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ENERGY ENGINEERING RESEARCH LABORATORYENERGY ENGINEERING RESEARCH LABORATORY

From High Voltage Power Laboratory to�Central Research Institute of Electric Power Industry�Takeyama Testing and Research Center (1977)

● Research using a high power short-circuit test facility�● Research on 500kV overhead power transmission lines�● Research on ultra-high voltage underground power transmission�　 lines�● Research on 250kV DC power transmission cable

The Yokosuka site is situated on the west coast (Sagami Bay) of the Miura Peninsula.�The R&D facilities are located on extensive site of 200,000m2, and employee of approximately 200 staff including core researchers in electrical engineering, mechanical engineering, chemistry and materials science in a wide range of R&D work from basic to practical applications.��On this site, Takeyama Testing and Research Center was inaugurated in 1977 as a branch of the Central Research Institute of Electric Power Industry and successor to the High Voltage Power Laboratory (incorporated foundation). Later, in 1985, the Center was reorganized into the Yokosuka Research Laboratory as a large-scale R&D base. Since then the Laboratory has been undergoing extensions along with expanding R&D activities, such as coal utilization technology and new technology for electricity utilization, as well as technology for evaluating the integrity of light water reactor materials. ��In April 2004, to further enhance its research capabilities, the Central Research Institute reorganized into eight specialized research laboratories and one research center. In the Yokosuka, three research laboratories (Electric Power Engineering Laboratory, Energy Engineering Laboratory and Materials Science Research Laboratory) were established, with new research staff joining from the Komae Site.

Summary of the Yokosuka site

Electric Power�Engineering Research�

Laboratory

Materials Science�Research Laboratory

Energy Engineering�Research Laboratory

Yokosuka Operation�&�

Service Center

Major R&D Milestones in the Yokosuka

1960s～1970s

Expansion of large research facilities as a bastion for large-scale�new technology development Yokosuka Research Laboratory�inaugurated (1985)

● Basic research on coal gasification combined cycle �● Research on ceramic gas turbine�● Basic research on molten carbonate fuel cell�● Development of new combustion technology for pulverized coal �● Research on 1000kV overhead power transmission lines�● Research for shallow underground power cables

1980s

From large-scale testing and research to a focus on extensive�basic research

● Research for practical application of coal gasification combined�　 cycle �● Research for development of molten carbonate fuel cell�● Research on gasification of new kinds of fuel�● Research on gas turbine high-temperature components �● Research on compact power transmission lines �● Research on reliability of electric power equipment using a high�　 power (including DC) short-circuit test facility�● Research for development of heat pump using natural coolant and�　 development of thermal storage medium�● Research for practical application of arc plasma �● Research on arcing horn of follow current breaking type

1990s

Toward a focus on extensive research for practical application and�assessment�High Power Testing Laboratory internationally certified by JAB�Three laboratories established in the Yokosuka site : �the Electric Power Engineering Research Laboratory, Energy�Engineering Research Laboratory and Materials Science Research�Laboratory (2004)�PD Center was inaugurated in Materials Science Research�Laboratory (2005)

● Research using multi-burner equipped coal combustion test facility�● Research on using coal gasification research equipment�● Research for advanced utilization of biomass�● Research on technical assessment of superconducting power cable�● Research on the service life of gas turbine hot components�● Research on water chemistry and materials management in light�　 water reactors�● Research on diagnostic techniques for electric power equipment�● Research on lightning protection and electromagnetic compatibility�● Development of advanced gas insulation technology�● Research on discharge induction using laser-produced plasma�● Development of all solid-state insulated transformer�● Research on T-cube laser�● Research on SCC initiation and propagation in the internal�　 structures and recircuration system piping of light water reactors�● Verification of remaining life assessment methods through actual�　 piping tests �● Research on performance evaluation of heat pump water heater�● Development of SiC semiconductor for power conditioning�● Research on dimethyl ether (DME) dewatering/deoiling�● Thermal efficiency analysis and evaluation for energy system

2000s

Central Research Institute of Electric Power Industry１１０３�

Introduction of Energy Engineering Research LaboratoryIntroduction of Energy Engineering Research Laboratory

　Central Research Institute of Electric Power Industry (CRIEPI) has reorganized its research organization

in April 2004, and Energy Engineering Research Laboratory has been established as one of the eight

laboratories in CRIEPI.�

　In Energy Engineering Laboratory, aiming at highly efficient, low cost and clean utilization of energy

resources such as fossil fuels, we are involved in research activities on energy conversion, energy storage,

energy utilization, environmental protection, biomass utilization, energy systems, and development of

elemental equipment in thermal power plant, diagnosis of plant equipment，and operation and maintenance

technologies.

　R&D on Integrated Coal Gasification Combined Cycle( IGCC) technology, operation and maintenance technology for thermal power plants and gas turbine hot gas path parts.��　R&D on high efficiency combustion, fuel upgrading, and environmental protection technologies for various fuels such as coal and biomass.��　R&D on high efficiency heat pump and thermal storage system technologies.��　R&D on high efficiency energy conversion and energy system evaluation technologies.

Sector of Research

■ High Efficiency Power Generation Sector��■ Advanced Fuel Utilization Sector��■ Heat Pump and Thermal Storage Sector��■ Energy Conversion Engineering Sector

Contents of Research

【Project Subjects】�

① Expansion of Fuel Types and Improvement of Efficiency in IGCC�

② Low Grade Fuel Utilization�

③ Advanced Utilization Technology of Biomass/Wastes�

④ Thermal Power Generation Systems with CO2 Capture�

⑤ High Performance Heat Pump

【Base Research Subjects】�

① High Efficiency Power Generation�

② Advanced Fuel Utilization�

③ Heat Pump and Thermal Storage�

④ Energy Conversion Engineering�

⑤ Numerical Analysis of Turbulent Heat Transfer and Reacting Flows


Introduction of Energy Engineering Research LaboratoryIntroduction of Energy Engineering Research Laboratory

【Contents of this leaflet】�

① Development of Coal Gasification Technology�

�

② Development of Dry Gas Purification System for High Efficiency Power Generation�

�

③ Development of Advanced Coal Combustion Technology�

�

④ Development of Evaluation Tool for Management on Boiler Tubes�

�

⑤ Advanced Utilization Technology of Biomass and Waste�

�

⑥ Thermal Power Generation Systems with CO2 Capture�

�

⑦ Development of Highly-Efficient Heat Pump�

�

⑧ Advanced Maintenance Technology of Gas Turbine Hot Gas Path Parts�

�

⑨ Developments of VOC Decomposition Catalyst�

�

⑩ Development of an Energy Efficient Dewatering and Deoiling Technology by Using Liquefied�

　Dimethyl Ether (DME)�

�

⑪ Thermal Efficiency Analysis and Evaluation Technique for Energy Systems�

�

⑫ Development of High Temperature Fuel Cells�

�

⑬ Numerical Analysis of Turbulent Heat Transfer and Reacting Flows


Development of Coal Gasification TechnologyDevelopment of Coal Gasification Technology

Fig. 1　Evaluation tool for design and operation of coal gasifierPhoto 5�

Coal gasifier for fundamental research

Photo 1�2T/D coal gasifier Photo 2�

Pressurized Drop�Tube Furnace (PDTF)

Photo 3�Ash adhesion test facility

Photo 4�Computer Controlled�Scanning Electron�Microscope (CCSEM)

Verification�test

Verification�test

Clarification and�modeling of�phenomenon

Clarification of coal/ash�properties and�

construction of database

･Reproduction of phenomenon�under actual condition�･Clarification of phenomenon�by detailed measurement

Numerical analysis of phenomenon�evaluation of influence of gasifier�

shape and scale

Verification test

Fundamental experiment Advanced analysis

Numerical simulation

Replace

Fundamental�experiment

Fundamental�experiment

Advanced�Analysis

　Coal is widely distributed & abundantly reserved, so it's possible to ensure the stable supply. However, CO2 emission from coal is larger than from other fossil fuels. The Integrated coal Gasification Combined Cycle

(IGCC) system is promising for a clean coal technology because of its high efficiency & eco-friendly performance. CRIEPI is developing the coal gasification technology that is a key technology of IGCC.

Backgrounds

･Development of air blown coal gasifier by 2T/D gasifier (Photo 1)�･Clarification of gasification reactivity by PDTF (Photo 2, Fig. 3)�･Clarification of ash adhesion characteristics by ash adhesion test

facility (Photo 3)�･Measurement of coal/ash mineral composition by CCSEM (Photo 4)�

･Development of numerical simulation technology for air blown gasifier (Fig. 4)

Clarification of gasification characteristics and phenomena in gasifier by coal gasifier for fundamental research (Photo 5, Fig. 2)�

Establishment of evaluation tool for designing and operation of coal gasifier (Fig. 1)

Principal Results

Future Developments

Relevant Research Subject : “Expansion of fuel types and improvement of efficiency in IGCC”�

･��･�


Development of Coal Gasification TechnologyDevelopment of Coal Gasification Technology

Fig. 2 Coal gasifier for fundamental research　In our 3T/D coal gasifier, gasification performances of many coal types are evaluated. Furthermore, new measurement technique, such as slag discharge monitoring system, is developed because it is important to clarify ash behavior in the gasifier, such as ash adhesion to the wall and discharge of the molten slag. These technologies are applied to the automatic monitoring system of ash behavior in gasifiers. In addition, the operation data of the 3T/D coal gasifier are important for the verification of the numerical simulation of gasifiers.

Fig. 4 Numerical simulation of coal gasifier　Recently, the numerical analysis techniques have been used in various fields with the developments in the computer technology. In our laboratory, the 3-dimension gas-particle 2-phase fluid analysis technique has been developed. The above figures show the examples of the numerical simulation for the 2T/D gasifier. The gas temperature distribution, gas concentration distribution and particle path are clarified as the left figure. The right figure shows the estimation of the gasification performance and the slag discharging performance correlating to the operating parameters of the gasifier. This map is helpful to increase the gasification performance and to maintain stable operation, and provide information for the optimum operation.

Fig. 3 The gasification rate analysis with PDTF　It is expected various coal are used in IGCC plants. It is necessary to clarify the gasification reaction rate on the high-temperature and high-pressure conditions for each coal, and to examine operating conditions of gasifiers.�　The gasification reaction rates of five coals were measured by the PDTF. The large differences in gasification reactivity between coals were observed. They are important data for the suitable design and operating conditions of gasifiers.

Specifications of coal gasifier�for fundamental research

Gasifier type : Pressurized entrained flow�

Fuel feed : Dry feed system�

Fuel capacity : 3 Ton/Day�

Operating pressure : 2 MPa�

Gasifying agent : Air, Oxygen, Steam

3. Probe and test panel to�　evaluate ash adhesion�　characteristic

4. Sampling probe of�　gas and particle in�　gasifier

1. Thermometer�2. Heat flux probe

8. Probe to evaluate performance�　of heat exchanger tube

Char feed�facility

Pulverized�coal feed�facility

Pulverized�coal

N2, O2, Air,�CO2, Steam

O2 and N2 feed facility�Air compressor boiler

Recycle char

Burner arrangement�is changeable

7. Monitor of slag flow condition

6. Dust sampling�　unit

5. Online gas�　chromatography

Gas cleanup�facility

Temperature Particle path & mass

Reductor

Combustor

The filled area is the unstable operation�area because of high slag viscosity.

Return to【Contents of this leaflet】


　Dry gas purification system is important technology for improving thermal efficiency of integrated coal gasification combined cycle (IGCC) power generation. The technology enables to attain high efficiency and environmental compatibility of IGCC by removing various impurities

(halides, sulfur compounds, mercury, and ammonia) from the coal derived gas at high temperature. We developed suitable processes for above impurities and are optimizing the system by combining the processes.

Backgrounds

　CRIEPI has developed halide sorbent, zinc ferrite desulfurization sorbent, copper based mercury sorbent, and ammonia decomposing catalyst for IGCC application. The process sequence of the purification system was determined by considering the operation temperature and

performance of the sorbents and catalyst. The system configuration proved to be rather simple equipment while the purified gas has extreme purity. We also launched research on the improved system for high efficiency IGCC adopted to CO2 capturing.

Principal Results

　We proceed with ( i ) halide removal reactor design with low pressure drop and sorbent exchange function, ( ii ) development of mercury removal process using regenerable sorbent, ( iii ) studies of catalyst lifetime extension for NH3 decomposition and optimization of an NH3

decomposition process, and aim at realization of a fully dry gas purification system, that is combined with dry desulfurization process, optimized for IGCC.

Future Developments

Development of Dry Gas Purification Systemfor High Efficiency Power GenerationDevelopment of Dry Gas Purification Systemfor High Efficiency Power Generation

Relevant Research Subjects : “Expansion of fuel types and improvement of efficiency in IGCC”,�　　　　　　　　　　　　　“Thermal power generation systems with CO2 capture”�

Fig. 1 Scheme of the dry gas purification system and target impurities ( indicated by blue hatch)　Sequential removal of halides, sulfur compounds, mercury from raw gas derived from the gasifier, followed by NH3 decomposition and dust polishing removal provides clean fuel gas to gas turbine.

Cu-based mercury sorbent・Honeycomb sorbent containing� CuS (28mm sq. , 5mm pitch)�・Regenerable for multi-cycle use.

Zinc ferrite desulfuriation sorbent・Honeycomb sorbent containing� ZnFe2O4 (75mm sq.×475mmL)�・Regenerable for multi-cycle use.

Halide sorbent・Halide sorbent containing� NaAlO2 (3.5mmφ×6～10mm)


Development of Dry Gas Purification System for High Efficiency Power GenerationDevelopment of Dry Gas Purification System for High Efficiency Power Generation

Fig. 4 Removal performance of halide sorbent　HCl and HF were concurrently reduced below 1ppm by passing the fuel gas through the packed column of halide sorbent.

Fig. 5 Enlarge operation range of zinc ferrite sorbent　Procedure is developed to provide performance for reducing sulfur compounds below 1ppm by eliminating carbon deposition effect under high CO concentration condition.

Fig. 7 Catalyst property for NH3 decomposition　A highly active and selective catalyst which achieves target level from 300 to 350℃ was found out in testing of prepared catalysts with practicable pellet shape.

Fig. 6 Image of mercury removal process　Removal and regeneration processes are repeated using alternately two reactors that are filled with the Cu-based sorbent. Released mercury in the regeneration process is condensed into activated carbon at low temperature.

Fig. 2 Evaluation of desulfurization performance in coal gas Optimization of operation condition is attained by evaluation of the sorbent performance in the actual coal gas derived from the gasifier.

Fig. 3 In situ XRD for analyzing reaction mechanism The instrument reveals the effect of coal gas composition on desulfurization sorbent by observing change in crystal structure at high pressure and high temperature condition.

※These instruments for the sorbent evaluation were introduced by the fund from research contract with NEDO.

Gasifier

Controller and�power supply

Data analyzer XRD instrument

Reactor

Reactor for honey�-comb sorbent

Gas�tube

Synthesized Fuel Gas�Temp.: 300℃�Press.: 0.1MPa�Gas flow: 180m3N/h

Fixed-bed�reactor filled�with sorbent

Concentration of HCl, HF [ppm]

Relative desulfurization rate [ －]

NH3 conversion to N2 [%]

Operation Time [h]Steam concentration [vol%]

Catalyst temperature [℃]

HCl injected

Ni/ZSM-5 catalyst�(φ4mm×L4mm)�　Pressure : 0.9 MPa�　S.V. : 20,000 h-1�　H2 : 10.5%, CO : 28.4%�　CO2 : 3.6%, H2O : 3.1%�　NH3 : 0.104% /N2�　O2/Fuel : 0.008mol/mol

Target level

＊ Carbon deposition was prevented�　 in all condition except at 500℃ and�　 H2O 5vol%.

HF injected

outlet HCl, HF

inlet HCl

inlet HF�(batch measurement)

Target level of�the reaction rate.

Regeneration�process�(250℃)

Removal�process�

(120～200℃)

Hg-free gas

Release

Activated carbon

Regeneration�Gas (1%-O2)Gasification�

Gas (Hg)

Cu-based�sorbent

Cu-based�sorbent



Development of Advanced Coal Combustion TechnologyDevelopment of Advanced Coal Combustion Technology

Fig. 1 World wide fuel reserves　Recoverable reserves of coal are the most abundant among the fossil fuels.

Fig. 2 Advanced coal combustion technology　As Compared with conventional coal combustion technology, NOx is reduced to half with same unburned carbon concentration in fly ash.

Recirculation flow

NOx reduction area

Combustion�accelerating area

Unburned carbon�reburning area

Secondary�combustion air

Tertiary�combustion air

Multi-stage injection of over fire air

Pulverized coal�

+�

Primary air

Swirl�vane

500�

400�

300�

200�

100�

0

250�

200�

150�

100�

50�

0

Recoverable Reserves�

( 109tonnes of Oil Equivalent)

Reserves/Production ratio �

[years]

COAL OILsource : World Energy Council 2009

Natural Gas

　Among various fossil fuels, coal is abundant and widely produces throughout the world; thus, it is one of the most important energy resources from the viewpoint of energy security. (Fig. 1). Pulverized coal

fired power generation is the most commonly used technology in Japanese coal fired power station. In this technology, it is important not only to reduce NOx and unburned carbon emission but also to promote the use of low rank coal such as sub-bituminous coal, to cope with the tightness of supply and demand for high-quality bituminous coal. On the other hand, to reduce CO2 emission, it is necessary to promote the use of biomass. Moreover, the flexible operation to load change will be required as nuclear power generation increases.

Backgrounds

( 1) The combustion technology to reduce both unburned carbon concentration in the ash and low NOx concentration was developed to apply to both the single combustion of bituminous coal and the

blended combustion of sub-bituminous coal (Blended ratio : 30%) (Figs. 2, 3). Now, the combustion technology to increase the blended ratio to more than 50% have been developed. �

(2) Tools for estimating NOx concentration and unburned carbon concentration in the ash were developed (Fig. 4). The estimation methods for ash properties, fouling & slugging and the sulfidation corrosion have been developed.�

(3) The characteristics of NOx and unburned carbon emission at co-firing of woody biomass and bituminous coal were clarified (Fig. 5). The combustion technology to increase the blended ratio of biomass have been developed.

　The advanced coal combustion technology, which enables both the use of low grade fuels such as sub-bituminous coal, biomass and the flexible operation to cope with the request of load change, will be developed

using coal combustion test facilities (Fig. 6), the laser diagnostics technology such as the measurement of coal particle velocity at a furnace and computer simulation technology on the basis of numerical analysis.

Principal Results

Future Developments

：Reserves�

：R/P RatioLignite

Sub-�Bituminous

Bituminous

Relevant Research Subjects : “Low grade fuel utilization”,�　　　　　　　　　　　　　 “Advanced utilization technology of biomass/wastes”�


Development of Advanced Coal Combustion TechnologyDevelopment of Advanced Coal Combustion Technology

Fuel Supply Equipment

Coal feed rate : 300kg/h�(100kg/h x 3 burners)

Coal brand

Coal�Operating�Instance�Search�System

Coal Adaptability Evaluation System

- Spontaneous combustibility�- Graindability�- NOx emissions and unburned� matter in the ash�- Coal ash characteristics

Coal Properties�Database

Equipment�operating

conditions

Power Plant�Unit Database

Coal Use Results�Database

Coal properties

Adaptability Evaluation�based on actual�operational data

Adaptability Evaluation based on�output from the assessment system

Temp. controller�(Simulated GGH)

Temp. controller�(Simulated GGH)

ESP

De-NOx

De-SOx

Alkali cleaning flue gas�treatment equipment

Stack

Water-cooled�Gas Cooler Bag Filter

Pulverized Coal�Refuse�Biomass AH

Furnace

Research data

Combustion test data�Basic experimental data

Fig. 6 Coal combustion test facility　CRIEPI has two coal combustion test facilities. One has a single burner system (100kg-coal/h) to investigate the combustion characteristics. Another (Fig. 6) has a three burners system (100kg-coal x 3 burners) and the flue gas treatment system simulates that of the actual power station. In this facility, pulverization, combustion characteristics and trace element behavior etc. are investigated.

Fig. 3 In-furnace blending combustion technology　As compared with the conventional blending before combustion, NOx and unburned carbon emission can be reduced using the in-furnace blending burning the coal (Coal A) of higher volatile content at upper burner stage and the coal (Coal B) of lower volatile content at lower burner stage.

Fig. 4 System for evaluation of coal�　　　adaptability to power station

　NOx concentration etc. are estimated from coal properties and combustion conditions etc. on the basis of accumulated actual boiler's data.

Fig. 5 Combustion characteristics at�biomass co-firing　　

　The coal mixture containing cedar chips of 5%-calorie could be burned well when the mixture was pulverized well.

Test facility�Air ratio 1.24�Two staged combustion 30％�Blened ratio of cedar chip 5％�

Test facility�Air ratio 1.24�Two staged air ratio 30%�Coal A (Blended ratio 33％)�　　　 (Fuelratio 1.0)�Coal B (Blended ratio 67％)�　　　 (Fuel ratio 1.9)

Commbustion efficiency : the�ratio of energy released at�combutsion to the potential�chemical energy of fuel

NL coal�conbustion

Cedar chip�co-firing

NL coal�conbustion

Cedar chip�co-firing

Combution efficiency [ %]

NOx concentration ( O26%) [ppm]

NOx concentration ( O26%) [ppm]

Unburned carbon concentration [ %]

Boiler

Two staged�combustion air

Two staged�combustion air

CoalA+B CoalB

CoalB

CoalA

CoalA+B

CoalA+B

Conventional�blending

In-furnace�blending Conventional�

blendingConventional�blending

In-furnace�blending

In-furnace�blending



Development of Evaluation Tool for Management on Boiler TubesDevelopment of Evaluation Tool for Management on Boiler Tubes

　We are dealing with the performance evaluation of newly constructed

power plants, the solution for aged power plants deterioration and the

various kinds of troubles about pulverized coal thermal power plants

mainly. Various problems are studied synthetically by specialists in various fields ( for instance, heat transfer,

combustion, material, and chemistry, etc. ) .

Backgrounds

　In our research laboratory, we are making tools with our knowledge

to find a solution for various problems quantitatively and easily.�

�

(1) Development of "Boiler operating condition evaluation program"�

　The program that analyzes the plant operation data and evaluates the boiler operating condition by

general purpose Windows PC was developed. This program has the several functions which are the

analysis for thermal absorption ratio of each heat exchanger panel, the analysis for temperature

distribution of combustion gas along the cross direction of boiler, and the analysis for amount of

accumulation damage of water wall tubes etc. (Fig. 1) .�

(2) Development of "Sulfide corrosion environment evaluation program"�

　The evaluation program which has "function to estimate corrosion structure from measured combustion

gas composition in boiler furnace" and "function to estimate combustion gas composition from the

operating condition of boiler" etc. was developed (Fig. 2). And the corrosion test results in the laboratory,

investigation reports of the sulfide corrosion conditions in regular boiler inspection and analysis data of

the combustion gas concentration under operation etc. are continuously stored and analyzed.�

(3) Correspondence to newly constructed and aged thermal power plants�

　Various results for the thermal power plant boilers have got in our research institute. For example, the

performance evaluation results by heat transfer analysis to newly constructed thermal power plants, the

solutions for aged boilers performance deterioration, for instance the temperature rises of the boiler

exhaust gas, and investigation into the cause and the proposals of the solution technology about various

troubles (Fig. 3).

　We try to propose the utilization method of our developed "Boiler

operating condition evaluation program" and "Sulfide corrosion

environment evaluation program" to each thermal power plant.�

　In the sulfide corrosion research, the corrosion test data by our sulfide corrosion test apparatus is

continuously stored, and we try to develop the tool that is quantitatively appreciable of the amount of sulfide

corrosion from the operating condition of the boiler.�

　We keep storing and classifying about analysis results and know-how in studies for actual boiler, and try to

extract of the problems and to develop the countermeasures.

Principal Results

Future Developments

Relevant Research Subjects : “Low grade fuel utilization”, “High efficiency power generation”�


Development of Evaluation Tool for Management on Boiler TubesDevelopment of Evaluation Tool for Management on Boiler Tubes

Fig. 1 Example of evaluation result of�　　boiler tube damage amount

Fig. 2 Example of evaluation result of�　　　sulfide corrosion environment

ASME Sec.ⅢSS-NH

future

pastAccumulated creep damage [-]

Accumulated thermal fatigue damage [-]

Present

8years

32years

21years

0.10

0.05

0.000.0 0.2 0.4 0.6 0.8 1.0

The past state at each regular inspection�Chemical cleaning interval 2years�Chemical cleaning interval 3years�Chemical cleaning interval 4years

Fig. 3�Measurement situation of combustion�gas temperature around boiler

Development of�"Boiler operating condition evaluation program"　This program has the several functions which are the analysis for thermal absorption ratio, temperature distribution of combustion gas, and amount of accumulation damage of water wall tubes etc.. The fig.1 shows�① The estimated cumulative damage amount in the present (◇)�② The forecasted state in the future on changing the chemical cleaning interval (×▲■)�　This result shows that the chemical cleaning interval of four years makes the creep damage increase rapidly.�　This analysis can execute even if the load pattern in the future or the water treatment method (AVT and CWT, etc.) and so on changes. And, it is possible to execute these analyses on general-purpose Windows PC.

Development of�"Sulfide corrosion environment evaluation program"　The evaluation program which is able to estimate corrosion structure from combustion gas composition and to estimate combustion gas composition etc. was developed.�　Fig. 2 shows the image of corrosion environment transition for decrease of oxygen concentration at outlet of boiler. In this example, the corrosion environment shifts from a current oxide scale generation area (●) to the sulfide scale generation area (◆) where the corrosion rate is fast.�　And, it is possible to execute these analyses on general-purpose Windows PC.

Correspondence to the newly constructed and the aged thermal power plantWe propose the problem solution by the analysis of the plant data and using our special measurement results.

Performance evaluation of newly�constructed thermal power plant

Solution for the boiler�performance deterioration on aged�

thermal power plant

Proposal of investigation�into the cause and solution�technology to trouble

Evaluation concerning balance�of the thermal absorption and�the combustion gas temperature�

in boiler

Analysis and evaluation of�heat flux distribution and�temperature of boiler tubes

Evaluation technique of�generation characteristic of�NOx and unburned�

carbon amount in coal ash

Measurement of combustion�gas temperature and�composition in boiler

Investigation of the boiler�tubes condition in regular�

boiler inspection

[ Analysis ]

[ Measurement and Investigation ]

etc.

etc.

Log (Oxygen Partial Pressure) [Pa]

Log ( Sulfur Partial Pressure) [ Pa]

Substrate�Temperature : �500℃�

Region Ⅰ�

Region Ⅱ�

Region Ⅲ�

Current state

Sulfide and Oxide Scale

Sulfide Scale

Oxide ScaleDecrease of O2 concentration�

at outlet of boiler

O2 -0.6%

O2 -0.3%



Advanced Utilization Technology of Biomass and WasteAdvanced Utilization Technology of Biomass and Waste

　The biomass which is derived biological materials has received an

attention as a renewable energy, so the development of the utilization

technology of the biomass is expected. The biomass co-firing in the coal-

fired power plant is one of highly effective utilization technologies of the biomass. However, the collection of

biomass is a big problem because a large amount of biomass is required for the biomass co-firing. CRIEPI is

working on the development of the technologies for the carbonized gasification of biomass/waste, the indirect

heating gasification with the molten carbonate and the storing safety evaluation of a large amount of biomass.

Backgrounds

(1) Biomass/Waste Carbonized Gasification Test Facility (Fig. 1)�

The synthesis gas generated from the woody biomass and the

coffee dregs was supplied to the gas engine generator (output

320kW), and the power generation tests were carried out. As the result, the generating efficiency of the

total power generation system reached 23-25% (HHV). Additionally, the test results of the carbonized

gasification by PKS (palm kernel shell ), EFB (empty fruit bunch) and JSD (Jatropha seed dregs) showed

a good performance.�

(2) Indirect Heating Gasifier with Molten Carbonate�

The indirect heating gasifier in which the gasification reaction heat is indirectly supplied through the

heat-transfer medium is able to generate the syngas of high calorific value compared with the direct

heating gasifier. We are developing the indirect heating gasifier (Fig. 2) in which the molten carbonate is

used as heat-transfer medium. The feature of the gasifier is that the tar decomposition, the

desulphurization and the dehalogenation are possible in parallel.�

(3) Storing Safety Assessment of Biomass�

There is worry of the gas evolution and the ignition by the spontaneous heating when a large amount of

biomass is stored. To formulate a guideline of the storing safety of biomass, we developed the test facility

that is able to simulate an actual stored condition of biomass. The accelerated storing test of RDF was

carried out, and we have succeeded in the confirmation of CO generation due to the spontaneous heating

(Fig. 3).

　To promote the use of low-grade biomass, we will develop the

gasification technology to convert the biomass into high-quality gas

available as chemical feedstock, and work on the research to create the

guidelines for the storing safety of biomass.

Principal Results

Future Developments

Relevant Research Subject : “Advanced utilization technology of biomass/wastes”�


Advanced Utilization Technology of Biomass andWasteAdvanced Utilization Technology of Biomass andWaste

b) Biomasses Used for Gasification Testsa) Biomass Carbonized Gasification Test Facility

b) Spontaneous Heating Property of RDFa) Biomass Storing Safety Evaluation Test Facility

b) Conceptual Diagram of Power & Liquid Fuel Production�System with Indirect Heating Gasifiera) Indirect Heating Gasification Test Apparatus

Biomass

Carbonizer

Reformer・Tar Cracking�・Desulphurization�・Dehalogenation

Pyrolysis Gas Syngas

Air Combustion�Gas

Combustion�Gas

Exhaust�Gas

Char

Dimension W1800 x D1050 x H1960Dimension W1800 x D1050 x H1960

Fuel FeederFuel Feeder

CombustorCombustor

Molten�Carbonate�Tube

Molten�Carbonate�Tube

Char�CoolerChar�Cooler

Char FeederChar Feeder

CarbonizerCarbonizer

Auxiliary�Fuel FeederAuxiliary�Fuel Feeder

Demo Test Section Basic Test Section

Cedar Pellet Coffee Dregs

PKS JSD

Fig. 1 Advanced Biomass Carbonized Gasification　Advanced biomass carbonizing gasification system (ABCG), which combines the highly effective carbonization process using waste heat of the system and the high temperature gasification processes where enables tar reforming and molten-slag discharging, are developed.

Fig. 3 Storing Safety Assessment of Biomass　Photograph shows the storing test facility. The left container is the demonstration test section and the right two containers are the evaluation test sections for basic spontaneous heating phenomena.

Fig. 2 Indirect Heating Gasifier with Molten Carbonate　Photograph shows a prototype testing apparatus. The moisture content in the biomass acts as a gasifying agent, and the product gas with high hydrogen concentration is obtained.

Combustor

Power�Generator

Gas to�Liquid

Temperature degC

CO Concentration ppm

Days

Inlet Air Temperature�

RDF Temperature�

CO Concentration

Spontaneous Heating by�Fermentation and Oxidation

Spontaneous Heating�by Chemical Adsorption

CO due to�Spontaneous Heating



Thermal Power Generation Systems with CO2 CaptureThermal Power Generation Systems with CO2 Capture

　In order to control global warming, electric utilities are required to

reduce CO2 emission from coal fired power stations. Therefore,

development and introduction of high -efficiency power generation

system and biomass utilization are promoted. In recent years, CO2 Capture and Storage (CCS) has been

attracting attention as an effective control measure for global warming. In Europe, the United States and

Australia, various CCS projects have been announced. However, conventional CCS technologies can't cope

with significant drop of generation efficiency and expensive cost for construction and operation.�

　To offer a futuristic option that solves these problems, CRIEPI has proposed newly developed "Oxy-fuel

IGCC system" (Fig. 1). The "Oxy-fuel IGCC system" is a combination of "O2 -CO2 blown gasifier" and "Oxy-fuel

closed gas turbine*1" (Fig. 1 , 2). This system is quite simple and expected to achieve high efficiency more

than 40% (HHV) even after CO2 capture (Fig. 3). [M07003] . In this project, we evaluate the feasibility of this

system, and clarify development issues and necessary elemental technologies for practical use.

＊1 : Oxy-fuel IGCC and Oxy-fuel closed cycle GT are improvement of Oxy-fuel combustion. Recycled exhaust gas is used as coal reaction agent with adding necessary amount of O2, therefore CO2 concentration in exhaust gas is almost 100% and CO2 separation unit is not required.�

＊2 : Char is small particle which consists of carbon and ash content, evacuated from gasifier after pyrolysis or gasification.

Backgrounds

(1) Modeling of char gasification for the O2 -CO2 blown gasifier�

We developed reaction model for char*2 gasification, applicable to

"O2 -CO2 blown gasifier" whose partial pressure of both CO2 and H2O

are quite high. This model evaluated reaction rate of char gasification with high accuracy. Simple

numerical analyses with this model proved that carbon conversion efficiency in reductor part of O2 -CO2

blown gasifier is 10 points larger than that of Air blown gasifier (Fig. 4) [M09014] .�

(2) Optimization of the dry gas desulfurization process�

CO concentration in this gasifier is so high (approx. 60vol%) that countermeasure for carbon deposition,

which deteriorates desulfurization catalyst, is required. We clarified boundary conditions for carbon

deposition phenomena, and evaluated effect of gas temperature and moisture content on desulfurization

and carbon deposition characteristics in order to optimize the desulfurization process [M09015] .�

(3) Fundamental issues and guideline for design of Gas Turbine (GT) combustor�

This system requires "oxy-fuel closed cycle GT", in which recycled flue gas (mainly CO2 and H2O) with

additional O2 is used as combustion air. The concept of this GT is so different from conventional GT, we

reviewed fundamental issues to design this GT combustor (Table 1). [M09009] .

・In order to simplify this system and improve the performance of

gasifier, we clarify O2 -CO2 gasification characteristics by gasification

experiments at 3TPD gasifier and numerical simulation.�

・In order to optimize "Oxy-fuel IGCC system", we evaluate GT combustion characteristics, carbon deposition

characteristics and we develop countermeasure for carbon deposition.�

・We evaluate the feasibility of this system and clarify necessary technologies for practical use.

Principal Results

Future Developments

Relevant Research Subject : “Thermal power generation systems with CO2 capture”�


＊Diluent is needed to control the flame temperature in oxy-fuel combustion system.

Fig. 1 Concept of "Oxy-fuel IGCC" Fig. 2 Detailed schematic diagram　The "Oxy-fuel IGCC system" is a combination of "O2-CO2 blown gasifier" and "Oxy-fuel closed gas turbine" (Fig. 1, 2). This system is quite simple and is expected to achieve high efficiency more than 40% (HHV) even after CO2 capture.

Fig. 3 Comparison of efficiency drop by CO2 capture�(In case of 1300 degree-C GT)

Fig. 4 Simple numerical analysis�results of the reductor ( the part where�char gasification mainly progress)�of the 2 stage entrained bed gasifier　Carbon conversion of O2-CO2 blown gasifier is expected to be much higher than that of air blown gasifier because of high CO2 partial pressure.

Table 1 Comparison of GT Combustor for Oxy-fuel IGCC and for conventional Natural Gas Combined Cycle.

a) Conventional pre-combustion b) oxy-fuel IGCC

Source:“Cost and Performance Baseline for Fossil Energy Plants”,DOE/NETL-２００７/１２８１�

Fundamental issues written in red for design have been clarified by comparing with conventional GT combustors.

Thermal Power Generation Systemswith CO2 CaptureThermal Power Generation Systemswith CO2 Capture

Coal

Oxygen

OxygenCO2

CO2

CO2

GasifierGas�

Clean Up

Gas�Turbine HRSG

Steam Turbine

Compression

Storage

O2/CO2�Blown�Gasifier

Coal�Gasifier

Dust�Filter

Hot�Desulfurization

Combustor

Com-�pressor

Comp Comp Comp

Gas�Turbine

Steam�Turbine

Steam�Condenser

Regenerative Heat�Exchanger

Heat Exchanger

Closed Gas�Turbine�

(Combustion�with O2/CO2)

Easy Removal of Halogen and Mercury at Low Temperature

CO2

CO2+H2O

O2

Coal

CO2�Storage

HRSG

Steam Turbine System

SteamSteam

Mist�Separator

Water�Scrubber

Hg�Removal

Air Separation�Unit

Net Power Output MW

Net Power Output MW

Net Thermal Efficiency ( HHV) %

Net Thermal Efficiency ( HHV) %

Net Thermal Efficiency

Net Thermal Efficiency

Net Power Output Net Power Output

NO NOGE CRIEPISHELLYES NO YES YESCO2 Capture CO2 Capture

Gasifier Gasifier

Carbon conversion efficiency�

in the reductor ( CCER) [%]

Temperature ( T) [℃]

Residence time [s]

T(Air blown)

CCER(Air blown)

T(O2/CO2blown)

CCER(O2/CO2blown)

Working Medium

Oxy-fuel IGCC�(Closed Cycle GT)

0～100vol.%�(Controllable)

Lower than 3080℃�(Controllable by O2 Concentration)

φ≒1 (Stoichiometric Combustion)�Reducing O2 in exhaust is needed for CO2 separation.

Ingenuity for reducing NOx conversion ratio is�required when the fuel includes nitrogen.

Even if flame temperature becomes high, as partial�pressure of N2 is so low that NOx concentration�does'nt become high. Therefore countermeasure is�

not required. (Non Premixed combustion)

21vol.%�(Not Controllable)

2219℃�(Not Controllable)

φ≒0.5 (Oxygen Rich Combustion)

The little nitrogen content in the fuel eliminates the�need for NOx reduction.

If flame temperature becomes so high,�large amount of NOx formed,�

that countermeasures are required.�(Premixed Combustion/Stratified Combustion)

diluent * Exhaust Gas (CO2+H2O)CO2Coal Syngas

OxygenFuel

NGCC (Natural Gas Combined Cycle)�(Air Breathing Open Cycle conventional GT)

Oxygen Air

Natural Gas (Major Conp.:CH4)Fuel

Fuel NOx

Thermal NOx

Local Maximum Temp.

O2 Concentration at�Combustion Zone

Equivalence Ratio�(at Combustor Exit )

Ｎ

Ｏ

ｘ�



Development of Highly-Efficient Heat PumpDevelopment of Highly-Efficient Heat Pump

Fig. 1 Features of CO2 and results�　 of performance analysis

　The graph represents analytical COP comparison between R22 and CO2 for hot water supplying. Y-axis means COP (= heating energy to water/electricity input), and x-axis means output temperature of hot water ( inlet temperature is 10℃).�　Bar graph shows COP when output temperature is 65℃. COP of CO2 is 15% higher than that of R22. CO2 T-S diagram in the figure shows that irreversible loss is small because of no condensation on heat transfer super critical CO2 to water.�　When water is heated above 65℃, R22 could be decomposed. CO2 has a potential of heating water above 85℃ with high efficiency, because its temperature dose not go up so high and it is difficult to decompose.

　Heat pumps, which are used as air-conditioning and hot water supply of residence and building, are promising technologies for reduction of CO2 emissions and energy conservation. However, fluorocarbons used as

refrigerant are controlled to prevent the destruction of the ozone layer and the emission of greenhouse gases. So CRIEPI focused on "natural refrigerant" and then especially has been involved in research about CO2 heat pumps. CO2 is a no-ODP*1 and low-GWP*2 chemical and neither toxic nor flammable.

Backgrounds

　CO2 becomes super-critical condition in high-pressure side because of low critical temperature (31℃), when it is used for air -conditioning and hot water supply. CRIEPI found that CO2 refrigerant had good

characteristics on supercritical condition to supply hot water (Fig. 1). Moreover CRIEPI demonstrated that CO2 cycle could be operated and controlled with conventional technologies like inverter motor driven compressor and auto expansion-valve by using the CO2 refrigerant heat pump apparatus (Fig. 2). Through these basic studies in CRIEPI, joint development of CO2 heat pump water heater for residential use started under the collaboration with electric power company and manufacturer in 1998. As a result, the CO2 heat pump water heater named "Eco Cute" was put on the market for the first time in the world in May 2001 in Japan (Fig. 3). In addition CRIEPI has given technical support in miniaturization, keeping performance of boiling water in cold area and reducing the cost through the evaluation study by environmental test facility since 2006 (Fig. 4). CRIEPI evaluated the performance data as the neutral organization to establish standard for revision of the Energy Saving Act in 2008.

・CRIEPI continues to evaluate of advanced and market Eco Cute and establishes evaluation method that can reflect the performance on the actual condition.�

・CRIEPI researches about promotion of heat exchange with low temperature air, frost -defrost performance and non-frost technology to improve heat pump efficiency in cold region.�・CRIEPI pays attention to CO2 and water refrigerant which are low GWP*2 and natural refrigerant, and investigate the possibility of industrial heat pump for steam generating and for drying to expand the range of application.

Principal Results

Future Developments

Relevant Research Subject : “High performance heat pump”�

＊1 : ODP (=Ozone Depletion Potential ) : Ozone depletion effect per unit weight, CFC11=1�＊2 : GWP (=Global Warming Potential ) : Greenhouse effect of released refrigerant to atmosphere, CO2=1


Development of Highly-Efficient Heat PumpDevelopment of Highly-Efficient Heat Pump

Fig. 4 Environmental test facility of heat pump

　The specifications of environmental test facility installed in January 2007 are mentioned below.��Evaluate two units of Eco Cute at the same time�

Control ambient air temperature and relative humidity in various conditions : -30℃～+50℃, 30%～90%�

Control tap water temperature in each season conditions : 5℃～40℃�

Control load of hot water supplying : IBEC-L Mode ( recognized as a standard load in Japan), etc.�

Control load of floor heating for multi functional Eco Cute

Fig. 2 CO2 refrigerant heat pump apparatus

　This apparatus was installed in 1996 to research the possibility of CO2 heat pump. Heat transfer measurements of pure CO2 are possible by oil -free compressor. We clarified that CO2 heat pump can be controlled by automatic expansion-valve and CO2 heat transfer is high under super critical condition.

Fig. 3 Annual shipment of Eco Cute

　Total shipments of Eco Cute reached 2 million units in October 2009. In NEDO project from 2005 to 2007 technical development for "miniaturization" and "performance increase in cold region" have done to promote Eco Cute.�　Various type of Eco Cute were commercialized owing to reflection of project achievement and market entry of new manufactures (8 manufactures in 2010). CRIEPI picked up the evaluation items to establish the appropriate evaluation method and study the feasible design of test facility to carry out the method.

Control Unit for Load�of Room Heating

Control Unit for�Tap Water Temp.�and Load of Hot�Water Supplying

Control Unit for�Outdoor Air Temp.�and Humidity

(Water Chiller,� Electric Heater,� Water Tank, etc)

(Refrigerating Machine,� Brine Chiller,� Brine Tank, etc)

(Brine Chiller, � Electric Heater,� Water Tank, etc)

Heated Brine for�Room Heating

Hot�Water

Brine,�Refrigerant

Tap�Water

Steam

Door

ShutterDoor

Air

Air

Humidifier

Dehumdifier

Window

DoorMeasuring�System

Disribution Board

Heat Pump�Water Heater

Heat Pump�Water Heater

Electric�Heater,�Cooling�Coil,�Fan, etc.Environmental Test Room�

（W4.5m×L7.5m×H3.5m）�

7m

20m

Controller

Eco CuteEco CuteEco Cute

①��

②��

③��

④��

⑤�



Advanced Maintenance Technology of Gas Turbine Hot Gas Path PartsAdvanced Maintenance Technology of Gas Turbine Hot Gas Path Parts

　Gas turbine combined cycle power generation now occupies the most important position in thermal power generation for its high thermal efficiency and low environmental impact. Hot gas path parts in these gas

turbines used under severe high temperature combustion gas environment have relatively short life spans, and are frequently repaired and replaced with new ones. And the latest technologies applied to these parts are one of the most contributing factors to the costly maintenance of the turbines. CRIEPI has been involved in the research and development of technologies to contribute to the rational maintenance of gas turbine.

Backgrounds

(1) Estimation method of blade durability based on non-destructive geometry measurement, computational fluid dynamics, finite element stress analysis (Fig. 1), and small sample tensile testing has been

developed.�(2) The observation on a thermal barrier coating (TBC) in a turbine blade after service confirms that the microstructural change hardly occurs in some area compared with the initial morphology. TBC specimens are prepared from the area of the blade devoid of the change, and are subject to high-temperature heating tests. Based on the microstructural change in the specimens after the tests, the method to derive an equation for temperature estimation of the blade is developed (Fig. 2).�

(3) New NDE system for heat resistance degradation of TBCs on gas turbine blades has been developed. Using this system, appropriate ranges of the measurement conditions are demonstrated, and the measurement accuracy are verified (Fig. 3).�

(4) Maintenance planning support system which enables users to perform effectively stock managements and to produce parts usage planning has been developed. Using this software, the users can reduce effectively the labor for maintenance planning (Fig. 4).

(1) Advancements in non-destructive measuring methods and analytical methods will be developed to evaluate durability of state-of-the-art gas turbine blades.�

(2) As for the temperature-estimation equation based on the microstructural change of TBC in a blade, the accuracy and applicable limits (temperature and operation time) are examined in more detail. And the temperature-estimation method is developed further in cooperation with analytical estimation using computational fluid dynamics.�

(3) Using the developed NDE system, TBCs on gas turbine blades will be evaluated for improving the accuracy of analytical life assessment of TBC-coated blades.�

(4) Improvements of user friendliness and performance of the maintenance planning support system will be made continuously based on the experiences of field use of the software.

Principal Results

Future Developments

Relevant Research Subject : “High Efficiency Power Generation”�

Used blade Computational�model

・Non-destructive durability assessment of gas turbine blade

Non-destructive�measurement (X-ray)

Estimated temperature�distribution (CFD)

Stress�distribution�(FEM)

Oxidation

Fig. 1 Analytical life assessment procedures

High temperature regions


AdvancedMaintenance Technology of Gas Turbine Hot Gas Path PartsAdvancedMaintenance Technology of Gas Turbine Hot Gas Path Parts

Data input

System configuration and flow chart for calculating heat resistance

Robot

Multijoint arm

Blade

IR camera

Setting of�conditions

Display of�parts status

Cost�comparison

Display of�schedule

Display of�usage history

Automatic or�manual parts�

rotation scheduling

Fig. 2 Outline of temperature estimation based on microstructural change in TBC

Fig. 3 Outline of the non-destructive evaluation system for TBC-coated blades

Fig. 4 Examples of displays of the maintenance planning support system

Supporting users to�produce parts rotation�schedules of hot gas�path parts��Management of a huge�number of parts usage�histories��Cost estimation of�produced schedule

・��・��・�

0

50

100

Typical microstructure of�thermal barrier coating (TBC)

Overview of�Measurement part

Temperature-estimation�equation

ADL thickness distribution in a�TBC-blade after service�

(Example)

Turbine blade

Turbine�blade

X-ray CT system Surface�geometry data

Multijoint�arm

IR�camera

Measured�temp.

Relationship�curve

TBC�surface temp.�calculation

Setting heat�resistance of�TBC

Heat conduction�analysis under the�same conditions

Relationship between�TBC surface temp.�and heat resistance

Developed system

Temperature

Heat resistance

Heat�resistance

IR

Laser�beamRobot

CO2 Laser

Rotary stage

Blade model

計測�

Boundary oxide�layer (TGO)

Top coat�(Ceramics)

Blade height 50%

The area where�specimens are extracted

Trailing�edge

Leading�edge

Suction�side

Pressure�side

Trailing�edge

T：Estimated temperature [K]�Q：Apparent activation� energy [J/mol]�k0：Constant�R：Gas constant� (8.31J/(mol・K))� l：ADL [μm]� t：Operation time [h]

Bond coat�(Metal)

Substrate�(Superalloy)

Two-pahse�microstructure

Al-decreased�layer (ADL)

ADL thickness [ μm]

Geometry measurement

Numerical analysis

Measurement 6�

5�

4�

3�

2�

1�

0150 250 350 450



Developments of VOC Decomposition CatalystDevelopments of VOC Decomposition Catalyst

　The legal control of volatile organic compound (VOC) has been

executed since April, 2006. Therefore, the needs of low-cost & saving-

place VOC decomposition module have rising in the source of small and

medium-size industry. A prototype VOC cracking module with a ceria oxide catalyst has been developed and

it was confirmed that a decomposition rate of more than 95% at 300℃ could be achieved to render the

toluene and xylene derived from printing and painting process.�

　However, VOC derived from printing, painting process involved several components. Therefore, it is

desired to clarify the decomposition performance and the by-products in the mock gas of several VOC

components. Because VOC is included in not only the print and painting but also odor, it is necessary to

clarify the decomposition performance and the by-product of the gas that simulates them. For the results,

application of CeO2 module is expanded.

Backgrounds

(1) Decomposition performance of mult-VOC�

　The decomposition reaction test was carried out about two case of

mixed practice gas which consists of the following three kinds of gas,

respectively (Fig. 2). CaseⅠ(printing process) : Tol/IPA/EA. Case Ⅱ(painting process) : Tol/Xy/EA.

Although few amount of acetaldehyde was detected at the temperature of 150℃, there was no formation

of acetaldehyde of other toxic by-products (Fig. 3 , 4). In the case, it turned out the over 95% of VOC in

the practice gas was decomposed about 300℃.�

(2) Decomposition performance of odor�

　The performance test of module was investigated about the following four kinds of odor gas

component, Methyl mercaptan, Acetaldehyde, Ethyl acetate and IPA used as a solvent. The following

results were obtained and it turned out that this module works well of the decomposition VOC. Methyl

mercaptan and acetaldehyde was decomposed at 150℃ and no by-product was detected over 300℃ by

GC-MS*1 measurement. Moreover, Dimethyl disulfide formation was not observed in Methyl mercaptan

(Fig. 5). The decomposition rate*2 of Ethyl acetate was achieved more 95% at 250℃, and decomposition

rate of IPA showed over 80% at 300℃ (Table 1).

　The behavior of a catalytic active site and a reactant is understood

from the characterization of CeO2, and it aims for the clarification of the

deactivation factor. A further research work will be investigated to

verify the applicability of the CeO2 catalyst to remove various odors, and to clarify the catalytic activity and

the degradation mechanism of CeO2.

Principal Results

Future Developments

Relevant Research Subject : “Advanced Fuel Utilization”�

＊1 : GC-MS : Gas Chromatography (GC)-Mass Spectrometry (MS)�

＊2 : Decomposition rate is evaluated by the difference between the outlet and the inlet concentration of total hydrocarbon.�

＊3 : ppmC ; ppmC convert into per a carbon (carbon number×concentration)�　　　For example, Toluene (C7) 100ppm ; 100×7=700ppmC


Developments of VOC Decomposition CatalystDevelopments of VOC Decomposition Catalyst

Heater

Catalyst

Heater line

Heater

Catalyst

Heater line

　It was clarified that the decomposition of Methyl mercaptan and Acetaldehyde were achieved at 150℃ by applying this module. Dimethyl disulfide formation was not detected in Methyl mercaptan. The decomposition rate of Ethyl acetate achieved more than 95% at 250℃, and decomposition rate of IPA also achieved over 80% at 300℃.

　A prototype VOC module that combined catalyst with heater was produced.

　In both case (Tol / IPA/EA、Tol /Xy/EA), it turned out the over 95% of VOC in the mock gas was decomposed about 300℃. Although few amount of acetaldehyde was detected at the temperature of 150℃, there was no formation of acetaldehyde of other toxic by-products.

Table. 1 Performance of decomposition with odor

Fig. 5 GC/MS chromatograms from the�decomposition of Methyl mercaptan

Fig. 4 GC/MS chromatograms from the�decomposition of mock gas (painting)

Fig. 3 GC/MS chromatograms from the�decomposition of mock gas (printing)

Fig. 2 Effect of several VOC components�on catalytic conversion

Fig. 1 Scheme of VOC module

Methyl mercaptan (MMC) used of standard�solution (MMC/toluene, MMC/benzene)

＊：The decomposition rate is evaluated by the difference�　　 between the outlet and the inlet concentration of total�　　 hydrocarbon.�＊＊：No detect at gas detector tube, GC-MS�condition：AV 2.8m/h，water vapor about 3%

VOC・odor�

Methyl mercaptan�

Acetaldehyde�

Ethyl acetate�

IPA

Concentration�

1～5ppm�

～5ppm�

100～150ppm�

100～150ppm

Decomposition rate*�

No detect at 150℃**�

No detect at 150℃**�95% at 200℃�

No detect at 250℃**�96% at 250℃�

About 80% at 300℃�

Methyl mercaptantoluene

Dimetyl�disulfide

benzene

propyleneIPA

Tol/ IPA/EA

Tol/Xy/EAtoluene

ethanol

tolueneEthyl acetate

xylene

Ethyl acetate

ethanoacetone

acetaldehyde

bypass

Ret. time [min]

Intensity

300℃�

250℃�

200℃�

150℃�

bypass

Ret. time [min]

Intensity

Ret. time [min]

Intensity

300℃�320℃�

250℃�200℃�150℃�

bypass

300℃�250℃�200℃�150℃�

Temperature [℃]

Conversion [ %]

Tol /Xy/EA�Tol/ IPA/EA

Gas Flow : N2/O2 18L/min�Water Vapor : 3%�AV : 2.8m/h�Tol/Xy/EA : 1150ppmC*3�Tol/ IPA/EA : 1350ppmC*3



Development of an Energy Efficient Dewatering and DeoilingTechnology by Using Liquefied Dimethyl Ether (DME)Development of an Energy Efficient Dewatering and DeoilingTechnology by Using Liquefied Dimethyl Ether (DME)

　Dewatering is an essential technology in the modern industry that normally used for removing of water from high-water-content materials such as coal, sewage sludge, biomass, and so on. However, it is noticeable that in the conventional dewatering process the heating is usually

carried out to evaporate the water from high-moisture materials, for this reason, a large amount of energy was cost. Therefore, an effective dewatering technology with a lower energy cost is stronger desired.�　On the other hand, for the oil bearing substance, such as heavy oil contaminated soil; benzene polluted soil etc., for such case the contaminants need to be recovered. Furthermore, for the biofuel production, an effective and energy efficient approach for the extraction of biooil from biomass is also required, for instance, the recovery of oleic compositions from microalgae.�　Our institute (CRIEPI) has originally developed a technology which capable for both of dewatering from high-water-content material and deoiling from oil bearing substance. This process was conceptualized based on the characters of dimethyl ether (DME) which has high affinity with oil and partially miscible in water under normal temperature and requiring only 0.5MPa. Now, this technology has been evaluated on a series of materials, meanwhile the dewatering-deoiling system is being established and improved together with scale-up studies. (Fig. 1)

Backgrounds

Capability for various water and oil contenting materials�　The water and oleic compositions can be extracted from water and oil contenting material by using liquefied DME. These extracted water and oleic compositions can be separated respectively by

decompressing the DME vapor stage by stage. Under such condition, the water was firstly separated from the mixture of DME and water when solubility of DME reached upper limit. After that, the oleic compositions could be separated from DME by evaporation of DME. (Fig. 1)�　Based on this theory, a series of high-water-content materials such as coal, sewage sludge, food waste etc., have been tested experimentally and it was clear that the water and oleic compositions can be successful extracted and separated from these materials. In addition to these, because of the dewatering and deoiling properties of liquefied DME, this technology shows the ability for many additional applications as well. For example, the treatment of the sewage sludge, in this case, sewage sludge was dewatered and solidified by liquefied DME; and at same time oleic malodorous substances were removed. (Fig. 2) Furthermore, this technology was also demonstrated to be usable for ( i ) drying and clearing up of heavy oil contaminated moist soil; ( ii ) removing of PCB from PCB polluted solid; ( iii ) desiccation of solid substance; ( iv) extraction of oleic compositions from a series of oil bearing solid. �　For the past few years, microalgae have received much attention as a new generation of sustainable biofuel resource. However, by mans of the conventional solvent extraction methods, the pretreatment such as drying and cell disruption must be performed which considerably resulting in energy ineffective. Comparatively, our DME technology provided a new approach for which high-effective direct extraction of oleic composition from high-moisture microalgae is becoming available. (Fig. 3)�Development of prototype�　CRIEPI has developed a small-scale dewatering and deoiling prototype system (10L/batch) in which DME can be used circularly. (Fig. 4) This prototype has been tested on high-moisture-content coal at normal temperature (<40℃). Compared with conventional thermal evaporation method, this small-scale equipment required energy of just less than 2100 kJ for removing 1kg water, this result clearly shows that the energy efficient of DME technology. Furthermore, this prototype was also success for dewatering of sewage sludge etc. For the future, it is possible that this technology would be utilized on mass application after the optimization of equipment and operating condition.

Principal Results

(2)

(1)

　With the aim of practical application of this energy efficient technology on pilot -scale as early as possible, we intend to ensure the more efficient way for the contact process between DME and target materials, and to optimize the equipment and operating condition.

Future Developments

Relevant Research Subject : “Advanced Fuel Utilization”�


Development of an Energy Efficient Dewatering and Deoiling Technology by Using Liquefied Dimethyl Ether (DME)Development of an Energy Efficient Dewatering and Deoiling Technology by Using Liquefied Dimethyl Ether (DME)

Academic Awards Received　Recipient Nobel Prize, Kenichi FUKUI, 1981, Advanced Technology Award, Vice-Grand Prize (2008), Young Researcher Award, The Association of Powder Process Industry and Engineering (2008), The Best Project Award, The Association of Environmental & Sanitary Engineering Research, Kyoto University (2008), The Chemical Society of Japan Award for Young Chemists in Technical Development for 2007 (2008), Environmental Technology/Project Award, Japan Society of Civil Engineers (2007), The Chemical Society of Japan, Presentation Award 2007 for Industries (2007), Technology Award of Society of Powder Technology, Japan (2006), The Japan Institute of Energy Award for Encouragement (2004)

①�

⑦�

②�

③�

④�

⑤�

⑥�

Dry can

Condenser

Compressor

Liquid DME�Sending pump

DME buffer tank

Flash Distillation tower

①�

⑦�

②�

③�

④�

⑤�

⑥�

Fig. 3 Extracted“Green Crude Oil”�at room temperature

Fig. 4 The world's first prototype DME dewatering and deoiling plant�(The arrows and numbers indicate the circulation route of DME)

Fig. 1 Schematic of dewatering and deoiling technology by using liquefied DME

Fig. 2 Dewatered and decolored�sewage sludge by removing grease

Liquefied DME

Water & oil�containing�materials

Water

DME vapor

OilDry�materials

Extraction of�water & oil by DME



　To advance a research and development on new power generation systems, it is necessary to clarify the expected performance of the total system and operating condition of each equipment. Also, in order to

maintain and improve thermal efficiency of an existing power plant, thermal efficiency analysis technique is essential to accurately grasp the current state of the total plant and each component.

Backgrounds

　We had developed the software "EnergyWinTM" which enables users to quickly and easily analyze the thermal efficiency of power generation systems on PC. Using this software, we had been contributing to the

many national R&D programs by performing the conceptual design, system optimization and evaluation of the power generation system. In addition, we are also working on the advanced technology for thermal efficiency management of existing power plants.

　We have been promoting the spread of the developed technology and the software. In addition, we have plans to expand the scope of the analysis to entire energy system including the demand-side equipment,

such as heat pumps.

This software allows flexibility for various computational conditions, and can calculate faster by adopting the special algorithms for heat and mass balance calculation of power systems.�

CSV file I /O functions and ODBC-Link functions help users to handle the huge number of calculation cases and results.�

Because it corresponds to various power systems, you can compare multiple power systems with the same calculation condition.�

GUI allows users to change the system configuration and the setting conditions easily.

Principal Results

Future Developments

Relevant Research Subject : “Energy conversion engineering”�

Thermal Efficiency Analysis and EvaluationTechnique for Energy SystemsThermal Efficiency Analysis and EvaluationTechnique for Energy Systems

【Outline of developed software - EnergyWinTM】�

［Basic usage of EnergyWinTM］�

Place models

Connect pipes

Display setting Show results

Calculation�condition setting

Loading long term data from CSV file,�performing sequential calculations�

automatically

Saving results to DB

Graphing the results

［Data analysis of existing power plants］�

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◇��

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Thermal Efficiency Analysis and Evaluation Technique for Energy SystemsThermal Efficiency Analysis and Evaluation Technique for Energy Systems

【Achievement】�

【Advanced technology for thermal efficiency management in existing thermal power plant】�

［Example usage for existing power plants］�

Measured trends

Usinga model based on�measured characteristics,�performance value are�converted to standard�

conditions.

Trends of actual performance

　Using EnergyWinTM, the technology has been developed to evaluate quantitatively the impact of each factor on the plant thermal efficiency.

Changes in the performance�of each device

Changes of plant thermal�efficiency by each factor

Quantitative evaluation of the impact�of changes in overall plant thermal efficiency by�the changes of performance of each device

　We have been contributing to many national R&D projects listed below.

□　National R&D projects on new power generation systems :�　・Hydrogen-combustion Turbine (NEDO)�

　・Advanced closed-cycle gas turbine cycle (NEDO)�　・Liquefied air energy storage (ENAA)�　・Advanced humid air turbine system (IEA, METI)��□　Other study on new power generation systems :�　・Fuel Cell hybrid systems�　・Integrated coal gasification combined cycles / fuel cell combined cycles�　・Compressed air energy storage systems�　・Carbon dioxide recovering systems��□　Existing power plants :�　・Steam power plants�　・Combined cycle power generation plants�　・Nuclear power plants�　・Geothermal power plants

□　Spread :�　・Electric power utilities�　・Universities�　・Other (private companies, Industrial Colleges)



Development of High Temperature Fuel CellsDevelopment of High Temperature Fuel Cells

Fuel gas

（Anode）�

（Cathode）�（Electrolyte）�

H2 , CO

Electricity

H2O , CO2

N2

H2

e- e-

e-e-

CO2

CO2O2

H2O

Air+CO2O2 , N2 , CO2

CO 2-3

Operating temperature�600-700℃�

　Molten carbonate fuel cell (MCFC) is one of the high temperature fuel cells which can be expected to a highly efficiency application in various fuels (Fig. 1). Moreover, it is technically obtains the prospect of a large

scale and a large capacity power generation system under the pressurized condition. Also it can be calculated that the net electric efficiency of an MCFC-GT hybrid system proved to be over 70% when natural gas is used as fuel and oxygen blown semi-closed cycle configuration is applied (Fig. 2). The MCFC technology is expected to be one of the key technologies for energy security and global environmental issue. On the other hand, the solid oxide fuel cell (SOFC) has potential as highly effective power generation technology for wide range of application such as home appliances and small-scale power generation use.

Backgrounds

We have demonstrated long term reliability over 60,000 hours operation under pressurized condition with a bench-scale cell. This result is a world record and shows the potential of the technology for

reliability. (Fig. 3)�We have established a new fabrication method of active component for the MCFC focusing low cost and high reliability. Moreover, the performance estimation model has been developed based on a relation equation between coefficients in cathode and anode reaction resistance model and carbonate properties. Cell performance has improved successfully using this model. (Fig. 4)�We have been developed the electrode polarization models with high prediction accuracy for various type of SOFC. (Fig. 5)�Thermal efficiency in an SOFC system for residential use was analyzed, and it proposed the analysis technique for the SOFC itself in the system. (Fig. 6)

We will focus on basic R&D of MCFC technology for the low cost and high reliability MCFC stacks and cells.�We will focus on the basic technology for the system design of SOFC

and the fuel diversification in order to realize highly effective power generation system.

Principal Results

Future Developments

(2 )��(3)��(4)

(1) ��(2)

(1)

Relevant Research Subject : “Energy conversion engineering”�

Fig. 1 Principle of MCFC　Fuel cells are different from electrochemical cell batteries, it produces electricity from hydrogen and an oxygen.

Fig. 2 Ultra high efficiency MCFC-GT�hybrid system　　　　�

　Semi-closed GT cycle MCFC hybrid system will achieve ultra high efficiency up to 70%.

MCFC combined with GT Stoichiometric ratio�CH4/O2 supply

CO2 recovery・O2 gas use as oxidant gas�・Ultra high efficiency� (70%HHV@ 300MWclass)�・CO2 recovery system

Minimum�heat loss�due to gas

4CO2+2O2 Noble gas supply

AnodeIR-MCFCCathode

1CH4+3H2O

4CO22O2

2H203H20

1CO2

1CH4

Combustor

Turbine

HRSG

Cooling water

Low pressure�turbine

Condenser

Reformer


Development of High Temperature Fuel CellsDevelopment of High Temperature Fuel Cells

1,000�

900�

800�

700�

600

8�

6�

4�

2

Voltage (mV)

Internal resistance ( mΩ)

Operating time (h)

cell 1 cell 2 cell 3

Open circuit voltage�Output voltage�Degradation trend�Internal resistance�Increasing trend

0 10,000 20,000 30,000 40,000 50,000 60,000 70,000

Test stands for MCFC

　Using pressurizing test stands, it is possible to operate single cells for several ten thousands hours. Cell performance is ale to be analyzed by performance factor analysis method. It will be revealed that which performance factor is major in cell performance degradation.

Fig. 3 A long term operation�over 60,000 hrs result with�a bench-scale cell

　The basic research and elemental technology development required in order to introduce SOFC systems to the market.�　CRIEPI has been performing operation test of the SOFC cells and stacks fabricated by SOFC developers and evaluation of the long-term performance (5,000-10,000hrs) with AIST and universities in Japan under the project of NEDO.

Fig. 5 Performance analysis�results for SOFC

　Our analysis method of impact factor of the performance is carried out efficiently, the cell performance has improved successfully.�　A 1kW class MCFC stack was also demonstrated with our cell technologies.

Fig. 4 Performance�analysis results for�CRIEPI original cells

　1kW class SOFC system has been tested. The system performance analysis was conducted using the electrode performance model which was derived using single cell tests. It is confirmed that the analysis has good accuracy even if system operating conditions such as temperature, reforming rate, were changed.

Fig. 6 Thermal efficiency�analysis result for�

1kW class SOFC system

1kW class MCFC�stack

Analysis result ( Initial performance)System diagram of flatten-tubular type

Voltage (mV)

Nernst loss

Cathode poralization(CO2)Anode poralization

Ohmic loss

Cathode poralization(O2)

Output voltage

950�

900�

850�

800�

750�

700�

650Cell average voltage (mV)

Operating time t (hr)

Quantitative analysis revealed the degradation factor

1 2 24 25 47 48

V４７�V２４�V１� Air flow direction Fuel flow direction

(Bottom) (Top)

Conceptual diagram of segment- in-series

Heat Ex. 3�Steam generator

Reformer

Heat recirculation

Initial

Fuel Energy�100%HHV

Radiation heat loss Mechanical &�Control loss

Heat output

Inverter loss

SOFC�Output (AC)

41.3%

Cathode�SOFC�Anode

Heat Ex. 1

Heat Ex. 2

Combustion

Fuel

Inverter

Water

Electric�power

Exhaust

Air

M

Heat flow

9999796054392487255

Pressure : 0.101MPa�Temperature : 900℃�Current density : 150mA/cm2�

Fuel : H2/CO/CO2/H2O=�　　　48/9/5/37%,Uf=60%�Oxidant : Air Uox=20%��　■ Nernst loss�　■ Anode polarization�　■ Cathode polarization�　■ IR drop�　■ Output voltage

Pressure：0.101MPa, Temperature：650℃, Current density：150mA/cm2,�Fuel：H2/CO2/H2O=64/16/20%,Uf=60%,Oxidant：Air/CO2=70/30,UOx=40%

Anode�improvement

Cathode�(&anode)�improvement



Numerical Analysis of Turbulent Heat Transfer and Reacting FlowsNumerical Analysis of Turbulent Heat Transfer and Reacting Flows

　In operation condition of equipments in thermal power plant such as a

pulverized coal combustion boiler, coal gasifier and gas turbines, highly

turbulent flow, laden particle, high temperature and rapid reaction

interact with each other. Performance of equipments is expected to be developed by performing numerical

analysis combining with conventional experimental approach.�

　Innovative and integrated numerical analysis technology is established by developing models of turbulent

heat transfer and chemical reactions and combining various numerical analysis technologies (Fig. 1).

Backgrounds

A highly accurate numerical models and methods for a combustion

flow has been developed in order to evaluate performance of

pulverized coal combustion boiler and coal gasifier (Fig. 2).�

Progress in simulation methods has been made for temperature estimation of gas turbine blades and vanes

that have extremely complicated cooling structures (Fig. 3).�

Reaction mechanism on de-NOx catalyst surface and particle attachment mechanism has been investigated

in order to develop evaluation method for flue gas treatment system (Fig. 4).�

Multi -scale analysis and modeling method has been developed in order to apply above highly accurate

analysis method to large-scale thermal power plant equipments (Fig. 5).

Highly accurate reaction model and particle-gas inter-phase reaction

model will be developed.�

Advancement in simulation methods to evaluate gas turbine blades

interaction will be made for simulations of real gas turbine cascade flow.�

Evaluation method for de-NOx catalyst will be developed, and this method will apply another catalytic

reaction.�

Large-scale, highly accurate numerical method for actual thermal power plant equipments analysis will be

developed.

Principal Results

Future Developments

・�

�

・�

�

・�

・�

�

・�

�

・�

・�

�

・�

Relevant Research Subject : “Numerical analysis of turbulent heat transfer and reacting flows”�

Fig. 1 Construction of research item　Numerical analysis specialist jointly work and develop a Innovative numerical simulator for the thermal power plants. Effective creation of research achievements will be expected though this research system.

Numerical�Analysis



Coal�Combustion

Core�Technology

Coal�Gasification

Gas�Turbine


Numerical Analysis of Turbulent Heat Transfer and Reacting FlowsNumerical Analysis of Turbulent Heat Transfer and Reacting Flows

Fig. 5 Development of large-scale numerical method　In order to accurately simulate large-scale equipments in thermal power plants, application method of advanced turbulence model and reaction model which developed for lab scale (10-2～-3m) ～bench scale (100～-1m) to actual scale (101m) has been investigated.

Fig. 4 Reaction mechanism of de-NOx catalyst　The effects of inner flow structure on de-NOx reaction on the catalyst surface and particle attachment has been investigated. The results contribute to the establishment of prediction method for degradation characteristics of de-NOx catalyst in thermal power plants.

Fig. 3 Advanced simulation of gas turbine flow fields　Turbulence models that can accurately predict heat transfer characteristics around gas turbine blades were installed to the developing code. From the comparison to the experimental results, the turbulence models were found to be reliable for the simulation of gas turbine thermal flow fields.

Flame image created�from numerical result

a) Spray combustion�(Corporative research with Komori & Kurose Lab. in Kyoto Univ.)

b) Pulverized coal combustion

Numerical results of spray�behavior and hot gas region

Actual pulverized coal�combustion flame

Numerical results of coal�particle behavior

Blades

Vanes

Gas turbine cascade

Flow

FlowTemperature fields

Reaction rate

Velocity

8.0

450K

240K

310K

380K

0.0

m/s

m/s

1.7×10-4 mol・m-3・s-1

0.0 mol・m-3・s-1

Lab. scale

Model developme

ntLarge-sc

ale simulation

Bench scale Demonstration scale Actual scale

Fig. 2 Development of multi-phase combustion model　A multi -phase combustion model which can accurately estimate interaction of heat transfer between gaseous phase and particle was developed. Numerical results can be simulate actual combustion flame by using developed model.

1900KParticle�temp.

453K

300K

Particle�temp.

Hot gas�region

350K


Central Research Institute of Electric Power IndustryURL:http://criepi.denken.or.jp/

Electric Power Engineering Research Laboratory��　　・High Power Testing Laboratory��　　・Shiobara High Voltage Testing Yard��Energy Engineering Research Laboratory��Materials Science Research Laboratory��　　・PD Center�　　・Komae Office�Yokosuka Operation & Service Center

Phone （046）856-2121　　FAX.（046）856-3540　　　2-6-1 Nagasaka Yokosuka-shi Kanagawa-ken　　240-0196��Phone （046）856-2121　　FAX.（046）856-2531　　　2-6-1 Nagasaka Yokosuka-shi Kanagawa-ken　　240-0196��Phone （0287）35-2048　　FAX.（0287）35-3604　　　1033 Sekiya Nasushiobara-shi Tochigi-ken　　　329-2801��Phone （046）856-2121　　FAX.（046）856-3346　　　2-6-1 Nagasaka Yokosuka-shi Kanagawa-ken　　240-0196��Phone （046）856-2121　　FAX.（046）856-5571　　　2-6-1 Nagasaka Yokosuka-shi Kanagawa-ken　　240-0196�Phone （046）856-2121　　FAX.（046）856-2249　　　2-6-1 Nagasaka Yokosuka-shi Kanagawa-ken　　240-0196�Phone （03）3480-2111　　FAX.（03）3480-3485　　　2-11-1 Iwadokita Komae-shi Tokyo　　　　　　　201-8511��Phone （046）856-2121　　FAX.（046）857-3072　　　2-6-1 Nagasaka Yokosuka-shi Kanagawa-ken　　240-0196

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