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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%
Reduction of CO2 by approximately 30%
Reduction of CO2 by approximately 10%
* The prospect of power generation efficiencies and discharge rates in the above Figure were estimated based on various assumptions at this moment.
Reduction of CO2 by approximately 20%
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
CO2 discharge rateApproximately 710 g-CO2/kWh
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)
Low carbonization in coal-fired power generationImprovement of power generation efficiency
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
CO2 discharge rateApproximately 570 g-CO2/kWh
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))
Low carbonization in coal-fired power generationImprovement of power generation efficiency
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
Low carbonization in coal-fired power generation:Development of CO2 Capture Technology
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
Low carbonization in coal-fired power generation:Development of CO2 Capture Technology
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)
Low carbonization in coal-fired power generation:Development of CO2 Capture Technology
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%
Mitsubishi-Hitachi36%
IHI4%
Ansaldo1%Russia
1%Foster
Wheeler1%
Alstom24%
CHN16%
KOR8%
Others9%
Africa & ME
55,840
Mitsubishi-Hitachi36%
IHI2%
Ansaldo11%
Foster Wheeler
7%
Alstom23%
KOR1%
Others20%
Mitsubishi-Hitachi
9%IHI5%
Foster Wheeler
27%
Alstom28%
CHN0%
KOR2%
Others29%
Mitsubishi-Hitachi35%
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
Mitsubishi-Hitachi29%
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
Utilization of low rank coal:Consideration ofbusiness model/Demonstration abroad
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)
Utilization of low rank coal:Consideration ofbusiness model/Demonstration abroad
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
Utilization of low rank coal:Consideration ofbusiness model/Demonstration abroad
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.