landfill disposal, CH4 (GHG) emission is greatly
reduced CH4+2O2 → CO2 + 2H2O
Fermentation 2000kWh/d electric power
35 ton/d liquid fertilizer
15 ton/d compost
85 ton/d of waste
6.2 Multi-Fuel (Biomass and Waste) Fired Boiler Utilization of biomass
and waste Multi-fuel fired boiler Fluidized bed boiler
1. Function
Utilization of various low grade fuels, waste and biomass such as low grade coal,
biomass (wood, bark, pulp sludge), used tire, RPF, RDF, oil cokes and others for
power generation
2. Features (1) Clean utilization of various kinds of fuels. Owing to in-furnace DeSOx system,
independent DeSOx equipment is not required. With Low NOx combustion
system and in-duct DeNOx equipment, independent catalytic DeNOx
equipment is not required.
(2) High combustion efficiency without fine grinding of fuel.
(3) Wide operating load range and excellent dynamic performance
Fluidized bed boiler system
In-duct DeNOxBiomass Waste Coal Steam turbine
Receive, store and supplyequipment of coal, biomass, waste
Limestone storage and supply system
Ash treatment system Ash treatment system
Circulatin fluidized bed boiler
6-3 Ethanol Production from Molasses and Bagasse Bio-fuel/Food Ethanol/Sugar Ethanol production from molasses and bagasse
1. Function
(1) Production of ethanol (bio-fuel) which is useful as alternative energy resource to petroleum from byproducts in sugar manufacturing process.
(2) Ethanol is carbon neutral clean energy resource which is made from bagasse which is a kind of waste produced and molasses in sugar manufacturing process.
(3) Depending on demand, production ratio of ethanol or sugar is controlled.
2. System
The system is the integration of sugar manufacturing plant and ethanol
manufacturing plant.
Sugar manufacturing factory integrated with ethanol manufacturing facility
Ethanol manufacturing facility • Molasses ethanol • Bagasse ethanol
Sugar manufacturing factory
Sugar cane Raw material Press Cane juice Concentration Crystallization
Bagasse Molasses
Raw
mat
eria
l
Raw
mat
eria
l
Product(Sugar)
Product(Ethanol)
3. Features (1) Integration of sugar manufacturing factory and ethanol manufacturing factory. (2) Effective utilization of waste bagasse for production of ethanol. (3) Control of products quantity of sugar and ethanol on market demand.
4. Energy Saving/ CO2 Emission Reduction (1) The raw material is biomass which is carbon neutral, therefore, ethanol is
essentially CO2 free. (2) Ethanol is a CO2 free alternative fuel to petroleum.
7-1 Di-methyl Ether Production Plant Environmentally
friendly fuel Organic waste
Natural gas Bio fuel
Natural gas derived fuel
1. What is di-methyl ether? (1) Di-methyl ether (DME CH3OCH3) is the simplest of all ethers.
(2) Heating characteristics similar to natural gas.
(3) DME is currently manufactured from natural gas-derived methanol. DME can
also be manufactured from methane and syngas (hydrogen and CO gas)
which are derived from natural gas, coal, oil and biomass
(4) DME is a clean-burning alternative to liquified petroleum gas, liquified natural
gas, diesel and gasoline.
(5) DME is expected to be good fuel for vehicles because of the excellent
combustion characteristics.
2. How is DME made ? Conventional DME production uses methanol dehydration method. For mass
production of DME, DME synthesis from hydrogen and CO gas (syngas) is
developed.
(1) Catalytic Dehydration of methane 2CH3OH → CH3OCH3 + H2O
(2) DME-synthesis 3 CO + 3H2 → CH3OCH3 + CO2
2CO + 4H2 → CH3OCH3 + H2O
2CH3OH → CH3OCH3 + H2O
CO + H2O→ CO2 + H2
4. Features (1) DME can be liquefied relatively easily owing to the low vapor
pressure(0.6MPa) or high boiling point(-25.1℃), being suitable for fuel for
transportation.
(2) Biomass is usable to manufacture DME in addition to natural gas, oil and coal.
CO2 emission is less than coal and oil. In case of biomass is used as the raw
material, CO2 emission is none (carbon neutral).
(3) Combustion characteristics with engine is excellent, no smoke emission and
lower NOx emission.
Therefore, it is considered that DME will become the main fuel for vehicles.
7-2 CO2 Recovery Plant - KM CDR Process Environment CO2 recovery CO2 utilization &
Prevention of global warming 1. Function
(1) KM-CDR process is a technology to capture CO2 from combustion gas from
utility and industrial plants developed by Mitsubishi Heavy Industries, ltd
(MHI) and Kansai Electric Power Co., Inc. (Kansai) in Japan.
(2) Recovered CO2 is used for;
①Chemical feedstock production such as urea (NH)2CO or methanol CH3OH.
②Enhanced oil or gas recovery by injecting it into the reservoirs.
③Sequestration of CO2 in geologic formations such as oil and gas reservoirs,
unmineable coal seams and deep saline reservoirs to avoid the increase of
CO2 in the atmosphere.
2. Plant system: The KM-CDR CO2 recovery plant consists of: (1) Flue gas pre-treatment plant, (2) CO2 recovery plant, and (3) Solvent regeneration section.
KM-CDR plant system
C.W.
C.W.Steam
Reboiler
C.W.
ABSORBER
Flue GasCooler
CO2Flue Gas
Outlet
Flue Gas
STRIPPER
Purity : 99.9 %
C.W.
C.W.Steam
Reboiler
C.W.
ABSORBER
Flue GasCooler
CO2Flue Gas
Outlet
Flue Gas
STRIPPER
Purity : 99.9 %
7-3 CO2 Capture & Storage System Environment CO2 capture and
storage CO2 sequestration
1. Function (1) Sequestration of CO2
CO2 in the combustion gas of fossil fuel is separated, captured and injected
into the underground aquifer for sequestration. So, no or minimum CO2 in
the combustion gas is emitted to the atmosphere. It is expected that no
secondary harm will be caused by the storage in the aquifer.
(2) Effect of CO2 sequestration The increase of CO2 content in the atmosphere is caused by mainly by
combustion of fossil fuel, therefore, it is very effective means to capture and
sequestrate the CO2 in combustion gas for preventing the increase of CO2
concentration in the atmosphere and mitigating the climate change.
8-1 Absorption type Heat Pump / Refrigerator Air conditioning &
refrigeration Waste heat utilization Absorption type heat pump
(1) Types of heat pump There are two types of heat pump, one is mechanical type (vapor compression
type) and the other is absorption type.
(2) Mechanical type The main components in the system are compressor (usually driven by electric
motor), condenser (heat discharger), expansion valve and evaporator (heat
absorber). The working fluid (gaseous refrigerant) from the evaporator
compressed to a high pressure and cooled in the condenser (to liquid) is
expanded to the low pressure of the evaporator by the expansion valve
evaporating and absorbing the heat from outside (cooling the outside fluid). So,
much electrical power is consumed by the compressor.
Mechanical (vapor compression) type
heat pump
Absorption type heat pump
1
4
Heat in
Input:Electricity
Engine
Heat out
Compressor
2. Compression
3. Condensation1. Evaporation
4. Expansion
Expansion valveEvaporator CondenserExpansion valve
Heat in
Evaporator Condenser
Heat outAbsorber
Heat
Regenerator
Pump
Expansionvalve
2
3
(3) Absorption type • Main components
The main components in the system are refrigerant absorber, pump, heater
(regenerator), condenser, expansion valve of working fluid, expansion valve of
absorbent and absorber cooler.
• Cycle Absorbent (water or lithium bromide is used usually) absorbs the working
medium (ammonia or water), then the pressure of the liquid is raised by the
pump. The liquid is, then heated for boiling off the gaseous working media from
the absorbent of liquid state. The gaseous working fluid is cooled in the
condenser to liquid state dissipating heat, then, it is expanded to the evaporator
pressure by the expansion valve absorbing the outside heat. Thus the driving
force of the cycle is basically produced thermally resulting in much less electrical
power requirement than the mechanical (vapor compression) type.
(4) Energy saving and less GHG (CO2) emission with absorption type As absorption type requires less electrical or mechanical energy though
requires heat for regeneration, it is higher in efficiency especially when waste
heat is available for regeneration.
Comparison of electrical power consumption
Type of HP Mechanical HP Absorption type HP
Electrical power consumption (kWh)
Large Small
Fossil fuel required None None (waste heat)
CO2 emission Large
CO2 is produced when the electricity for compressor use
is generated.
Small
The electrical power for the pump is small
(5) Application of cogeneration As waste heat is effectively utilized in absorption type heat pump / refrigerator,
the combination of power generation and refrigeration (cogeneration) is
preferable from view point of higher energy efficiency, cheaper operating cost
and less CO2 (GHG) emission (No increase of fuel consumption and CO2
emission).
8-2 Energy Efficient Cooling System with Temperature - layered Heat Storage Tank
Food & beverage industry
Cooling system Cascade type cooling system with temperature-layered heat storage tank
1. Function
(1) High energy efficiency operation of product cooling system with high temperature difference.
(2) Reduction of power consumption of refrigerating system for carbonated drink and beer.
(3) By coupling temperature layered heat storage tank, high efficiency operation of refrigerating system is obtained.
2. System The system is composed of cascade type refrigerating unit and temperarure-layered heat storage tank.
Temperature layered heat storage tank
Cascade type Refrigerating unit
3. Features (1) High energy efficiency for product cooling process is obtained.
(2) High energy efficiency operation of refrigerator is possible regardless of the
operation such as start-stop and load fluctuation of the production system.
(3) With operation adjusted for large temperature difference corresponding to the
temperature difference of product, the power consumption of pumps and other
auxiliaries is minimized.
(4) Suitable for strict temperature control required for such as carbonator.
(5) Cooling tower is useful for UHT cooling process of chiller temperature range.
(6) Further reduction of energy consumption is possible by utilizing natural energy.
4. Energy Saving/ CO2 Emission Reduction Approximately 30% of power consumption can be reduced from conventional
cooling system, resulting in the reduction of CO2 emission by about 30%.
8.3 Vapor Compression Heat Pump Food industry Waste heat utilization Vapor recompression
1. Function (1) Utilization of waste or used low temperature vapor (steam in most cases) for
producing higher temperature vapor required for concentration and volume reduction of commodity in production process.
(2) By recompressing low temperature vapor, steam in most cases, higher temperature steam is obtained with much less energy consumption, resulting in no fuel consumption and CO2 emission except for the power for compressor.
2. Features (1) Steam supply from outer source for heating of product for concentration and
volume reduction is not required resulting in simple compact plant system. (2) Waste energy contained in low temperature vapor is effectively utilized
resulting in energy saving for producing high temperature vapor. (3) Vapor recompression technology is useful for various manufacturing industries
including food and beverage, semiconductor, plating and others where waste liquid is discharged.
(4) Investment for installation of vapor compression equipment will be recovered within a few years or less.
3. Example of a system
Concentration system of liquid product
Evaporated steam at 100°C
Compressor
Motor
Heatingsteam at 110°C
Air
Condensed waterLow concentration solution tank
Concentrated product tank
Pre-heater
8.4 Compression Type Heat Pump-Ecocute Hot water production Effective use of
Electricity Compression heat pump
1. Function (1) Economical hot water production with cheaper electricity at night and its
storage for daytime use.
(2) Clean hot water production.
(3) Energy(electricity) storage as hot water (temperature~90°C).
2. Features (1) Refrigerant
Environmentally much more friendly substance CO2 than commonly used
materials previously such as CFC (R12) and HCFC (R22) is used as
refrigerant. Refrigerant, CO2, is stable natural substance, not manufactured
chemically.
(2) Coefficient of performance It is as high as about 5, which means “5” times energy (heat) is obtainable with
“1” input of energy (electricity to drive compressor).
The energy of “4” times of the input energy is absorbed from ambient air, a kind
of solar energy.
(3) Environmentally friendly hot water supply equipment
As the energy consumption is much less than fossil fuel combustion type, CO2
emission is much less also.
As electricity is used, no combustion gas is emitted being suitable for inside
installation.
(4) High economic performance
As the amount of electricity consumed is small and it is operated when the
electricity charge rate is low such as at night, the economic performance is
excellent. The investment is recoverable within a few years.