Future Development of Clean Coal Technology in Japan

Transcription

1 Future Development of Clean Coal Technology in Japan Clean Coal Day in Japan 2015 International Symposium September 9, 2015 Nobuyuki Zaima Director General New Energy and Industrial Technology Development Organization (NEDO) Japan

2 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 Mtoe Mtoe 29% 24% 47% 37% World primary energy demand by source World power generation by source Reference: World Energy Outlook 2002, 2004, ,

3 Comparison CO 2 emission by power generation 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 and introduction carbon capture utilization and storage (CCUS). [g-co 2 /kwh] Reduction by CCS 695 DOT:500 g-co 2 /kwh EIB: 550 g-co 2 /kwh India China U.S. Germany World Coal Fired thermal power in the World Coal Fired (Japan) USC IGCC IGFC Coal Oil Power (Japan) with CCS Coal Fired thermal power in Japan LNG LNG (steam)(gas turbine combined) Reference :Central Research Institute of Electric Power Industry(2009) CO 2 Emissions Fuel Combustion (2012) 2

4 Cumulative CO 2 emissions reduction thorough 2050 in a 2 by CCS When we doesn t perform carbon dioxide emission, the quantity of annual CO 2 emission increases to 50 billion tons in 2050, and world average temperature will increase approximately 6 degrees. It is necessary to reduce annual CO 2 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 CO 2 reduction. G tons/year Power generation efficiency and fuel switching Nuclear Renewable Energy 6 increase 50Gtons End-use fuel switching End-use fuel and electricity efficiency 14% 2 Increase 15Gtons GCCSI Global Status of CCS

5 Development of Clean Coal Technology by NEDO Carbon Capture Technologies Low carbonization in coal-fired power generation Improvement of power generation efficiency Development of CO 2 capture technology NEDO Projects IGCC (EAGLE STEP 1) 2006 Clean-up of synthesis gas for IGFC Establishment of Technology (Year) 2017 Entrained flow steam gasification 2030 Chemical/physical absorption (EAGLE STEP 2 & 3) Oxy-fuel IGCC Chemical looping combustion Low carbonization in iron and steel industry CO 2 capture & emissions reduction CO 2 emissions reduction in iron and steel industry (COURSE50 Project) Utilization of low rank coal Drying & upgrading Consideration of business model/ Demonstration abroad 4

6 Power generation efficiency 65% 60% 55% 50% 45% 40% The prospect of highly efficient and low-carbon next-generation thermal power generation technology Ultrahigh Temperature Gas Turbine Combined Cycle Gas Turbine Combined Cycle (GTCC) Combined power generation utilizing gas turbine and steam turbine Power generation efficiency: Approximately 52% CO 2 emissions: 340 g/kwh IGCC(Verification by blowing air) Ultra Super Critical (USC) Pulverized coal thermal power utilizing steam power Power generation efficiency: Approximately 40% CO 2 emissions: Approximately 820 g/kwh Combined power generation for LNG utilizing ultrahigh temperature (1700 deg. C or above) gas turbine Power generation efficiency : Approximately 57% CO 2 emissions: Approximately 310 g/kwh Technological establishment: Around 2020 Advanced Humid Air Gas (AHAT) 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 5 CO 2 emissions: 350 g/kwh Technological establishment: Around 2017 A-USC 1700 deg. C-class GTCC 1700 deg. C-class IGCC Advanced Ultra Super Critical (A-USC) Gas Turbine Fuel Cell Combined Cycle (GTFC) Pulverized coal thermal power utilizing high temperature and pressure steam turbine Power generation efficiency: Approximately 46% CO 2 emissions: Approximately 710 g/kwh Technological establishment: Around 2016 Power generation utilizing the triple combined cycle combining GTCC with fuel cell Power generation efficiency: Approximately 63% CO 2 emissions: Approximately 280 g/kw Technological establishment: 2025 GTFC Reduction of CO 2 by approximately 10% Reduction of CO 2 by approximately 20% Reduction of CO 2 by approximately 20% IGFC LNG thermal power Coal-fired thermal power Reduction of CO 2 by approximately 30% Integrated Coal Gasification Fuel Cell Combined Cycle (IGFC) Coal-fired thermal power utilizing the triple combined cycle combining IGCC with fuel cell Power generation efficiency: Approximately 55% CO 2 emissions: Approximately 590 g/kwh Technological establishment: Around 2025 Integrated coal Gasification Combined Cycle (IGCC) Coal-fired thermal power generated through coal gasification, utilizing the combined cycle combining gas turbine and steam turbine Power generation efficiency: Approximately 46 to 50% CO 2 emissions: 650 g/kwh (1700 deg. C class) Technological establishment: Around 2020 Photos by Mitsubishi Heavy Industries, Ltd., Joban Joint Power Co., Ltd., Mitsubishi Hitachi Power Systems, Ltd., and Osaki CoolGen Corporation * The prospect of power generation efficiencies and discharge rates in the above Figure were estimated based on various assumptions at this moment. Present Around

7 Low carbonization in coal-fired power generation Improvement of power generation efficiency USC Technical Summary This 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. Characteristics As 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 million kw, use this technology. Pulverized coal Boiler Steam Isogo Thermal Power Plant (Source: J-POWER s web sit Timing of technological establishment 1995 or later Coal Pulverized coal Exhaust gas ST Generator CO 2 discharge rate Approximately 820 g-co 2 /kwh Mill Air Transmission end efficiency (HHV) Approximately 40% Slug Feed Pump Condenser Cost Approximately 250 thousand yen/kw (The power generation cost verification WG of the Advisory Committee for Natural Resources and Energy, May 2015) (Source: JCOAL Japanese Clean Coal Technology (2007)) 6

8 Low carbonization in coal-fired power generation Improvement of power generation efficiency Technical summary This is a highly efficient power generation technology that increased the steam temperature of the steam turbine to 700 deg. C and higher as a further temperature increasing technology based on USC. Characteristics This 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 establishment Around 2016 A-USC 35MPa, High-temperature and large-diameter piping material (Provided by Nippon Steel & Sumitomo Metal Corporation) CO 2 discharge rate Approximately 710 g-co 2 /kwh Boiler Transmission end efficiency (HHV) Approximately 46% Target cost To achieve a power generation unit cost equivalent to that of conventional turbine Steam Turbine (Source: The material for the 1 st Next-generation Thermal Power Generation Council (A-USC development promotion committee) (June 2015)) 7

9 Low carbonization in coal-fired power generation Osaki CoolGen (OCG) Demonstration Project IGCC Air Air separation unit Coal Oxygen Gasification Gasifier Steam turbine Gas clean-up facilities Steam Gas turbine Combustor Syngas (CO, H 2 ) Air Compressor Generator Stack HRSG (heat recovery steam generator) CO 2 Capture Technology Shift reactor CO 2, H 2 H 2 rich gas Fuel Cell CO 2 Capture Technology Fuel cell H2 CO 2 CO₂ transportation and storage processes 8

10 Low carbonization in coal-fired power generation Osaki CoolGen (OCG) Demonstration Project Scaling up of IGCC with the results from EAGLE Project 166MW IGCC plant Syngas Treatment Coal Gasification Subsidized by METI 9

11 Low carbonization in coal-fired power generation The schedule for OCG Demonstration project CO 2 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 IGCC optimization feasibility study 1 st Stage Oxygen blown IGCC Design,Construction Operations testing 2 nd Stage CO 2 Capture IGCC FS Design, Construction Operations testing 3 rd Stage CO 2 Capture IGFC FS Design, Construction Operations testing 10

12 Low carbonization in coal-fired power generation Improvement of power generation efficiency Entrained Flow Steam Gasification Technical summary This 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. Characteristics Adding steam into an entrained bed gasification furnace as a gasification agent reduces oxygen ratio and increases cool gas efficiency. Expected timing of technological establishment Around 2030 CO 2 discharge rate Approximately 570 g-co 2 /kwh Expected transmission end efficiency (HHV) Approximately 57% Expected cost To achieve a power generation unit cost of a commercial turbine equivalent to or lower than that of USC (Source: The material for the 1 st next-generation thermal power generation (NEDO) (June 2015)) 11

13 The prospect of the development of next-generation CO 2 capture-related technologies CO 2 separation and capture cost Oxygen combustion method Utilization of CO 2 High Low Chemical absorption method This method uses a solvent, such as amine, so that CO 2 is chemically absorbed into absorbing solution for separation. Separation and capture cost: 4200 yen/t-co 2 Storage of CO 2 This technology enables to store separated and captured CO 2 in the ground. The research development and verification test are in process toward the practical realization of CCS technology by around In 2012, a verification business for separating, capturing and storing approximately a hundred thousand tons of CO 2 a year was initiated. The plant for this business is under construction, and the storage will be initiated in Present This method recirculates highly concentrated oxygen using a boiler to increase the CO 2 concentration in exhaust gas. Separation and capture cost: 3000 yen level/t-co 2 For pulverized coal thermal power Physical absorption method This method separates CO 2 by making it absorbed into a physical absorption solution under high pressure. Separation and capture cost: Approximately 2000 yen level/t-co 2 Technological establishment: Around 2020 Closed IGCC Around 2020 This technology utilizes captured CO 2 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. For IGCC Solid absorbent method This method reduces energy requirement and separate CO 2 by combining amine, etc. with a solid but not with a solvent. Membrane separation method This method applies the oxygen fuel technology to the IGCC technology to maintain high power generation efficiency after CO 2 capture. Around 2030 This method separates by using a membrane which penetrates CO 2 selectively. 12

14 Low carbonization in coal-fired power generation: Development of CO 2 Capture Technology Coal Firing Boiler Post Combustion CO 2 Capture Developed by Private Companies Oxy-fuel CO 2 Capture Private Company development supported by METI Chemical Looping IGCC Pre Combustion CO 2 Capture (Chemical or Physical) CO 2 Membrane Separation Development supported by METI Oxy-IGCC NEDO Development With Capture Unit Without Capture Unit 13

15 Low carbonization in coal-fired power generation: Development of CO 2 Capture Technology Chemical/Physical Absorption (EAGLE STEP-2 & 3) Physical Absorption Solubility of CO 2 mainly depends on CO 2 partial pressure in vapor phase. (image) CO 2 Vapor Phase CO 2 CO 2 CO 2 CO 2 CO 2 selexol selexol Liquid Phase CO 2 CO 2 CO 2 CO 2 CO 2 selexol CO 2 selexol Solubility of CO 2 Physical Absorption Suitable for higher pressure Chemical Absorption Suitable for lower pressure Saturation Chemical Absorption Solubility of CO 2 mainly depends on concentration of an amine in liquid phase with which CO 2 makes a weak ionic bonding in liquid phase. (image) Vapor Phase CO 2 CO 2 CO 2 CO 2 CO 2 CO 2 Amine Liquid Phase Amine CO 2 2 Amine CO 2 2 Amine CO 2 2 CO 2 2 CO 2 Partial Pressure 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. 14

16 Low carbonization in coal-fired power generation: Development of CO 2 Capture Technology EAGLE Pilot Plant (150 tons/day) CO 2 Separation facilities Gas purifier Air separation facilities Gasifier (150 tons/day) Physical adsorption Chemical adsorption Gas turbine house (8 MW) STEP 1 ( ) - Oxygen-blown entrained-flow gasifier was developed - Gas cleanup technology was established STEP 2 ( ) - CO 2 capture technology (chemical absorption) was developed - Coal type diversification (high ash fusion temperature coal) was carried out STEP 3 ( ) - Development of CO 2 capture technology (physical absorption) 15

17 Low carbonization in coal-fired power generation: Development of CO 2 Capture Technology Chemical/Physical Absorption (EAGLE Stage-2 & 3) Method of CO 2 Capture Net Thermal Efficiency Loss of Efficiency With CO 2 Capture (Recovery Rate: 90%) Without CO 2 Capture 45.6% Chemical Absorption Heat Regeneration (conventional) Heated Flash Regeneration (newly-developed) 34.8% 10.8% 38.2% 7.4% Physical Absorption 39.2% 6.4% (With a 1,500ºC class gas turbine) Improvement: 3.4 points Further Improvement: 1.0 point A drastic reduction in loss of efficiency for CO 2 capture was achieved. It will be studied whether the cost of CO 2 capture can be reduced from USD 0.03/kWh to USD 0.02/kWh. (Higher Heating Value Basis) 16

18 International Research & Development Trend worldsteel CO2 Breakthrough Program (from ) North American Program Coal-based direct reduction process(unive rsity collaboration base) South American Program Biomass etc. Europe Ultra Low CO2 Steelmaking ULCOS Hisarna(smelting reduction) etc. (Ulcos BF :freezed) Korean Program aqueous ammonia base chemical absorption method etc. Australia Program Japan Program Heat Recovery from molten slag etc. COURSE50, CO2 Storage program etc. 17

19 Low carbonization in iron and steel industry: CO 2 emissions reduction (COURSE50 Project) Conventional steelmaking technology Iron ore COG Iron Ore Reformer Cokemaking plant Coke oven H 2 : 50% Coke oven Coke Coke Blast furnace Blast furnace 4 BFG Pig iron BFG Pig iron Fuel Steelmaking technology under development (1) CO 2 Emissions Reduction H 2 : 70% (2) CO 2 Capture 6 5 Heat CO 2 emissions 100% CO 2 emissions 70% A technology which could reduce CO 2 emissions from steelmaking plant by 30%. Subjects (1) Suitable ore preparation and coke-making for reduction with H 2 (12) / Reforming of coke oven gas to increase H 2 ratio (3) / Utilization of H 2 to partly replace coke for reduction of iron ore in blast furnace (4), (Reduction of CO 2 by 10%) (2) Utilization of unused heat in plant (5) / Efficient CO 2 capture from blast furnace gas (BFG) (6). (Reduction of CO 2 by 20%) Target Cost of CO 2 Capture USD 40/t-CO 2 USD 20/t-CO 2 Realization & Dissemination

20 Low carbonization in iron and steel industry: CO 2 emissions reduction (COURSE50 Project) Year Schedule of COURSE50 Project (2008~12) ~ ~50 Step 1 Step 2 CO 2 emissions reduction from blast furnace Development of element technology Construction of test blast furnace (10 m 3 ) Present Phase 1 Test operation, Data analysis Development of CO 2 capture technology Improvement of chemical absorbent Phase 2 Demonstration Realization Dissemination Improvement of physical adsorption Study on utilization of unused heat Study on scale-up Engineering Improvement of physical structure of adsorbent Development of highly efficient heat exchanger to recover lowlevel unused heat Reduction of CO 2 capture energy COURSE50: CO 2 Ultimate Reduction in Steelmaking process by innovative technology for cool Earth 50 19

21 KOR 4% Utilization of low rank coal:consideration of business model/demonstration abroad CHN 0% Others 2 Others 29% KOR 2% World coal-fired power plant market (boiler) Mitsubishi Hitachi 7% World share of 15 years between 2000 and 2014 Mitsubishi- Hitachi Others 12% KOR IHI 0% KOR 76% Russia Foster Wheeler Alstom Other CHN Others Other JPN 2% JPN 6% 10% 0% 3% Alstom Alstom Global 3% Eurasia & 4% China IHI Japan 1,765,356 East Europe Mitsubis 1,092,519 34% 39,865 Foster 31,262 Russia hi- Others Wheeler 78% Hitachi 20% 3% 6 Russia Ansaldo CHN CHN Alstom 83% KOR Mitsubishi- 57% Other JPN OECD Mitsubishi- Hitachi Europe Others Hitachi 13% 82,294 36% CHN 3% 29% Alstom 28% North America 46,235 IHI 2% Mitsubishi- Hitachi 9% IHI 5% Foster Wheeler 27% KOR 17% CHN 8% Other JPN 0% Others 23% Latin Ameri ca 16,114 Alstom 3% Alstom 23% Mitsubishi- Hitachi 35% IHI 3% Foster Wheeler 9% Ansaldo Russia 2% Foster Wheeler Ansaldo 2% Foster Wheeler 7% CHN 16% KOR 8% Alstom 24% IHI 2% Ansaldo 1 Others 9% Africa & ME 55,840 Foster Wheeler Others 63% Mitsubishi- Hitachi 0% Mitsubishi- Hitachi 36% IHI 4% Ansaldo Russia India 251,314 KOR 5% Others 23% KOR 6% CHN 29% Mitsubishi -Hitachi 9% ASEAN 75,846 Korea 36,358 IHI 10% Other JPN Russia Foster Wheeler Alstom 5% 16% Alstom 12% Foster Wheeler 7% IHI 44% Foster Wheeler Others Others 30% Taiwan 21,252 KOR 1 Alstom 7% Foster Wheeler 1 Others 8% Oceania 12,996 Mitsubishi- Hitachi 29% IHI 12% Other JPN 0% Mitsubish i-hitachi 36% Note) Unit is MW. Source) Mitsubishi Research Institute analysis 20

22 Utilization of low rank coal:consideration of business model/demonstration abroad USC and O&M experience in Japan The highest level of thermal efficiency and the lowest CO 2 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. Gross thermal efficiency (%, HHV) Japan China Korea Taiwan Indonesia EU Long history of USC experience According to METI FS research 2010 & Year Coal-fired power plant in Japan Maintaining High Efficiency Degradation of Efficiency Coal-fired power plant in a country Years in operation According to The Federation of Electric Power Companies of Japan 21

23 Utilization of low rank coal:consideration of business model/demonstration abroad 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. 1 USC Existing Sub-C 0 Capital Cost O&M Cost Fuel Cost Total Cost (Per kwh) Load factor USC: 80% from Estimated power generation costs by power source, Cost Verification Committee, Japan Fuel cost Sub-C: 73% from the presentation of BEE, Power Plant Summit 2014:CII Delhi Imported coal: USD69/t from the report of JOGMEC, 2015, Japan Net thermal efficiency USC: 40% from Evaluation of Life Cycle CO2 Emission of Power Generation Technologies, CRIEPI, Japan 22 Sub-C: 26% from International comparison of fossil fuel power generation efficiency, ECOFYS, 2013 (However the figure as gross)

24 Utilization of low rank coal:consideration of business model/demonstration abroad 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 High-efficiency coalfired power plant Utilization of low rank coal The others Total Asia Pacific Europe and America Mongolia 2 2 China Taiwan 1 1 Vietnam Thailand 1 1 Indonesia Myanmar 1 1 India Sri Lanka 2 2 Kazakhstan 2 2 Uzbekistan, Tajikistan and Kyrgyz 1 1 Uzbekistan and Tajikistan 1 1 Kyrgyz 1 1 Australia USA Canada 1 1 Poland 2 2 Bulgaria 2 2 Turkey 1 1 Hungary, Romania and Serbia 1 1 Hungary 2 2 Bosnia and Herzegovina 1 1 Brazil 1 1 Total

25 World present development of IGCC-CCS Improvement of gasification technology Higher efficiency, realization of CCS and lower cost Many 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 :Japanese Pj. First 250MW IGCC in China First 2000t/d Dry Coal Powder Gasifier in China Design, Construction, Commission and Operation by CHNG IGCC New Energy and Industrial Technology Development Organization Puertollano (Spain,318MW,1997) Polk Power (US,315MW,1996) Wabash River (US,296MW,1995) Buggenum (Netherland,284MW,1994) IGCC+CCS Teeside (GB,2018, 850MW, 4.2Mtpa) Don Valley Hatfield (GB,2018, 650MW, 4.75Mtpa) Cash Creek New Gas Green Gen (China,2013, MW, 2Mtpa) Nakoso (Japan,250MW,2007~) IGFC IGCC HECA (US,2018, 400MW, 3Mtpa) Kemper (US,2015, 582MW, 3.5Mtpa) Taean (Korea,400MW,2015) Edwardsport (US,618MW,2013~) Osaki CG (Japan,2021, 166MW, 0.3Mtpa) IGCC:2017 IGCC+CCS:2019 (US,2018, 770MW, 5Mtpa) Summit (US,2018, 400MW, 2Mtpa) Hirono Nakoso (Japan,each 500MW,2020~)

26 Summary Future Development of Clean Coal Technology by NEDO Development to improve the efficiency in coal-fired power generation Development of CO 2 capture technology for cost reduction in coal-fired power generation Development of CO 2 emissions reduction and CO 2 capture cost reduction in iron and steel industry Dissemination of the CCT in the world 25

27 Thank you for your attention.