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Commercialization of UBC® Process
Shohei Manabe Executive Officer
Head of Coal & Energy Division Head of Iron Unit Division
Natural Resources & Engineering Business Kobe Steel, Ltd.
-Upgrading the Future-
Agenda
• Company Profile • Kobe Steel’s approach to low-quality
natural resources utilization • UBC Process • Commercialization of UBC
-Upgrading the Future-
Company Profile
• Kobe Steel is known as KOBELCO – A steel, aluminum, copper and machinery producer as well as
engineering company and coal-based power supplier (1400MW)
• Now focusing on low-grade natural resource utilization
– UBC Process – New ironmaking technology (pellet feed + steaming coal)
Kobe Steel’s approach to utilize low-quality natural resources
<Iron-making> • Pellet utilization in BF instead of lump ore 1966~ • Pulverized coal injection to BF 1980~ • FASTMET direct reduced ironmaking 1992~ • ITmk3 iron nugget making 1994~
<Energy industry> • Coal liquefaction in China 1939-1944 • Coal liquefaction in Australia 1981-1993 • UBC process development 1990~ • Hyper Coal process development 1999~
’81~: After the 2nd oil crisis, Brown Coal Liquefaction (BCL) project was started in Australia & Japan. (AC, 0.1t/d PDU, 50t/d Pilot Plant Operation) ’93~:Follow-up Studies in Japan (AC, 0.1t/d BSU Operation) ’99~:Indonesian BCL Feasibility Study ’04~:Follow-up Studies on Indonesian BCL ’08~:US PRB Coal Liquefaction Project
Catalyst Hydrogen
Gasoline Kerosene Gas-oil
H/C ratio: 0.8 H/C ratio: 1.5~2
Coal Liquefaction
Coal
450℃ 15MPa
Coal is hydrocracked & hydrogenated at high temperature and pressure to obtain liquid fuel.
50t/d PP (Morwell, Australia)
Over flow
Extraction temp 350-400℃
Slurry Making
Solvent extraction coal
Solid-Liquid
separation Solvent recovery
Solvent recovery settler
Hyper-Coal (HPC) Process Extracted Coal
HPC Over flow
Under flow
HPC
① Solvent recycled ② No hydrogen used ③ Low temperature, low pressure
Additive of coke for blast furnace
Residue
RC
Excellent thermal plasticity
HPC process
High Strength Coke
COAL
+ HPC
UBC Process
• Basic Concept • R&D Project in Indonesia • Process Description • Commercialization
-Upgrading the Future-
Basic Concept of UBC
Turn Un-utilized Low Quality Lignite into
High-Value Energy Resource
-Upgrading the Future-
Lignite & UBC spec.
Coal (Indonesian Lignites)
Type A Type B Type C
Raw UBC Raw UBC Raw UBC
Moisture wt% ar 33.6 <10 34.0 <10 60.5 <10
Heating Value kcal/kg 4,460 6,380 4,200 5,810 2,328 6,020
Ash wt%db 2.5 2.7 4.6 4.6 7.7 7.8
Volatile Matter wt%db 51.2 52.5 48.5 50.9 43.3 47.3
Fixed Carbon wt%db 46.3 44.8 46.9 44.5 34.2 38.6
Sulfur wt%db 0.48 0.49 0.17 0.19 0.26 0.27
-Upgrading the Future-
Demonstration Project
• Capacity: 600 t/day on product basis (1,000 t/day on feed coal basis)
• Location: Satui, South Kalimantan • Coal run: from December 2008 to May 2011 • Raw coal: Arutmin Ecocoal (TM=35%)
Kalimantan
Java Pilot Plant (3t/d) 14
-Upgrading the Future-
R&D Project Structure <Japan – Indonesia GG-based R&D Project>
Participate as assigned entity
MOU
Strong Support
Kobe Steel PT Bumi Resources
PT Arutmin
MEMR Ministry of Energy and Mineral
Resources
Japan Indonesia METI
Ministry of Economic Trade and Industry
JCOAL Japan Coal Energy Center
Results of R&D Project
• Development of the UBC Process was successfully completed.
• Combustion and transportation tests were successfully conducted.
• Scaled up information was collected. • Capital and operation cost data were collected. • Several research subjects were found and
studies are underway.
-Upgrading the Future-
Commercialization Concept Lignite
<Disadvantages> •Low CV •Spontaneous combustion
<Advantages> •Widely spread in the world •Huge reserve •Cheap mining cost
Technology (UBC)
•Increase CV •Stabilize
Stable Energy Source •Stable Supply •Stable Cost
+
=
-Upgrading the Future-
Location and Client
Target Areas
Where will we built UBC plants?
Target clients With whom are we having discussions?
-Upgrading the Future-
Canada(6 .6bi l . t )
13%
53%34%
U.S.A .(237,3bi l .t)
42%
45%13%
China(114.5bi l .t)
16% 55%
29%
India(60.6bi l .t)
7%
93%
Indones ia(5.5bi l .t)
20%27%
53%
Others (As ian) (47.6bi l .t)
2%
52%46%
Austra l i a (76.4bi l .t)
49% 48%
3%
Russ ia(157bi l .t)
3% 33%
62%Europe(108bi l .t)
17%20%
63%
South Africa(30.2bil .t)
100%
Others (Africa)(1.5bil .t)
89%11%
Bitumino
us
Lignite
Sub-Bitumin
ous
Others(South Amer ica)(5 .8bi l . t )9% 0%
Colombia (6.8 bil.t)
Target Areas
<First priority area> • Indonesia <Second priority area> • India • China <Third priority area> • Australia • Russia
-Upgrading the Future-
Candidate Clients / Partners
• Mine owners who want to sell high-moisture lignite, which has no
commercial value now.
• Power utility companies who want to have a stable price & source of energy.
• Traders who want to use UBC as a calorie booster.
-Upgrading the Future-
UBC Application
<Briquette form: moisture 8-10%, 6000kcal/kg) • Ocean or rail transport for long distance • Mix with LRC as calorie booster
<Powder form: moisture 0%, 6670kcal/kg> • Direct feed to mine-mouth power plant • Feed to UBC power (including IGCC) plant in
distant location
-Upgrading the Future-
Project coming up
• F/S for 1st Commercial Plant is now in progress with PT DH Energy (Bumi Gr.) and an Asian power utility.
• The project is in Pendopo, South Sumatra. • We are also having discussions with several
lignite mine owners in Indonesia and in other countries.
-Upgrading the Future-
KOBELCO’s business scheme
• EPC Business
• License Business – Construction License to engineering company – Production License to producer of UBC
• UBC Production Business
– For Captive Use – For Merchant Sale
-Upgrading the Future-
Conclusion
• Kobe Steel has completed R&D of the UBC Process. The Process has now reached the commercialization stage.
• The UBC process gives calorific and commercial value to un-utilized lignite, which is available all over the world.
• The UBC process has various applications beside briquette export.
• A feasibility study for a 5-million-ton project in Sumatra is now under way.
• Kobe Steel is ready to discuss commercial projects with mine owners, power utility companies, traders and engineering companies.
-Upgrading the Future-