JDF Developments & Industry Initiatives
Kaoru FujimotoChairman
Japan DME Forum (JDF)
4th International DME Conference
Hilton Stockholm Slussen, Stockholm, 6-9 September 2010
2
Contents
・ Japanese Government Policies related to DME
・ Organizations and its Activities for DME
・ DME Production Technology Update
・ DME Utilization Technology Update
・ DME Promoting Activities
・ Conclusion
Government Policies related to DME
Organizations and its Activities for DME• Public organization conducting R&D on DME
• Private organization for DME promotion
4
Governmental Policies related to DMEGHG emission reduction target in 2020 has been enforced in September 2009.(exPM Hatoyama)• 25 % reduction target of GHG emission in 1990 has been announced in COP15 in Copenhagen. Law Concerning Promotion of the Development and Introduction of Alternative Energy has been amended in August 2009.(METI)• Electricity, City gas and Petroleum industries are obliged to introduce non-fossil energy. For the moment, this obligation is not applied to LPG industry.Environmental quality standards for PM2.5 is effective since September 2009.(MOE)• Annual standard for PM2.5 is less than 15.0 g/m3 and 24 hour standard less than 35g/m3. Achievement date is not yet fixed.
5
Public Organizations conducting R&D on DMENTSEL(National Traffic Safety and Environment Laboratory)• For promotion of practical use of DME vehicles, Public road running tests being conducted to evaluate durability and reliability, and to collect data for a technical guideline.AIST(National Institute of Advanced Industrial Science and Technology)• Promote Technology developments of DME fueled engine and prototype vehicle, Standardization of DME.• Research for effect of lubricity improver and impurities on engine performance.LPG Center of Japan • Promote R&D for practical use of fuel grade DME mainly in LPG market of household and commercial use. • DME/LPG mixture combustion test by existing home appliances specified to LPG.
6
Private Organizations for DME promotionJapan DME Forum• established in 2000. 36 corporate and 40 individual members.• Promote Awareness of DME and Information exchange from production to utilization of DME, Economic evaluation and LCA study, and Standardization work of fuel DME. • International activities with IDA,CDA,KDA,etc.DME Promotion Center• established in 2004 by 11 private companies(upstream).• Study of DME introduction scenario into Japan market for short- and long-terms.• Operation of a governmental subsidy program for DME boiler investment. DME Vehicle Promotion Committee• established in 2006 by 17 private companies(upstream & downstream).• Promotion of R&D for practical use of DME vehicle, DME supply infrastructure and safety tests, Standardization of DME filling station for vehicles and Deregulation for distribution network.• Study of Bio-DME production and its use for vehicle.
8
DME Production Technology (1)• Fuel DME product Co. (Japan) has constructed 80 Kt/y commercial plant at Niigata Japan, supplying Fuel DME to customers in near region.
Plant OutlinePlant OutlineProducts: Fuel grade DME
Purity 99% (according to JIS TS)Annual Production Capacity:80,000ton
expandable to approx. 100,000tonPlant Construction Amount:
Approx. 2.5billions Japanese YenFeedstock: Imported Methanol
Transportation by pipeline form Mitsubishi Gas Chemical (MGC)’s owned existing Methanolimport terminal at Niigata East Port to MGCNiigata Factory
Production Process: MGC Methanol Dehydration Process(commercially established technology)
9
DME Production Technology (2)
”DME Direct Slurry Process”(ex JFE process: one-step DME synthesis process)
Licensor: Total, Inpex, Japex, Toyota Tsusho
Originally developed by JFE, then demonstrated through multiple-year operation of 100 t/d demonstration plant by a consortium of 10 companies*, this technology is now owned jointly by the above 4 companies who are willing to work with potential partners for a commercial utilization. * the demonstration project was completed
and the plant no longer exists
10
DME Production from Multi-resourcesDME can be produced from such stranded resources as;• CO2 rich natural gas• Coal (Sub-bituminous to Lignite)
DME produced from coal emits 1.5 times CO2 by calorie of coal, but if DME is used at home as cooking fuel, life cycle CO2 is even less than coal fired cooking stove. CO2 sequestration should be integrated to DME production in future.
• Biomass Bio-DME is a Second generation Biomass fuel which has no conflict
with food supply.• Remote renewable electricity resources as Wind, Solar, Hydro power,etc.
DME has a big potential as energy carrier from remote resources.
DME Production from Biomass and its use• Bio DME was produced by bench scale plant of Hiroshima Biomass research center of AIST in the joint research project with DMEVPC. • Eucalyptus chip was gasified with oxygen enriched air(O2 31.5%) in downdraft gasifier and a part of synthesis gas was supplied intosynthesis reactor after gas cleaning. [ presented by Dr.Miyazawa]• Produced DME was mixed with DME from Niigata plant, and used for the first DME truck test run with Bio DME on May 18 at Yokohama LP Gas terminal. [ presented by Mr.Mikita]
Eucalyptus chips Downdraft gasifier DME synthesis equipment
Potential of DME as Energy carrier
Liquid H2 Liquid Ammonia
Methanol DME CO2
Formula H2 NH3 CH3OH CH3OCH3 CO2Liquid density [kg/L] 0.07 0.7 0.795 0.67 1.1Boiling point [℃] @0.1Mpa
-253 -33.4 64.4 -25 (-50)*1
Vapor pressure [Mpa] @25℃
- 1.02 0.0129 0.53 (0.7)*1
Energy density by Weight [MJ/kg]
120.8 19.2 21.1 28.8 -
Energy density by Volume [MJ/L]
8.5 13.4 16.8 19.3 -
Explosion limit [%] 4~75 15~28 6.7~36 3.4~27 -
Allowable limit of toxicity
- 25ppm 200ppm - -
*1: Marine transportation condition of liquid CO2
• DME is promising as Energy carrier from remote resource for high energy intensity by volume and safety aspect.
Conversion efficiency estimation from Electricity to DME
(1) Electrolysis of water 6H2O+Electricity→6H2+3O2
(2) Reverse shift 3H2+3CO2→3CO+3H2O(3) DME synthesis 3H2+3CO→CH3OCH3+CO2
(2)+(3) 6H2+2CO2→CH3OCH3+3H2O(4) Total system 3H2O+2CO2 +Electricity→CH3OCH3+3O2
Renewable Electricity
Electrolysis
H2Reverse Shift
CO+H2DME synthesis
DME
0.01Kmol-H2/KW (4KW/H2-Nm3)
1Kmol(CO+H2) /KmolH2
0.15KmolDME/Kmol(CO+H2)
1KW(3.6MJ) (100%)
2.4MJ(67%) 2.6MJ(72%) 2.0MJ(55%)
69g(103mL)CO2 220g(100mL)
( E-mail: [email protected] )
15
DME/LPG mixture combustion testVaporized gas composition from liquid DME/LPG mixture container• DME concentration in gas is not constant and slightly increases with vaporization. In order to keep lower than 20% in gas, initial DME concentration in liquid should be less than 15%.
Initial liquid DME concentration (wt%)
10 15 20 40
Initial DME concentration in gas (wt%)
9.4 13.7 18.8 33.7
Final DME concentration in gas (wt%)
10.9 17.1 24.8 52.1
Home appliances performance• Up to 20% DME in gas, DME/LPG mixture can be used as same as LPG for Tabletop stove, Infrared stove, Hot-water unit, 40% with minor modification (Nozzle diameter, Air damper opening and so on). • No degradation of performances for 1,000 hours (cumulative combustion time) on these appliances.
16
DME/LPG mixture combustion testThermal efficiency of LPG appliances• Thermal efficiency is almost constant, independent on DME concentration of DME/LPG mixture, a little better than that with Propane.
LPG appliance(Maximum output)
DME content in gas (wt%) DME content in liquid (wt%)
0 10 15 20 20 30 40 50
Tabletop gas stove(4.21kw)
54.0 55.7 56.0 55.3 54.8 54.9 56.4 55.3
Tankless gas hot-water heater (10.5kw)
84.2 83.2 84.2 84.5 84.6 84.7 84.4 84.4
Hot-water unit(43.6kw)
77.4 78.1 78.8 77.6 77.9 77.6 77.6 76.8
with small change of equipment
( E-mail: [email protected] )
Developing DME tolerant rubber materials
• Among the versatile rubber materials, EPDM (ethylene propylene diene Monomer) with high Ethylene content has smaller swelling-rate against DME than others.
• By blending above EPDM as base-rubber and low molecular weight Polyethylene, which has well compatibility with EPDM, Japanese firms have succeeded in developing the versatile rubber which is superior in DME tolerance.
• Based on this technology, they established two kinds of practical blend-rate having different hardness, obtained basic property and carried out tests with actual equipment. Finally, they confirmed that all these rubber materials can be used as DME sealing rubber withoutany problems.
• This result was applied to patent on January 20, 2010 in Japan.
Application No. : 2010-10037 “DME tolerant rubber composition”(E-mail: [email protected] )
18
DME Diesel Vehicle Public Road Tests• NTSEL: Medium duty truck verification road test for commercial freight
Project sponsorship: Ministry of Land, Infrastructure and TransportProject partners: ISUZU ADVANCED ENGINNERING CENTER., Niigata Prefecture, JAPAN DME, Idemitsu Kosan.Project schedule: November 2009-March 2012, 3 yearsSpecifications of Middle duty-trucks: ISUZU ELF, GVW 7.9 tons, 5.2 litre DME engine, Common rail DME injection system, 2009 H/D regulation compliantVerification road test area: Niigata and Kanto with each DME filling station supplied from Fuel DME Production Co., Ltd.
Project sponsorship: Ministry of Land, Infrastructure and Transport Running test: December 2006 - September 2009Specifications of Light duty-truck: ISUZU ELF, GVW 5.0 tons, 4.8 litre DME NA engine, Common rail DME injection system, In-tank feed pumpRoad test : Test course, high way, urbanDurability: Engine valve seat wear, injector nozzle seat wear and Oxidation catalyst deterioration were found important.Practicality: The use through the season has been confirmed. [presented by Mr.Takase]
• ISUZU: Light duty truck 100,000km without serious trouble.
[ presented by Dr.Sato]
19
Fundamental researches for DME EngineEffect of lubricity improver and impurities in DME
[presented by Dr.Oguma]
0
200
400
600
800
1000
0 200 400 600 800 1000
WS1
.4 [μ
m]
Water Contamination ratio [ppm]
Water contaminationwith LI 100 ppm
Average of WS1.4 of diesel fuel: 450μm
• Adding 100ppm of fatty acidbased lubricity improver (LI)gives diesel level lubricity toDME.
• Excess adding fatty acid basedLI increases fuel acid valuewhich is a factor of corrosion.
• Water contamination impact onwear scar of fuel injection parts.
• There is no effect of methanolcontamination on wear scar. DiskDisk
FuelFuelStroke:Stroke:1 mm x 50 Hz1 mm x 50 Hz
Y
X
Y
X
Fundamental researches for DME EnginePM emission from DME engine
• Most of PM from DME engine is generated from oils lubricating engine and injection pump, which are core of PM.
• Nano-particles number emitted from DME engine are very few level with oxidation catalyst.
• Impurities with larger carbon numbers might increase nano-particle numbers. ( E-mail: [email protected] )
20
100 120 140 160 180 200
Reference DMEwater5%Methanol5%
CPC
cou
nt [x
109 #/
cm3 ]
Time from test start [sec]
00.20.4
0.60.8
1.0
1.21.4
FAME5%
Propane5%
Developing DME High Speed Filling System
P
Pump
DME Storage Tank Filling Equipment
used for LPG VehicleDME middle/heavy-duty truck with
250 to 600 Liter storage tank
Fuel storage tank
Pressurized Filling
SystemP
Pump
DME Storage Tank Filling Equipment
used for LPG VehicleDME middle/heavy-duty truck with
250 to 600 Liter storage tank
Fuel storage tank
Pressurized Filling
System
Pressure Sensor
Pressure balanced filling systemDME middle/heavy-
duty truck
Filling equipment Integrated nozzle for filling and vapor return lines
FMP
Flow meter for liquid DME
Level sensor
Transmitter/Receiver Communicating
level signalPT2
PT1
Liquid lineVapor line
2-stage cut-off valve
Storage tank
Fuel storage tank
Pressure Sensor
Pressure balanced filling systemDME middle/heavy-
duty truck
Filling equipment Integrated nozzle for filling and vapor return lines
FMP
Flow meter for liquid DME
Level sensor
Transmitter/Receiver Communicating
level signalPT2
PT1
Liquid lineVapor line
2-stage cut-off valve
Storage tank
Fuel storage tank
Necessity to improve filling speed up to the level of Diesel oilNecessity to improve filling speed up to the level of Diesel oil
Present System
20 to 30Liter/Min.
DevelopedSystem
Secured 80 Liter/Min.
Newly developedHigh SpeedFilling Equipment
Newly developedIntegrated nozzlefor Filling and Vapor lines
(E-mail: [email protected] )
22
New Combined Process of DME to Olefins・CH3OCH3 → X → CnH2n + H2O ・Atmospheric ~ Slightly Pressurized・DME + Diluent : Reaction Control・Solid Catalyst : Zeolite (MFI) + binder + additive
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.04 0.05 0.06 0.07 0.09 0.11 0.12 0.15 0.19 0.37 0.47 0.49 0.75 1.01 1.5 2.5 3
W/F (g・h/mol)
Prod
uct d
istri
butio
n . C
.%
C2=
Ar
C6
C5
C1-4
c-C4=
t-C4=
1-C4=
i-C4=
C3=
Conv.DME0
5
10
15
20
25
30
35
40
45
0 0.5 1 1.5 2 2.5 3
W/F
produ
ct
dist
ribu
tion C
.% C3=
C4=
C1-4
C5
C6
Ar
C2=
DME+MeOH
methylationpolymerization hydrogen transfer
Crackingdesorptionadsorption
* adsorbed species
cokes
MeOH DME
C1*
C2*
Zeolite
Aromatics
C4-C2= C5-
-H2O
C3-
C3* C4* C5*
CH4
C2- C3= C4= C5=
C5*C6*
C7*
C3=
C4=
C5=
C6*
Reaction model of New Combined Process
Propylene : 45% (one pass)75~80% (recycle)
Ethylene 5~10%Aromatics + paraffin 15~20%・ Catalyst life : > 10,000 hr・ On the way to Industrialization
( E-mail: [email protected] ) 24
DME reaction Olefins Hi Olefins
Propylene
Total system performance estimation
26
Standardization Activities on DME Fuel• Standardization in Japan• JDF has worked, in 2005, drafted TS(Technical Specification) for DME
standard for industrial and power generation fuel excluding internal combustion equipment as diesel engine.
This TS will be finalized as JIS with ISO’s progress. • Fuel standards for vehicle are under study in JSAE (Society of Automotive
Engineers of Japan, Inc.). As for vehicle use, effects of impurities and additives on durability and
performance of engine are investigated.
• International Standard• JDF is cooperating on International work for DME standard since 2007 in
subcommittee SC4 and SC5 of ISO/TC28. • New committee, “National Committee for DME Fuel Qualitative
Standardization” has established to support PAJ (Petroleum Association of Japan) who is a domestic secretariat of TC28 in DME standardization field.
27
Supplementary edition of DME HandbookDME handbook was published in 2006 and its English edition in 2007. Supplementary edition will cover progress since the last publication. Japanese edition will be published in April 2011 and English edition in October 2011 before 7th Asian DME Conference.Ch.1 DME production (Production system from various resources, Production technologies and Projects)
Ch. 2 Residential use of DME (LPG/DME blend use, Seal materials, Sulfur free odorant and Development of residential DME use)
Ch. 3 Industrial use of DME (Distributed energy use and Chemical use)
Ch. 4 Transportation use of DME (Performance of DME vehicles, Effect of impurities, Lubricity improver and Rapid fueling equipment)
Ch.5 Standardization and Legislation (Standard of fuel DME and Standardization of DME utilization/ancillary system)
28
7th Asian DME ConferenceOrganizing committee has just started.Date and Venue16-18 November 2011Niigata Toki Messe Convention Center350km from Tokyo (2 hours by Shinkansen)
ConferenceProduction and consumption business Technology progressStrategy
Site visitFuel DME Production Co. 80,000ton/year DME production plantDME consumer factory Commercial-use DME vehicle and Fueling station
29
Conclusion• Coal to DME is important to supply DME as clean fuel in energy demand growing countries.
• Bio-DME is a key to open DME market in energy saturated countries as Japan.
• DME diesel vehicle can correspond to much stronger environmental regulation,such as “Particle number regulation” in near future.
• DME is also promising as chemical feedstock.
• As Potential market is so huge, International cooperation such as Standardization,DME vehicle promotion and utilization technologies can contribute to “Low Carbon World”.