Future Development of Clean Coal Technology in Japan 4_Zaima... · Even most efficient coal fired thermal power generation discharge about 2 times CO2 compared to LNG-Fired. Coal

September 9, 2015

Director GeneralNew Energy and Industrial Technology Development Organization

(NEDO)Japan

Future Development of Clean Coal Technology in Japan

Nobuyuki Zaima

Clean Coal Day in Japan 2015 International Symposium

47% 37%

Reference: World Energy Outlook 2002, 2004, 2007–2012, 2014

World primary energy demand by source World power generation by source

Mto

e

Mto

e

Global Primary energy demand and power generation by sources

Coal is known as very important energy resource that has the characteristics distributed over a wide

area and stable low price relatively, compared with others energy resources.

Coal shares will be about 25% in Global Primary energy demand and about 40% in Global power

generation in 2035.

29% 24%

1

DOT：500 g-CO2/kWhEIB： 550 g-CO2/kWh

1400

1200

1000

800

600

400

200

0

[g-C

O2/k

Wh]

1195

967907 889

958864 806

695476

375

China U.S. Germany WorldIndia Coal Fired（Japan）

USC IGCC IGFC Oil（Japan）

LNG（steam）

LNG（gas turbine combined）

Reference ：Central Research Institute of Electric Power Industry（2009）、CO2 Emissions Fuel Combustion (2012)

Even most efficient coal fired thermal power generation discharge about 2 times CO2 compared to LNG-Fired.

Coal fired thermal power generation needs Improvement of the efficiency andintroduction carbon capture utilization and storage (CCUS).

2

Comparison CO2 emission by power generation

Coal Fired thermal powerin the World

Coal Fired thermal powerin Japan

Reduction by CCS

Coal Power with CCS

GCCSI Global Status of CCS 2014

１４％

When we doesn‘t perform carbon dioxide emission, the quantity of annual CO2emission increases to 50 billion tons in 2050, and world average temperature will increase approximately 6 degrees.It is necessary to reduce annual CO2 emission to approximately 15 G tons to keep

raise of world mean temperature to 2 degrees in the IEA model. CCS is expected to carry 14% of the quantity of CO2 reduction.G tons/year

Nuclear

Renewable Energy End-use fuel switching

Power generation efficiency and fuel switching

End-use fuel and electricity efficiency

6℃increase50Gtons

2℃Increase15Gtons

Cumulative CO2 emissions reduction thorough 2050 in a 2℃ by CCS

3

Carbon Capture Technologies

Clean-up of synthesis gas for IGFC

CO2 emissions reduction in iron andsteel industry (COURSE50 Project)

NEDO ProjectsIGCC (EAGLE STEP 1) 2006

Low carbonization in iron and steel

industry

Low carbonizationin coal-fired

power generation Development of CO2capture

technology

Improvement of power

generation efficiency

CO2 capture & emissions

reduction

Utilization of low rank coal

Drying & upgrading

Consideration of business model/Demonstration abroad

2017

2014

2030

2035

2030 - 2050

Establishment ofTechnology (Year)

Chemical/physical absorption(EAGLE STEP 2 & 3)

Oxy-fuel IGCC

Chemical looping combustion

Development of Clean Coal Technology byNEDO

Entrained flow steam gasification 2030

4

Photos by Mitsubishi Heavy Industries, Ltd., Joban Joint Power Co., Ltd., Mitsubishi Hitachi Power Systems, Ltd., and Osaki CoolGen Corporation

65％

60％

55％

50％

45％

40％

Gas Turbine Combined Cycle (GTCC)Combined power generation utilizing gas turbine and steam turbinePower generation efficiency: Approximately 52%CO2 emissions: 340 g/kWh

Power generation efficiency

GTFC

IGCC（Verification by blowing air)

A-USC

Ultra Super Critical (USC)Pulverized coal thermal power utilizing steam power

Power generation efficiency: Approximately 40%CO2 emissions: Approximately 820 g/kWh

1700 deg. C-class IGCC

1700 deg. C-class GTCC

IGFC

LNG thermal power

Coal-fired thermal power

2030Present

Integrated coal Gasification Combined Cycle (IGCC)

Coal-fired thermal power generated through coal gasification, utilizing the combined cycle combining gas turbine and steam turbinePower generation efficiency: Approximately 46 to50%CO2 emissions: 650 g/kWh (1700 deg. C class)Technological establishment: Around 2020

Pulverized coal thermal power utilizing high temperature and pressure steam turbinePower generation efficiency: Approximately 46%CO2 emissions: Approximately 710 g/kWhTechnological establishment: Around 2016

Advanced Ultra Super Critical (A-USC)

y ( )Integrated Coal Gasification Fuel Cell

Combined Cycle (IGFC)Coal-fired thermal power utilizing the triple combined cycle combining IGCC with fuel cellPower generation efficiency: Approximately 55%CO2 emissions: Approximately 590 g/kWhTechnological establishment: Around 2025

Gas Turbine Fuel Cell Combined Cycle (GTFC)

Power generation utilizing the triple combined cycle combining GTCC with fuel cellPower generation efficiency: Approximately 63%CO2 emissions: Approximately 280 g/kWTechnological establishment: 2025

Combined power generation for LNG utilizing ultrahigh temperature (1700 deg. C or above) gas turbinePower generation efficiency : Approximately 57%CO2 emissions: Approximately 310 g/kWhTechnological establishment: Around 2020

Ultrahigh Temperature Gas Turbine Combined Cycle

The prospect of highly efficient and low-carbon next-generation thermal power generation technology

The single-cycle LNG thermal power technology for medium and small plants achieves power generation efficiency as high as that of large GTCC by utilizing humid air.Power generation efficiency: Approximately 51%CO2 emissions: 350 g/kWhTechnological establishment: Around 2017

Advanced Humid Air Gas (AHAT)

Around 2020

Reduction of CO2 by approximately 20%



* The prospect of power generation efficiencies and discharge rates in the above Figure were estimated based on various assumptions at this moment.


5

Technical SummaryThis method ejects and burns pulverized coal in a furnace, generates high temperatures and pressure steam using a boiler, and then rotates the turbine with the steam to generate electricity.

CharacteristicsAs an extremely reliable and established technology, about half of domestic coal-fired thermal power generation plants (base on installed capacity), which is as high as approximately 19.60 million kW, use this technology.

Timing of technological establishment1995 or later

CO2 discharge rateApproximately 820 g-CO2/kWh

Transmission end efficiency (HHV)Approximately 40%

CostApproximately 250 thousand yen/kW

(The power generation cost verification WG of the Advisory Committee for Natural Resources and Energy, May 2015)

Isogo Thermal Power Plant (Source: J-POWER’s web sit

(Source: JCOAL Japanese Clean Coal Technology (2007))

Pulverizedcoal

CoalST

Pulverized coalBoiler

Condenser

Generator

Air

Steam

Exhaust gas

Feed Pump

Mill

Slug

Low carbonization in coal-fired power generationImprovement of power generation efficiency

USC

6

Technical summaryThis is a highly efficient power generation technology thatincreased the steam temperature of the steam turbineto 700 deg. C and higher as a further temperature increasing technology based on USC.

CharacteristicsThis technology achieves 46% of the power generation efficiency(transmission end efficiency, HHV) almost without changing the conventional pulverized coal-fired thermal power generation system.

Timing of technological establishmentAround 2016


Transmission end efficiency (HHV)Approximately 46%

Target costTo achieve a power generation unit cost

equivalent to that of conventional turbine

Boiler

35MPa, 700℃

Steam Turbine

720℃720℃

(Source: The material for the 1st Next-generation Thermal Power Generation Council (A-USC development promotion committee) (June 2015))

High-temperature and large-diameter piping material(Provided by Nippon Steel & Sumitomo Metal Corporation)


A-USC

7

SteamAir separation unit

CoalAir

Oxygen

CO₂ transportationand storage processes

Shift reactor

CO2 Capture Technology

CO2 Capture TechnologyIGCC Gas clean-up facilities

CO2, H2

Ｈ２

Compressor

Steamturbine

Gasturbine

Air

Generator

Stack

HRSG (heat recovery steam generator)

Gasifier

Gas

ifica

tion

Combustor

Fuel Cell

Fuel cell

Syngas (CO, H2)CO2

H2 rich gas

Low carbonization in coal-fired power generationOsaki CoolGen (OCG) Demonstration Project

8

Coal Gasification

Scaling up of IGCC with the results from EAGLE Project

Subsidized by METI

166MW IGCC plant

Syngas Treatment

Low carbonization in coal-fired power generationOsaki CoolGen (OCG) Demonstration Project

9

10 11 13 15‘09 12 14 16 17 18 19 20 21

IGCC optimizationfeasibility study

2nd StageCO2 Capture IGCC

1st StageOxygen‐blown IGCC Design ,Construction Operations testing

Design, ConstructionFS

Design, Construction

Operations testing

FS

22

Operations testing

3rd StageCO2 Capture IGFC

CO2 capture IGCC is to be demonstrated with the result from EAGLE Project.IGFC will be demonstrated with the result from the basic research of syngas

clean-up.

Low carbonization in coal-fired power generationThe schedule for OCG Demonstration project

10

Technical summaryThis is an applied technology based on IGCC system that adds steam generated from the exhaust heat of a gas turbine into an entrained bed gasification furnace.

CharacteristicsAdding steam into an entrained bed gasification furnace as a gasification agent reduces oxygen ratio and increases cool gas efficiency.

Expected timing of technological establishmentAround 2030


Expected transmission end efficiency (HHV)Approximately 57%

Expected costTo achieve a power generation unit cost of a commercial turbine equivalent to or lower than that of USC (Source: The material for the 1st next-generation thermal power generation (NEDO) (June 2015))


Entrained Flow Steam Gasification

11

Around 2030Present

The prospect of the development of next-generation CO2 capture-related technologies

Around 2020

CO2 separation and capture cost

M b timethod

Membrane separation method

This method separates by using a membrane which penetrates CO2 selectively.

Low

High

This method uses a solvent, such as amine, so that CO2 is chemically absorbed into absorbing solution for separation.Separation and capture cost: 4200 yen/t-CO2

Chemical absorption method

Ph i l b timethod

Physical absorption methodThis method separates CO2 by making it absorbed into a physical absorption solution under high pressure.Separation and capture cost: Approximately 2000 yen level/t-CO2Technological establishment: Around 2020

Oxygen combustion method

This method recirculates highly concentrated oxygen using a boiler to increase the CO2concentration in exhaust gas.Separation and capture cost: 3000 yen level/t-CO2

Storage of CO2Storage of CO2

This technology enables to store separated and captured CO2 in the ground. The research development and verification test are in process toward the practical realization of CCS technology by around 2020.

In 2012, a verification business for separating, capturing and storing approximately a hundred thousand tons of CO2 a year was initiated. The plant for this business is under construction, and the storage will be initiated in 2016.

Utilization of CO2Utilization of CO2

This technology utilizes captured CO2 to produce valuables such as alternatives to oil and chemical raw material

The technologies for microalgal biofuel, artificial photosynthesis and green concrete, etc. are under development.

Solid absorbent method

This method reduces energy requirement and separate CO2 by combining amine, etc. with a solid but not with a solvent.

Closed IGCC

This method applies the oxygen fuel technology to the IGCC technology to maintain high power generation efficiency after CO2 capture.

For pulverized coal thermal power

For IGCC

12

Development supported by METI

Private Company development supported by METI

NEDO Development

Post CombustionCO2Capture

Pre CombustionCO2Capture

（Chemical or Physical）

Oxy-fuelCO2Capture

Oxy-IGCC

Coa

l Firi

ng B

oile

rIG

CC

Developed by Private Companies

Chemical Looping

CO2 Membrane Separation

With Capture Unit Without Capture Unit

Low carbonization in coal-fired power generation:Development of CO2 Capture Technology

13

Physical AbsorptionSolubility of CO2 mainly depends on CO2 partial pressure in vapor phase.

Chemical AbsorptionSolubility of CO2 mainly depends on concentration ofan amine in liquid phase with which CO2 makes a weak ionic bonding in liquid phase.

Sol

ubilit

y of

CO

2

CO2 Partial Pressure

PhysicalAbsorption

Saturation

(image)

(image)

Vapor Phase Liquid Phase

selexol

selexol

CO2

selexol

selexol

CO2 CO2 CO2

CO2 CO2

CO2

CO2 CO2

CO2

CO2

CO2

Vapor Phase Liquid Phase

CO2Amine

CO2Amine

CO2Amine

CO2Amine CO2

CO2

CO2

CO2

CO2 CO2 CO2 CO2

CO2 CO2


Chemical/Physical Absorption (EAGLE STEP-2 & 3)

The process pressure will be increased for utilization of a high temperature gas turbine which makes power generation efficiency higher in the near future.

Physical Absorption could be superior to Chemical Absorption for such a high pressure process.

Suitable forhigher pressure

ChemicalAbsorptionSuitable for

lower pressure

14

■STEP 1 (2002–2006) - Oxygen-blown entrained-flow gasifier was developed- Gas cleanup technology was established

■STEP 2 (2007–2009) - CO2 capture technology (chemical absorption) was developed - Coal type diversification (high ash fusion temperature coal) was carried out

■STEP 3 (2010–2013) - Development of CO2 capture technology (physical absorption)

Air separation facilities

Gas purifier

Gas turbine house (8 MW)

EAGLE Pilot Plant (150 tons/day)Gasifier

(150 tons/day)CO2 Separation

facilities

Chemicaladsorption

Physicaladsorption


15

Improvement:3.4 points

FurtherImprovement:

1.0 point

A drastic reduction in loss of efficiency for CO2 capture was achieved. It will be studied whether the cost of CO2 capture can be reduced

from USD 0.03/kWh to USD 0.02/kWh.

Chemical/Physical Absorption(EAGLE Stage-2 & 3)

Method of CO2 Capture Net Thermal Efficiency

Loss of Efficiency

Without CO2 Capture 45.6%

With CO2Capture

(Recovery Rate: 90%)

Chemical Absorption

Heat Regeneration(conventional) 34.8% 10.8%

Heated Flash Regeneration(newly-developed)

38.2% 7.4%

Physical Absorption 39.2% 6.4%

(Higher Heating Value Basis)

(With a 1,500ºC class gas turbine)


16

International Research & Development Trend

worldsteel CO2 Breakthrough Program (from 2003.10)

EuropeUltra Low CO2 Steelmaking

ULCOSKorean

ProgramJapan

Program

AustraliaProgram

North AmericanProgram

South AmericanProgram

Coal-based direct reductionprocess(University collaboration base)

COURSE50,CO2 Storage program etc.

Heat Recoveryfrom moltenslag etc.

aqueous ammoniabase chemicalabsorptionmethod etc.

Hisarna(smeltingreduction) etc.(Ulcos BF :freezed)

Biomass etc.

17

BFG①Iron Ore

②

③

Ref

orm

er

Heat

⑤

⑥

④

Coke oven

Coke

Blastfurnace

Pig

iron

Coke oven

CokeCokemaking plant

Blastfurnace

BFGCOG

Pig iron

Fuel

Iron ore

Conventional steelmaking technology

Steelmaking technology under development

CO2emissions100%

Subjects(1) Suitable ore preparation

and coke-making for reduction with H2 (①②) / Reforming of coke oven gas to increase H2 ratio (③) /Utilization of H2 to partly replace coke for reduction of iron ore in blast furnace (④), (Reduction of CO2 by 10%)

(2) Utilization of unused heat in plant (⑤) / Efficient CO2capture from blast furnace gas (BFG) (⑥).(Reduction of CO2 by 20%)

CO2emissions

70%

(2) CO2 Capture(1) CO2 Emissions Reduction

Realization & Dissemination2030 - 2050

Target Cost of CO2 CaptureUSD 40/t-CO2 → USD 20/t-CO2

H2: 70%

H2: 50%

Low carbonization in iron and steel industry:CO2 emissions reduction (COURSE50 Project)

A technology which could reduce CO2 emissions from steelmaking plant by 30%.

18

Schedule of ＣOURSE50 Project

(2008～12) 2013 2014 2015 2016 2017 2018～27 2030～50

Test operation,Data analysis

Construction of test blast furnace (10 m3)

Improvement of chemical absorbent

Improvement of physical adsorption Study on scale-up

Study on utilizationof unused heat Engineering

Phase 2Step 1 Step 2

Development of element technology

DemonstrationRealizationDissemination

PresentYear

Low carbonization in iron and steel industry:CO2 emissions reduction (COURSE50 Project)

Phase 1

CO2 emissions reduction from blast furnace

Development of CO2 capture technology

Development of highly efficientheat exchanger to recover low-level unused heat

Reduction of CO2capture energyImprovement of physical

structure of adsorbent

COURSE50: CO2 Ultimate Reduction in Steelmaking process by innovative technology for cool Earth 5019

World share of 15 years between 2000 and 2014

Utilization of low rank coal:Consideration ofbusiness model/Demonstration abroad

World coal-fired power plant market (boiler)

20

Mitsubishi-Hitachi13%

Other JPN1%

Foster Wheeler

7%

KOR76%

Others3%

Note) Unit is MW. Source) Mitsubishi Research Institute analysis

Mitsubishi-Hitachi

1%

IHI0%

Russia1%

Foster Wheeler

1%Alstom1%

CHN83%

KOR1%

Others12%

Ansaldo1%

Russia1% Alstom

1%

CHN29%

KOR5%

Others63%

China1,092,519

Korea36,358

Mitsubishi-Hitachi

9%

IHI10%

Other JPN1%

Russia1%

Foster Wheeler

5%Alstom16%

CHN29%

KOR6%

Others23%

Mitsubishi-Hitachi

36%IHI

44%

Alstom12%

Others8%

Oceania12,996

ASEAN75,846

Mitsubishi-Hitachi

0%

Other JPN0%

Russia78%

Foster Wheeler

3%

Alstom3%

CHN6%

Others10%


IHI4%

Ansaldo1%Russia

1%Foster

Wheeler1%

Alstom24%

CHN16%

KOR8%

Others9%

Africa & ME

55,840


IHI2%

Ansaldo11%

Foster Wheeler

7%

Alstom23%

KOR1%

Others20%

Mitsubishi-Hitachi

9%IHI5%

Foster Wheeler

27%

Alstom28%

CHN0%

KOR2%

Others29%


IHI3%

Ansaldo2%Foster

Wheeler9%

Alstom3%

CHN8%

KOR17%

Others23%

Latin Ameri

ca16,114

North America46,235

Eurasia &East Europe

31,262

OECD Europe82,294

India251,314

Mitsubishi‐Hitachi7%

IHI2%

Other JPN0% Ansaldo

1%Russia2%

Foster Wheeler2%

Alstom4%

CHN57%

KOR4%

Others21%

Global1,765,356 Mitsubis

hi-Hitachi61%

IHI34%

Other JPN3%

Foster Wheeler

1% Others1%

Japan39,865


IHI12%

Other JPN0%

Foster Wheeler

11%Alstom

7%

KOR11%

Others30% Taiwan

21,252

The highest level of thermal efficiency and the lowest CO2 emissions by USC.

The longest history of utilizing USC technology. Impressive track record of thermal efficiency as well as high load factor

by lots of O&M experience.

2020Year

201520102005200019951990

Japan

China

Korea

Taiwan

Indonesia

2015

1993

2006

2008

2016

Long historyof USC experience

According to METI FS research 2010 & 2011.

EU 2002

2015

Gross thermal efficiency (%, HHV)

Coal-fired power plant in Japan

Coal-fired power plant in a country

Years in operation

Maintaining High Efficiency

Degradation of Efficiency

◆

According to The Federation of Electric Power Companies of Japan


USC and O&M experience in Japan

21

Capital cost per kWh depends on load factor. Proper O&M is essential to maintain load factor high.

Fuel cost per kWh depends on net thermal efficiency. High-efficiency plant helps.

USC plant properly managed would deliver lower power generation cost in the long-term.

Load factorUSC: 80% from “Estimated power generation costs by power source”, Cost Verification Committee, JapanSub-C: 73% from the presentation of BEE, Power Plant Summit 2014：CII DelhiNet thermal efficiency USC: 40% from “Evaluation of Life Cycle CO2 Emission of Power Generation Technologies,” CRIEPI, JapanSub-C: 26% from “International comparison of fossil fuel power generation efficiency”, ECOFYS, 2013 (However the figure as gross)

0

1

Capital Cost O&M Cost Fuel Cost Total Cost

USCExisting Sub-C

Fuel costImported coal: USD69/t from the report of JOGMEC, 2015, Japan

(Per kWh)


22

50 feasibility studies for 24 countries conducted since 2011 High efficiency coal-fired power plants (USC etc): 22 Utilization of low rank coal (gasification, upgrading, drying): 16

Number by country and by item

Hig

h-ef

ficie

ncy

coal

-fir

ed p

ower

pla

nt

Util

izat

ion

of

low

rank

coa

l

The

othe

rs

Tota

l

Asia

Pac

ific

Mongolia 2 2China 1 4 5Taiwan 1 1Vietnam 2 1 3Thailand 1 1Indonesia 5 7 12Myanmar 1 1India 1 1 2Sri Lanka 2 2Kazakhstan 2 2Uzbekistan, Tajikistan and Kyrgyz 1 1Uzbekistan and Tajikistan 1 1Kyrgyz 1 1Australia 1 2 3

Euro

pe a

nd A

mer

ica USA 1 1 2

Canada 1 1Poland 2 2Bulgaria 2 2Turkey 1 1Hungary, Romania and Serbia 1 1Hungary 2 2Bosnia and Herzegovina 1 1Brazil 1 1

Total 22 16 12 50


23

New Energy and Industrial Technology Development Organization

●Puertollano（Spain,318MW,1997）

×Buggenum（Netherland,284MW,1994）

●Polk Power（US,315MW,1996）

●Wabash River（US,296MW,1995）

2005 20201995 2000 201520101990

Edwardsport ●(US,618MW,2013～）

Taean ○(Korea,400MW,2015）

Teeside △（GB,2018, 850MW, 4.2Mtpa）

Don Valley Hatfield △（GB,2018, 650MW, 4.75Mtpa）

Green Gen●(China,2013, 250−400MW, 2Mtpa）IGCC

IGCC

IGCC＋CCS

HECA △(US,2018, 400MW, 3Mtpa）

Kemper ○（US,2015, 582MW, 3.5Mtpa）

Cash Creek New Gas △(US,2018, 770MW, 5Mtpa）

Osaki CG ○（Japan,2021〜, 166MW, 0.3Mtpa）

※IGCC:2017〜 IGCC+CCS:2019〜

Nakoso ●(Japan,250MW,2007～）

Summit △（US,2018, 400MW, 2Mtpa）

Hirono、Nakoso △

(Japan,each 500MW,2020～）

IGFC

• First 250MW IGCC in China • First 2000t/d Dry Coal Powder Gasifier in China •Design, Construction, Commission and Operation by CHNG

World present development of IGCC-CCS ●Improvement of gasification technology●Higher efficiency, realization of CCS and

lower costMany demonstration plants are planned in the world

【Example of Project】Kemper・US Southern Company・Power output 582MW・Operation start 2016・Capture capacity3.0Mtpa

Green Gen・China GreenGen・Power output 250～400MW・Operation start 2013

●:Operating○:Constructing△:Planning× :Finished

●:Operating○:Constructing△:Planning× :Finished

:Japanese Pj.

24

Summary

Development to improve the efficiency in coal-fired power generation

Development of CO2 capture technology for cost reduction in coal-fired power generation

Development of CO2 emissions reduction and CO2 capture cost reduction in iron and steel industry

Dissemination of the CCT in the world

Future Development of Clean Coal Technology by NEDO

25

Thank you for your attention.

Documents

Future Development of Clean Coal Technology in Japan 4_Zaima... · Even most efficient coal fired thermal power generation discharge about 2 times CO2 compared to LNG-Fired. Coal