Clean Coal Technology for the Future Power Generation ... · N2 S 70-75 around 5 0.2-3 Problems CO2 Steam NOx SOx ... Gas Turbine Steam Turbine Fuel Cell Pulverized Coal (USC)

Keiji MAKINOSenior Fellow

Japan Coal Energy Center

1

Astana, Kazakhstan

9 March, 2016

Clean Coal Technology

for the Future Power Generation

~~~Experiences in Japan~~~

The Kazakhstan Green Bridge Initiative Conference 2016

Critical Element of the Green Bridge Initiative:

Advanced Fossil Fuel Technologies

JCOAL

2

121 Associations

(As of March 2016)

CONTENTS

1. Coal Now ~~Situation of Japan~~

2. What is Clean Coal Technology?

3. Coal Preparation

4. Environmental Protection

5. Global Warming

5.1 High Efficiency

5.2 CO2

Capture

5.3 Biomass Co-Combustion

6. Utilization of Coal Ash

7. Japanese Roadmap of Clean Coal

Technology R&D

8. Lastly-------

3

4

World Coal Production and Consumption

IEA Coal Information 2015

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

Co

al C

on

sum

pti

on

(Mill

ion

to

nn

es)

World Coal ConsumptionIEA Coal Information 2015

China India United StatesGermany Japan South AfricaPoland Korea AustraliaTurkey Kazakhstan TaiwanIndonesia Ukraine United KingdomGreece Others

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

Co

al P

rod

uct

ion

(Mill

ion

to

nn

es)

World Coal ProductionIEA Coal Information 2015

China United States IndiaAustralia Indonesia RussiaSouth Africa Germany PolandKazakhstan Canada CzechUkraine Viet Nam Mongolia

1. Coal Now –Situation of Japan--

5

IEA Coal Information 2015

World Coal Import

0

200

400

600

800

1000

1200C

oal

Imp

ort

(Mill

ion

to

nn

es)

People's Republic of China Japan

India Korea

Germany Netherlands

Chinese Taipei United Kingdom

Turkey Russia

Coal and Electricity Demand

IEA World Energy Outlook 2014

Trend for 50 years : 1990, 2012, 2020, 2025, 2030, 2035, 2040

0

100

200

300

400

500

600

700

800

0 1000 2000 3000 4000 5000 6000 7000

Co

al D

em

an

d(M

tce

)

Electricity Demand(TWh)

America Electricity and Coal Demand

0

1000

2000

3000

4000

5000

6000

0 5000 10000 15000 20000

Co

al D

eman

d(M

tce)


Asia Electricity and Coal Demand

0

100

200

300

400

500

600

700

0 1000 2000 3000 4000

Co

al D

em

and

(Mtc

e)

Electricity Demand (TWh)

Europe Union Electricity and Coal Demand

0

1000

2000

3000

4000

5000

6000

7000

0 10000 20000 30000 40000

Co

al D

Eman

d(M

tce)


World Electricity and Coal Demand

6

7

Electricity Generation Mix of Japan

July 2015, Japan’s New Energy Mix towards 2030 was decided.

The basic policy of “Energy Mix” is to realize a balanced power

source composition, while achieving 3E+S(Safety, Energy

Security, Economic efficiency and Environment ).

Coal is positioned as the important energy source to be used

while the environmental burden.

0

5

10

15

20

25

2030

Re

ne

wab

le E

ne

rgy(

%)

Renewable Energy

Geothermal BioenergyWind SolarHydro

0

20

40

60

80

100

2013 2030

Ele

ctri

city

ge

ne

rati

on

mix

(%)

Electricity generation mix

Oil Coal LNG Nuclear Renewable Energy

Oil 12%

Coal

30%

LNG

43%

Nuclear1%

Renewable

11%

Oil 3%

Coal

26%

LNG

27%

Nuclear

22-20%

Renewable

22-24%8.8-9.2%

7.9%

1.7%

3.7-4.6%

1.0-1.1%

METI Website

8

2. What is Clean Coal

Technology ?

9

Components of Coal and Emissions

Oxygen O2 around 8Support

combustionNone

Ash

Heavy metals

Molecule Content(%) Emission

SiO2, Fe2O3,Al2O3, etc.

Hg, Cl, F, Cd,Se, Pb, etc.

0 .1-5

15-50

Component

Carbon

Hydrogen

Nitrogen

Sulpher

Fly ash

Countermeasures

C

H2

N2

S

70-75

around 5

0.2-3

Problems

CO2

Steam

NOx

SOx

Heavy metals Health Problems

High eff ic iency, CCS

De-NOx(SCR)

De-SOx

EP, Bag Filter,Cyclone SeperatorActivated Carbon,

Wet Scrubber

Global Warming

None

Problemstorespiratory organ




====== Remove emissions from flue gas

2. Clean Coal Technology



Environmental

Protection

Low NOx Combustion

Flue-gas

Treatment

De-SOx De-NOx Dust Removal

Global Warming

High Efficiency

PF Combustion

SC, USC, A-USC

Gasification

IGCC, IGFC

CO2 Capture

CCS

Biomass

Co-combustion

Coal Preparation

Washing

10

Ash utilization

3. Coal Preparation


Environmental

Protection

Low NOx Combustion

Flue-gas

Treatment


Global Warming

High Efficiency

PF Combustion

SC, USC, A-USC

Gasification

IGCC, IGFC

CO2 Capture

CCS

Biomass

Co-combustion

Coal Preparation

Washing

11

Ash utilization

Mined Coal = Coal +Mineral Matter

Separate coal and mineral by heavy

medium or dry-system

4. Environmental Protection


Environmental

Protection

Low NOx Combustion

Flue-gas

Treatment


Global Warming

High Efficiency

PF Combustion

SC, USC, A-USC

Gasification

IGCC, IGFC

CO2 Capture

CCS

Biomass

Co-combustion

Coal Preparation

Washing

13

Ash utilization

14

Environmental Protection of

Coal Fired Power Station

CondenserAsh treatment

facility

Turbine

Coal unloader

MillAsh recovery

Generator

Low NOx Furnace

Low NOx Burners

Boiler

De-SOx

EP

De-NOx

Flue Gas Treatment Facilities

15

De-NOx Catalyst

De-NOx Reactor

Low NOx Burner

De-SOx Facility Electrostatic Precipitator

Low NOx Furnace

Japanese History of NOx Regulation

16

17

Environmental Monitoring of SO2

and NO2

1st stage of NOx emission regulation2nd stage

3rd stage

4th stage5th stage

Environmental standards of NO2 and SO2

- Environmental protection for SO2 emission from factories completed in 1970’s

- Environmental protection for NO2 emission from factories completed in 1980’s

Co

nc

en

tra

tio

n in

th

e a

tmo

sph

ere

(p

pm

)

Po

we

r g

en

era

tio

n (

10

8k

Wh

)

Renewable

Nuclear

Hydro

LNG

Coal

Oil

SO2NO2

Drastic Change of Air Pollution in Japan

Present Tokyo

Tokyo industrial area 1970



19

0.0

0.5

1.0

1.5

2.0

2.5

3.0

UnitedStates

Canada UnitedKingdom

France Germany Italy Japan

Emis

sio

n(g

/kW

h)

Comparison of SOx and NOx Emission from Fossil Power Station

SOx NOx

NOx and SOx emission levels in

Power Generation by country

OECD StatExtracts, IEA Energy Balances of OECD Countries 2014

5. Global Warming


Environmental

Protection

Low NOx Combustion

Flue-gas

Treatment


Global Warming

High Efficiency

PF Combustion

SC, USC, A-USC

Gasification

IGCC, IGFC

CO2 Capture

CCS

Biomass

Co-combustion

Coal Preparation

Washing

20

Ash utilization

Boiler Steam Turbine Gasifier

Gas

Turbine

Steam

Turbine Gasifier

Gas

Turbine

Steam

Turbine

Fuel

Cell

Pulverized Coal

(USC)

IGCC

(1500C Class Gas Turbine)IGFC

Gross Efficiency :44%

Net Efficiency :41％



Under Development

High-Efficient Coal Fired Power Generation

21

Efficiency: HHV Basis

Commercialized



Commercialized

High Steam Temp: 620C

5.1 High Efficiency

Year of operation

Steam pressure

(16.6)

(24.1)

450

483485

538

566 593

(31.0)

5

10

15

20

25550

500

450

400

Ste

am

pre

ss

ure

( M

Pa

)

(4.1)

‘55 ‘60 ‘65 ‘70 ‘90 ‘95 2000

30

~~~

600

610

~~

~

Ste

am

tem

pera

ture（℃）

620

Tem

pera

ture

/P

ress

ure

22

Hekinan No.1

Isogo No.2

Isogo No.1

Tachibanawan No.1

Steam

Temperature

USC Zone

Steam Temperature Increase of Boiler

(Japanese Ultra Super Critical Units)

23

World Highest Efficient Coal fired Power Station

---Isogo No.2 600MW 600/620C USC (Japan)---

Efficiency :

Gross 44%

Net 41%

(HHV Basis)

24

Installation of USC in the World

McCoy Power Reports

・First Ultra Super Critical Unit (USC) was installed in Japan in 1993.

Since then, USC is increasing RAPIDLY and Super-Critical and Sub-Critical

units are decreasing.

・60% of recent installation is USC in the world.

SC is less than 10% and Sub-Critical is small number.

Countries where USC were already operated:-

Japan, Germany, Italy, Poland, Czech Republic, Netherland, Slovenia, USA, China,

Korea, Taiwan, Malaysia,

Countries where USC is planned:-

Greece, Indonesia, India, Philippines, Morocco, Vietnam

0

10

20

30

40

50

60

70

0

20

40

60

80

100

120

19

92

19

93

19

94

19

95

19

96

19

97

19

98

19

99

20

00

20

01

20

02

20

03

20

04

20

05

20

06

20

07

20

08

20

09

20

10

20

11

20

12

20

13

20

14

20

15

20

16

20

17

20

18

Sha

re o

f U

SC(%

)

Ca

pa

city

(G

W)

Annual installed capacity of coal fired power generation in the world

USC SC Sub-Critical Share of USC(%)

World first

USC

installed in

Japan

25

Efficiency of Coal Power Generation

of Various Countries (HHV, Gross)

IEA Electricity Information 2015 :

Calculated by JCOAL

Hard Coal Lignite

0

10

20

30

40

50

1980 1990 2000 2010 2011 2012

Gro

ss

Eff

icie

ncy

(%)

HH

V b

asis

Efficiency of Coal Power Generation in the World(Lignite)

United States Australia Germany India

20

25

30

35

40

45

1980 1990 2000 2010 2011 2012 2013

Gro

ss E

ffic

ien

cy(%

) H

HV

ba

sis

Efficiency of Coal Fired Power Generation in the World(Hard Coal)

Japan KoreaChina United StatesAustralia GermanyUnited Kingdom India

26

0

0.5

1

1.5

2

Capital cost O&M cost Fuel cost Total cost

Re

lati

ve C

ost

(-)

Comparison of Cost

Sub-critical plant USC plant

Net thermalefficiency

Load factor Data source

USC 0.4 0.8 CRIEPISub-

Critical0.26 0.73 ECOFYS 2013

CCT Workshop 2015

Life Cycle Cost of USC

Total cost of USC is smaller when compared with Sub-Critical unit,

when studied about the case in developing country.

Conditions of estimation:-

27

Japan 2012

700 degree C, 500MW Class

India 2011

700 degree C, 800MW

EU 2021

700 degree C, 540MW

USA 2021

760 degree C 35MPa Developed by NETL

China 2011

700 degree C, Double Reheat

Advanced USC (A-USC)

System flow of IGCC (Nakoso 250 MW IGCC)

28

ＭＥＴＩ資料

New IGCC (Website)

Osaki CoolGen 170MW : Operation: 2017

Nakoso About 540MW : Start of construction 2016(Planned)

Start of operation Early 2020(Planned)

Hirono About 540MW : Start of construction 2016(Planned)


Development of IGCC

Nakoso NO.10 : 250MW

Commercial Operation : April 2013

Osaki CoolGen : 170MW

Operation: 2017

New IGCC plan(Website of Nakoso and Hirono)

Osaki CoolGen 170MW : Operation: 2017

Nakoso About 540MW : Start of construction 2016(Planned)


Hirono About 540MW : Start of construction 2016(Planned)


37

Japanese IGCC

Produce Chemicals from Coal Gasification

30

Hydrogen

Fertilizer

Chemicals CoalGasoline

Diesel

Kerosene

Electricity

Gasification

(H2+CO)

Reference

5.2 Carbon Capture and Storage


Environmental

Protection

Low NOx Combustion

Flue-gas

Treatment


Global Warming

High Efficiency

PF Combustion

SC, USC, A-USC

Gasification

IGCC, IGFC

CO2 Capture

CCS

Biomass

Co-combustion

Coal Preparation

Washing

31

Ash utilization

Carbon Capture and Storage METI

CCS 2020

Sequestration –

CaptureStorage Transport Injection

Injection from

surface

facilities

Sequestration – Capture

Pipeline

transport

Pipeline

transport

Tanker transport

Large-scale CO2 emission

source

Land zone

Underground water

bearing stratum

Structural Cap Rock

(impervious bed)

Structural Cap Rock

(impervious bed)

Sea zone

Underground water

bearing stratum

Injection

from sea-

based

facilities

32

No less important is “High Efficient

Power Generation + CCS”

Distribution of Storage Capacity

(IPCC Special Report)

33

CO2

Injection Point

34

SnøhvitSleipner

Weyburn

(CO2 from Coal Gasification)

In-Salah

SaskPower

Boundary Dam (CO2 from Coal firing)

2. Post-combustion

3. Oxyfuel

Oxygen

production

Coal Boiler

Exhaust gas recirculation （CO2 ）

O2Air

N2

Flue gas treatment

ASU

O2Air

N2

GasifierCO shift

CO2 Storage

CO2 seperation

GT

HRSG

Coal

1. Pre-combustion

Boiler

CO2

Coal

Air

Flue gas treatment

CO, H2 CO2,

H2

CO2 Storage

CO2 Storage

CO2

seperation

CO2

Capture from Coal-fired Power Plant

Gas Refining

35

36

Japanese CCS Demonstration Project

• Place: Tomakomai(Japan)

• Injection capacity : 0.1Mt-CO2/year

• Schedule : Project start 2008

Injection 2016-2018

Tomakomai CCS Website

37

Japanese CCS Demonstration Project

Tomakomai CCS Website

5.3 Biomass Co-combustion


Environmental

Protection

Low NOx Combustion

Flue-gas

Treatment


Global Warming

High Efficiency

PF Combustion

SC, USC, A-USC

Gasification

IGCC, IGFC

CO2 Capture

CCS

Biomass

Co-combustion

Coal Preparation

Washing

38

Ash utilization

Pulverization Biomass with Coal

39

SEM

Pulverization coal/biomass

Cedar bark

Newlands coal

Pine tree bark

Cedar chip Saw dust of pine tree

CRIEPI Biomass Forum

Reduction of Coal Consumption

with Biomass mixing

40

Coal technology conference(Shikoku Power)

Biomass mixing ratio

Re

du

ctio

n o

f c

oa

l c

on

su

mp

tio

n

6. Utilization of Coal Ash


Environmental

Protection

Low NOx Combustion

Flue-gas

Treatment


Global Warming

High Efficiency

PF Combustion

SC, USC, A-USC

Gasification

IGCC, IGFC

CO2 Capture

CCS

Biomass

Co-combustion

Coal Preparation

Washing

41

Ash utilization

42

Amount and Utilization of Ash

from Boiler in Japan

JCOAL 2015

0

10

20

30

40

50

60

70

80

90

100

0

2000

4000

6000

8000

10000

12000

14000

Pe

rce

nt

of

Uti

lizat

ion

(%)

Am

ou

nt

of

Ash

(Th

ou

san

d t

on

ne

s)

Utilization of Ash from Power Stations

Total ash Utilized ash Percent of utilization

67%

14%

4%

1%

14%

Utilization of Ash (2013)

Cement

Civil

Building

Agriculture,Fishery

2014 2020 2030 2040 2050

① A-USCCommercial

（800℃）Commercial

（700℃）

Low rank

coal

utilization

High

efficiency

and low

carbon

Environmen-

tal protection

② IGFC1) Demonstration

(Osaki） CommercialIGCC demo.

(Osaki）

⑧Chemical Looping CommercialStudy of

Reactor30MW PP 100MW Demo.

⑪CO2 Conversion Pilot scale testCO2 Conversion test Small scale test

⑦ CO2 recycleIGCC Commercial

CO2 Cycle

test 300MW demo.O2-CO2

Gasifier test

⑤ Ferro Coke4) Demonstration Commercial

⑯ TIGAR7) CommercialDemonstration

⑬High efficiency

fluidized bed dryingBench

testPP test Commercial

⑥ COURSE505) Commercialmin. blast

furnace test Blast furnace demo.

⑰ ECOPRO8) CommercialDemonstration

Mid-long term R&D

Steel

Industry

Power

genera-

tion

CO2

capture

Upgrading

Industrial

use

Low environ-mental burden

⑱Low environmental

burden （B, Se）

R&D of reducing

tech.

Standardization of

analytical methods

(JIS/ISO)

⑫Brown coal

carbonizationCommercialPP test

⑮ IGCC with

renewable energyCommercialDemonstration

⑭ Hyper Coal6) CommercialDemonstration

③ A-IGCC2) Commercial （GT1700℃)

⑨Oxy-fuel combustion Demonstration Commercial

⑩Post combustion Demonstration Commercial

④ ABC3) Commercial

（>10%）Commercial

（<10%）

7. Japanese Roadmap of Clean Coal Technology R&D

Technologies

44

8. Lastly-------------

• Coal should be used as a main fuel in the future.

• Especially, non-OECD countries will use more coal

for there economic growth than OECD countries.

• However, consideration should be paid to reduce air

pollution and CO2

emission in order to continue using

coals.

• Now, Clean Coal Technology is essential.

• Japan will contribute in the world for use of clean

and high efficient coal power generation.

Thank you

for your attention.

45

Documents

Clean Coal Technology for the Future Power Generation ... · N2 S 70-75 around 5 0.2-3 Problems CO2 Steam NOx SOx ... Gas Turbine Steam Turbine Fuel Cell Pulverized Coal (USC)