clean coal technology for the future nedo’s challengepsdg.bgl.esdm.go.id/makalah/sunichi...

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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Hyper Coal Bench-Scale Uunit (0.1 t/d BSU)Hyper Coal Bench-Scale Uunit (0.1 t/d BSU)

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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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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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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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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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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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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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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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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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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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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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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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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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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

clean coal technology for the future nedo’s challengepsdg.bgl.esdm.go.id/makalah/sunichi...

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