ADVANCED INDUSTRIAL TECHNOLOGIES FOR … · advanced industrial technologies for energy...

ADVANCED INDUSTRIAL TECHNOLOGIES FOR ENERGY CONSERVATION IN JAPAN

November, 2007

JAPAN EXTERNAL TRADE ORGANIZATION JAPAN CONSULTING INSTITUTE

Source: UNFCCC HP

1. Importance of Energy Conservation / CO2 Emission Reduction (1) For Suppression / Mitigation of Global Warming

In order to prevent / mitigate climate change (global warming), CO2 in the atmosphere must be reduced to the level before the industrial revolution. In case that CO2 increases at the present rate, the environment of the earth will be disastrous within the century.

(2) Preservation of Energy Resources

World primary energy demand by fuel in the reference scenario Data source: IEA 2004

Recoverable Fuel Resources

Fuel Oil Natural gas

Coal Uranium

Recoverable reserve

1.15 trillion barrels

176 trillion m3

984 billion tons

4.6 million tons

Annual production

28 billion barrels

2.6 trillion m3

5.1 billion tons

54 k tons

Recoverable years

41 67 192 85

Source of data

BP Statistics 2004 OECD/NEA, IAEA

URANIUM (year 2003)

(3) Reduction of Product Cost The cost of products which consume more energy for production will be higher due to higher cost of energy which will soar. In order to lower the manufacturing cost, therefore, it will be essential to reduce the energy consumed for the production. Thus, to survive in the market, the energy consumption must be reduced to the minimum from the view point of lowering production cost emission and CO2.

(4) Effect of CO2 Emission on Commercial Value of Products in the future From the viewpoints of global warming problem and exhaustion of fuel resources, the commercial value of products which consumes more energy accompanying more CO2 emission for production will be lowered resulting in the forfeiture of the market. It is expected that trade barriers may be set against commodities based on their CO2 emission during the production in the countries such as EU.

Energy consumption Higher production cost

Energy consumption

CO2emission

Lower commercial value of productMay become a trade barrier in near future

2. Advantage of CDM (UNFCCC Clean Development Mechanism) Those manufacturing / production technology which produces less GHG (CO2) than the baseline technology (most commercially plausible technology) can take advantage of CERs (Certified Emission Reductions) of CDM which is salable further lowering the production cost while contributing to suppression of global warming. CDM, therefore, is very effective both for improvement of project economics and suppression of global warming.

Example of power generation with 500 MW unit (20 years operation at plant load factor of 75%)

Power generated 500,000 kW×8,760h/y×20y×0.75 = 65.7×109 kWh Primary energy Renewable energy Coal Fuel consumption None 65.7×109 kWh / 0.36×3,600 kJ/kWh = 657×1012 kJ

657×1012 kJ / (24.49×109 kJ/103 ton) = 26.8×106 ton Fuel cost None 26.8×106 ton ×US$ 50/ ton-coal = US$1.34×109 CO2 emission None 25.8 ton-c/109 kJ (Source: IPCC)

657×1012 kJ×25.8 ton-c/109 kJ×44/12=62×106 ton-CO2 CO2 emission credit (Equivalent value)

62×106 ton-CO2 ＝62×106 ×US$20/ton-CO2

＝US$ 1.24×109

Base

Presumption: Net plant efficiency = 36%, Net heat value of coal=24.49×109 kJ/103 ton (referring to IPCC) Carbon emission factor=25.8 ton-c/109 kJ (Source: IPCC), CO2 market price= US$20/ton-CO2

3. What shall be done to mitigate global warming? As the global warming is caused mostly by the accumulation of CO2 in the atmosphere which is caused by combustion of fossil fuels such as coal, oil and natural gas, the consumption of fossil fuels shall be reduced. This will be possible with the following measures:

(1) To adopt high energy efficient technology (system and equipment). (2) To recover and utilize waste energy/heat effectively, including cogeneration. (3) To use less carbon intensive fuels (less CO2 emission for same heat

generation).

Approximate comparison of CO2 emission by fuel Fuel Coal Oil Natural gas

For same amount of heat generation

100 80 60

For same amount of power generation

100 80 45 (Combined cycle plant)

(4) To use of renewable energy such as hydraulic power, solar energy, wind power, geothermal energy and biomass Note: Biomass and biomass derived fuel are considered carbon neutral.

4. Background for high energy efficient industrial technologies developed in Japan

(1) Three time Middle East Oil crises forced Japanese industry to make efforts

for developing high energy efficient industrial technologies in Japan Japan has been dependent on the import mostly from the Middle East of its demand for oil and have suffered oil crises (embargo on oil export by the Middle East oil producing countries) three times, which forced Japanese industry develop high energy efficient technologies.

(2) High energy efficiency industrial technologies developed in Japan High energy efficient industrial technologies have been developed vigorously by Japanese industry since the first oil crisis leading other industrialized nations.

The 1973 oil crisis: began in the wake of the fourth Middle East war. The 1979 oil crisis: occurred in the wake of the Iranian Revolution. The 1990 energy crisis: occurred as a result of the first Gulf War.

GDP and primary energy consumption of Japan

112

496

306

259

0

100

200

300

400

500

600

230

240

250

260

270

280

290

300

310

GDP

Primary energyconsumption

Con

sum

ptio

n （

１０

００

ｋL）

GD

P （

trill

ion

yen）

112

496

306

259

0

100

200

300

400

500

600

1973 2004230

240

250

260

270

280

290

300

3101973 2004

GDP Trillion Yen

Primary EnergyConsumption 1000kLoe

year

Energy Consumption per GDP of Major Industrialized Countries

TOE / million US$

Canada

England USA

France

Japan German

Calculated based on 1995 US$ Source: ENERGY BALANCES OF OECD COUNTRIES 1999-2000,

Energy Consumption of Manufacturing Industries in Japan - 1/2 Thermal power generation (2003)

(Index : 1kWh power basis)

Japan Germany USA France China (Source: ECOFYS)

Manufacturing petroleum product (2002) (Index : 1kl of product basis)

Japan Industrialized Europe USA, Canada Asian countries (Source: Solomon associates)

Steel manufacturing (2003) (Index : 1ton of product basis)

Japan Korea EU China USA Russia (Source: the Japan I & S Federation)

Paper manufacturing (2003) (index : 1ton of product basis)

Japan Sweden Canada USA (Source: METI of Japan)

Base: 100 for Japan Base: 100 for Japan

Base: 100 for Japan Base: 100 for Japan

Energy Consumption of Manufacturing Industries in Japan - 2/2 Cement manufacturing (2000)

(Index : 1ton of clinker basis)

Japan Europe Korea M & South China USA Russia America (Source: Battelle Institute)

Manufacturing caustic soda by electrolysis (2003) (Index : 1ton of product basis)

Japan Korea China USA East E. West E. (Source: SRI Chemical Economics Handbook)

Copper manufacturing (Index : 1ton of product basis)

Japan Europe Asia N. America S. America (Source: Japan mining industry association)

Aluminum plate manufacturing (Index : 1ton of product basis)

Japan World (Source: International Aluminum Institute)

Base: 100 for Japan

Base: 100 for Japan

Base: 100 for Japan

Base: 100 for Japan

ADVANCED INDUSTRIAL TECHNOLOGIES

1. Power generation

2. Steel manufacturing

3. Cement manufacturing

4. Fertilizer and chemical manufacturing

5. Refinery

6. Food industryEnvironment

7. Energy & CO2

8. Heat pump

1. Ultra supercritical pressure coal–fired power generation system

1000MW High temperature ultra supercritical pressure coal–fired power plant

(Source: HP of Mitsubishi Heavy Industries)

2. Pressurized fluidized bed boiler combined cycle plant system

360MW Pressurized fluidized bed boiler combined cycle plant system

(Source: HP of Kyushu EPC)

Coal-fired Power Generation - 1

1ry & 2ry Cyclones Pressure vessel Electrostatic precipitator

Fluidized bed boiler

Coal bunker

DeNOx equipment

Exhaust gas feedwater heater

Gas turbine

Cal slurry pump

Steam turbine

(Source: HP of Toshiba Corporation)

(Source: Catalogue of IHI Corporation)

3. Integrated coal gasification combined cycle system


250MW Integrated coal gasification combined cycle plant


4. Coal gasification SOFC combined cycle

Coal gasification SOFC (Solid Oxide Fuel Cell) combined cycle (Source: HP of Mitsubishi Heavy Industries)

Coal gasification SOFC (Solid Oxide Fuel Cell) combined cycle plant


Coal-fired Power Generation – 2 (for very near future use)

Pulverizer

Coal bunker

Coal gasifier Heat exchange

Oxygen/air

Slag Char

Filter

Sulfur removal device

Inverter Steam turbine

Condenser

Exhaust gas

Compressor

Gas turbine HRSG

Coal

Coal gasifier Filter

Gas turbine

Steam turbine

HRSGChimney

Coal gasifier

Coal feed system

Coal gas

Porous filter

Combustor

Gypsum Wet DeSOx

AirStack

N2

O2

Char

Air Air separating unit

Air compressor

Char

Air

1. Natural gas-fired combined cycle plant system

(Source: HP of Toshiba Corporation)

Gas turbine for 455MW single-shaft Natural gas-fired combined cycle plant


2. SOFC-GT combined cycle (being developed)


SOFC-gas turbine combined cycle package for DPHC


Natural Gas-fired Power Generation

SOFC module SOFC cell tube

Recirculation device

Inverter

Combustor

Gas turbine

Heat exchanger

Fuel

Air

1. Diesel Engine power generation

(Model: Mitsubishi 18KU34)

2. Gas engine power generation

(Model: Mitsubishi Gas Engine)

3. Gas turbine cogeneration (heat/power ratio controllable type)

(Source: HP of Hitachi Zosen Corporation)

4. PEFC cogeneration


Process steam

Feedwater

Fuel

Superheated t

Generator

Compressor

Turbine

Gas turbine

Power Air

Heat recovery boiler

Stack

Exhaust gas

Combustor

Distributed Power & Heat Cogeneration

Wind turbine power generation

(Model: Mitsubishi Heavy Industries MWT95/2.4)

Photovoltaic cell power generation

1,000kW Photovoltaic power generation plant

(Model: Mitsubishi Heavy Industries MA100)

Hydraulic power generation

412MW Pump turbine generator (Francis type pump turbine supplied by Mitsubishi Heavy Industries)

Refuse incineration power generation

132.6MW Refuse incineration power plant

(Singapore Tuas South incineration plant constructed by Mitsubishi Heavy Industries)

Renewable Energy Power Generation

1-1 Advanced Supercritical Pressure Coal-fired Power Plant Power generation Coal-firing Supercritical pressure plant

1. Function and features (1) High efficiency power generation

By applying high temperature supercritical steam condition such as 25MPa 600/600°C to steam cycle, much higher thermal efficiency of plant than subcritical pressure plant is obtainable. Applicable to 300MW and larger unit.

(2) High thermal efficiency over whole operating load range As the boiler is designed suitable for variable pressure operation, high plant efficiency over whole load range is obtainable owing to sliding pressure operation.

(3) Excellent dynamic performance Owing to once-through boiler design with less heat storage capacity of water and metal, excellent dynamic performance is obtained.

(4) Environmentally friendly operation Owing to state of the art combustion technology, environmentally friendly operation in addition to CO2 emission reduction is assured.

2. Plant system

Supercritical coal-fired power generation plant

Electrostatic precipitator

Low NOx burner

Boiler

Lime stone

Unloader Dust net

Coal carrier

Stacker

Reclaimer Coal conveyer

Electricity Transmission cable

Switch -gear Transformer

Generator

Building DeNOx reduction measures

Coalbunker

Steam turbine Catalytic DeNOx

Air preheater

Induced draft fan

Desulphurization plant

Stack 200m height

Flue gas analyzer

Gypsum

Coal ash

Useful ashAsh pond To DeSOx

Forced draft fanRaw water

Water purifier

Ocean

Pulvelizer

Steam

Boi

ler f

eedw

ater

pum

p

Feed

w

ater

Coo

ling

wat

er Ash

Circ

ulat

ing

wat

er p

ump

Indu

stria

l wat

er

Dis

char

ge w

ater

Coa

l

Conde -nser

3. Performance advantage

Steam Pressure & Temperature

0 25 50 75 100 107

SC Pressure MPa

SC Main steam temp °C

SC Reheat steam temp °C

Sub PressureMPa

Sub Mainsteam

Sub RH Steam temp °C

Unit load %

0

50

100

150

200

250

300

350

400

450

500

550

600

650SC steam temp.

Sub steam temp

SC steam pressure

Sub steam pressure

Tem

pera

ture

℃

30

25

20

15

10

5

Pre

ssur

e M

Pa

Improvement of plant efficiency

4. System and structure

(1) Boiler

The main difference of supercritical sliding pressure boiler from subcritical pressure drum type boiler with regard to structure is furnace water wall construction due to once-through flow in the former furnace water wall and recirculation flow in the latter.

High reliability of furnace water wall is assured with vertical tube structure with rifled tubes or spirally-wound structure with smooth or rifled tubes.

(2) Turbine generator

The structure of steam turbine for supercritical plant is basically same as that for subcritical plant except for the alteration material and physical dimensions.

(3) Plant

•Distributed Digital Control system is installed for better dynamic performance.

• Demineralizer is provided for better boiler feedwater quality control.

5. FWW mass velocity & FWW structure

Furnace water wall (FWW) flow Furnace water wall structure

Vertical tube wall with rifled tube Spirally-wound tube wall with smooth tubes

60deg. Inclined tube wall

Vertical tube wall

Critical mass velocity

0

500

1000

1500

2000

2500

3000

3500

0 25 50 75 100 107

Unit load %

Mas

s ve

loci

ty k

g/m

2 /s

Massvelocity(MV)in verticaltube kg/m2/s

MV in 60deginclinedtube kg/m2/s

Critical MVfor smoothtube kg/m2/s

Critical MVfor insiderifled tube kg/m2/s

6. Energy Saving /CO2 Emission Reduction

More than 5%～(8%) reduction of fuel consumption and CO2 emission are

achievable compared with the conventional plant with steam condition of

16.7MPa×538°C /538°C.

500MW coal-fired power plant (load factor 0.75)

Plant Conventional plant Supercritical plant

Coal consumption Base - 50,000～90,000 ton/year CO2 emission Base - 140,000～230,000 ton/year

1-2 Integrated Coal Gasification Combined Cycle Plant Power Generation Coal gasification IGCC 1. Function (1) Integrated coal gasification and power generation (2) High efficiency power generation with coal (3) Environmentally friendly coal-used power generation

2. Plant system

Integrated coal gasification combined cycle

Coal gasifier

Coal feed system

Coal gas

Porous filter

Combustor

GypsumWet DeSOx

AirStack

N2

O2

Char

Air Air separating unit

Air compressor

3. Features (1) High efficiency (～50% LHV base) power generation with coal is obtainable,

resulting in less coal consumption and less CO2 emission.

Presently 250MW air-blown IGCC is being demonstrated for performance and

operability.

(2) Wide range of coal can be used for fuel.

A wide range coal is gasified in gasifier, transforming into coal gas suitable for

combustor of gas turbine.

(3) Less emission of SOx, NOx and particulate emission per kWh.

In addition, SOx is recovered as gypsum with DeSOx equipment and NOx

formation is minimized by reducing atmosphere in gasifier and low NOx

combustor of gas turbine. Dust is removed with porous filter before entering

into combustor of gas turbine.

(4) Useful byproduct-slag

250MW IGCC demonstration plant at Nakoso PS in Japan Source: HP of Mtsubishi Heavy Industries, Ltd.

1-3 Gas Turbine Combined Cycle PlantPower generation Natural gas firing Gas turbine combined cycle (GT CC)

1. Function (1) Highest efficiency is obtainable among the natural gas-fired power generation

technologies commercially available at the present (ηHHV～52%). (2) Most environmentally friendly power generation using fossil fuel commercially

available at the present.CO2 emission is less than a half of coal fired plant. (3)Suitable for large output. The output of a single shaft type CC (gas turbine

combined cycle plant composed of a gas turbine with a steam turbine on one shaft) is ～ almost 500MW.

2. System

Single shaft type CC

LP steam turbine

HRSG

Stack

Gas turbine

HP/IP STturbine

Generator

Structure of advanced large capacity gas turbine

(Source: HP of Mitsubishi heavy industries, Ltd.)

1- 4 Distributed Power & Heat Generation (Cogeneration) Power Generation of

power and heat Gas turbine, Steam turbine, Diesel engine, Gas engine, Fuel Cell

1. Function

(1) Cogeneration (combined heat and power generation or CHP) means generation of not only electric power generation, but also heat (steam and/or hot water) using the energy of exhaust gas or low temperature steam from power generation plant.

(2) As for the engine, diesel engine, gas engine, gas turbine, gas turbine combined cycle, steam turbine plant and fuel cell are used depending on quality of available fuel, steam/hot water condition required, capacity and so on.

(3) Compared with power generation plant of which energy efficiency is about 20 - 52%, much higher energy efficiency up to 80 to 90% is obtainable, saving fuel and reducing GHG (CO2) to about a half. The heat (steam/hot water) is used for refrigerating system, factory, swimming pool, bath, home uses.

2. System The following cogeneration system is an example which uses gas engine. By installing HRSG (heat recovery steam generator) to produce steam with waste heat of exhaust gas and heat exchangers to produce hot/warm water with the heat of cooling water, energy efficiency is increased from 43.5% to 72.5% while maintaining power generation efficiency of 43.5%.

Power generation efficiency: 43.5% ⇒ Cogeneration efficiency : 72.5%

(Source: HP of Mitsubishi heavy ind)

Warm waterOil

l

Cooling water Lub.oil

OptionalOilcooler

Feedwater HRSG

Exhaust

Fuel 100%

STEAM

Power

Hot water

Engine

Optional

Generator

Air

1ry cooler

Air cooler

Warm water

3. Features (1) High energy efficiency while keeping high power generation efficiency. (2) Various kinds of engines are applicable as the main engine. (3) High energy efficiency results in reduced fuel consumption and CO2 emission.

4. Energy Saving/ CO2 Emission Reduction (1) Fuel consumption is much reduced to maximum about 50% by cogeneration

from exclusive power and independent heat generation (Example: Power generation efficiency of ηg＝40% is possible to be raised to ηc＝80% of cogeneration efficiency)

(2) CO2 emission is reduced at the rate of ηg /ηc

Comparison of energy efficiency

Plant Power generation only Cogeneration Energy efficiency 20～50 ％～80 ％ Fuel consumption Base 1/2 CO2 emission Base 1/2

1- 5 High Temperature Chemical Recovery Boiler Pulp/paper industry Chemical recovery & power

generation Chemical recovery boiler

1.Function Chemical recovery boiler burns black liquor as fuel for chemical recovery boiler for power generation and recovers chemicals contained in black liquor.

2. Features (1) Elevated Steam Conditions

Our highest steam condition of 13.3 MPa, 515 is the world record.

(2)Anti-Corrosion Measures for Furnace Tubes

As a countermeasure to corrosive black liquor, one of following furnace wall

protection is used.

- 25 Cr and 18 Cr overlay weld (for high pressure boilers)

- Stud +P.C.O. (for low - medium pressure boilers)

- Composite tube (optional)

High temperature chemical recovery boiler

High temperature high pressure steam above 500°C 9.8kPa

Steam drum Super heater

Evaporator

Economizer

Steam

Feedwater pump Deaerator

Exhaust gas temperature ˂ 130°C

3ry air

FD fan

FD fan

Furnace

2ry air

1ry air


ID fun

Feedwater Exhaust feedwater heater

Stack

Indirect black liquor heater

Black liquor

Steam

1- 6 Geothermal Power plant Power generation Geothermal energy Steam turbine generator

1. Outline (1) Clean power generation without fuel

Geothermal energy takes the form of high temperature water or steam that comes from deep (300 to 3,000 meter deep production wells) in the earth where it has been heated by magma. This is a high efficiency source of ecologically friendly energy for electric power generation.

(2) No CO2 (GHG) emission Eligible for CDM In geothermal electric power generation, no fossil fuel is used for generation of power since the heat energy is contained in the hot water or steam from the underground so that basically no CO2 is emitted except for that accompanied (approx. 1/20 of fossil fuel-fired power generation).

(3) Effective utilization of geothermal energy High temperature water or steam under pressure gushes out passes through separator (High pressure fluid separator) and flusher (Low-pressure fluid separator) to separate steam from high-temperature water and to produce low pressure steam. The clean steam produced at these stages is sent to steam turbine which converts the geothermal heat energy to electric power.

2. Types of geothermal power plant cycle

(1) Dry steam cycle In case dry steam comes from geothermal reservoir, the steam is directly routed to turbine generator to produce power.

(2) Flash steam cycle Hot water usually at temperatures greater than 360° F (182° C) that is pumped under high pressure to the generation equipment at the surface. Upon reaching the generation equipment the pressure is suddenly reduced, flashing some of the hot water into steam. This steam is then used to power the turbine/generator units to produce electricity. The remaining hot water not flashed into steam, and the water condensed from the steam is generally pumped back into the reservoir.

(3) Binary cycle The water from the geothermal reservoir is used to heat another “working fluid” which is vaporized and used to turn the turbine/generator units. The geothermal water and the “working fluid” are each confined in separate circulating systems or “closed loops” and never come in contact with each other. The advantage of the Binary Cycle plant is that they can operate with lower temperature waters (225°F - 360°F), by using working fluids that have an even lower boiling point than water.

3. Energy saving / Reduction of GHG emission As no fossil fuel is burnt, fossil fuel required for the power generation equivalent to that generated with geothermal energy is saved.

Example: 300MW power generation with load factor 75%

Energy source Geothermal Coal firing Fuel required 0 690×103 ton/year

CO2 emission Approx. 90×103 ton/year

1,870×103 ton/year

Emission reduction 1,780×103 ton/year Base

Present worth of ERs for 20US$/ton CO2

35.6×106 US$/year Base

As shown in the table, geothermal power generation is a very effective means of power generation to reduce GHG emission. In case that the project (300MW geothermal power generation with load factor 75%) is registered as a CDM project, the CER will worth for approx. 17.8×106 US$/year as shown in the above table.

Schematic of typical plant system

(Source: HP of Mitsubishi heavy industries, Ltd.)

1- 7 Amorphous-Micro Crystal Si Thin Film Solar Cell Power generation Renewable energy Photovoltaic cell

1. Function (1) Clean power generation with sunlight (renewable clean energy) with no fuel

consumption and no CO2 emission (2) Suitable for distributed power generation which can be deployed anywhere where sun

shines. 2. Structure / System

It is a thin film tandem type PVC composed of amorphous silicon layer and crystal silicon PVC layers to absorb the wider range of wavelength of sun light.

Mechanism of high conversion rate of sunlight to electricity of amorphous-microcrystalline Si PVC

3. Features (1) Much less material required

The quantity of raw material required for amorphous-microcrystalline Si

tandem type thin film photovoltaic cell is much less than crystalline Si PVC.

The thickness is approx. 1/100 of single crystalline PVC.

(2) Excellent performance at higher temperature

It is advantageous for hot/warm region because that amorphous-

microcrystalline Si PVC produces more electricity than crystalline Si and

polycrystalline Si PVC at higher temperature (>25℃).

(3) High quality Si is not required

It does not require high quality Si as required for crystalline/polycrystalline Si

PVC, requires much less Si and less energy for manufacturing, resulting in the

most environmentally friendly PVC of all types.

4. Energy Saving / CO2 Emission Reduction

Photovoltaic power generation is a typical renewable energy power generation

technology which does not consume any amount of fuel for power generation.

Therefore the quantity of fossil fuel required for the same amount of power

generation with thermal power is saved with photovoltaic power generation

resulting in no emission of CO2.

Example: 10 MW power generation

PVC power

generation

Coal-fired power generation

Fuel consumption None Approx. 3,500 kg coal/h

CO2 emission None Approx. 9,500 kgCO2/h

1- 8 Micro water turbine plant Power generation Renewable energy

(hydraulic power)Micro water turbine

1. Function (1) Clean power generation

Power generation utilizing hydraulic power (renewable clean energy), using no fossil fuel and producing no CO2 (GHG).

(2) Suitable for distributed power generation Electric power is generated utilizing water stream of small flow rate and head, such as small river, irrigation channel, sewage water, pressure reduction and other sources.

2. Feature (1) Installation at site is simple and easy owing to the package type design.

Type: horizontal shaft propeller type (2) Maintenance is easy due to the simplified structure. (3) Appropriate selection for the needs is possible.

Generation output: 3～250kW, Flow rate: 0.1～3m3/s, Net head; 2～20m

3. Structure

Horizontal shaft propeller type water turbine generator

Source: Fuji Electric Systems Co. Ltd.

4. Energy saving / CO2 emission reduction

Example: 100kW hydraulic plant Power plant Coal-fired plant Hydraulic plant

Coal consumption Approx. 35 kg/h 0 CO2 emission Approx. 95 kg CO2/h 0

1- 9 Wind Turbine Generator Power Generation Wind turbine

1. Function

(1) Clean power generation with wind (renewable clean energy) with no fuel consumption and no CO2 emission

(2) Suitable for distributed power generation deployed where wind is available.

2,400 kW wind turbine generator and major dimensions

( Model： Mitsubishi MWT95/2.4)

2. Structure

3. Features

(1) Excellent performance in moderate wind speed zone (IEC Class ⅡA)

(2) Variable pitch control for high efficiency over a wide range of wind speed and

for wind load reduction

(3) Smart Yaw technology indigenous to MHI’s wind turbine which increases

reliability for the frequent change of wind direction


Power generation with wind turbine does not consume any amount of fuel.

Therefore the quantity of fossil fuel required for the same amount of power

generation with thermal power plant is saved with wind power generation,

resulting in no emission of CO2.

S-4 Sintering material supply equipment S-1 Blast furnace gas (BFG) firing

gas turbine combined cycle S-6 Direct current arc furnace with S-8 Hot slab direct transfer rolling S-9 Continuous annealing furnace

S-5 Pulverized coal injection into blast S-7 Continuous casting machine S-10 Wire-rod coil convection heat treatment

S-15 High efficient ignition equipment for S-2 Blast furnace top pressure

power generation equipment S-12 High frequency electric melting furnace S-11 Tube low-temperature forge-welding

S-16 Coke oven coal humidity conditioning S-13 Cast iron electric melting groove type S-21 Continuous Annealing Furnace

S-17 Cokes dry quenching equipment S-3 Ditto S-14 High energy efficiency type alloy refining

S-18 Heat recovery from sintering machine

cooler

S-22 Energy recovery from converter furnace

exhaust

S-19 Heat recovery from sintering furnace h

S-23 Heat recovery from converter exhaust gas

Blast furnace gas holder

Factory

Dust catcher Venturi scrubber Raw

coal Coke

Gas separating unit Generator

Oxygen, secondary raw material Scrap iron

Coke furnace Molten iron

Air heating furnace Blast furnace

Sintering machine

Powder coke

Coke furnace

Coke car Coke at 200°C

High pressure steam Low pressure

steam

Exhaust heat boiler

Exhaust duster

Turbine Generator Condenser

Belt conveyor Deaerator

Circulation blower Cyclone Pure water tank

Electric furnace

Scrap iron

Molten steel

Converter

Continuous casting equipment

Billet

Bloom

Slab

Heating furnace

Major products Rail Steel sheet pile Section steel Bar

Wire rod

Plank

Hot rolled coil Hot rolled plank

Cold rolled coil Cold rolled steel sheet Steel sheet for plating Welded steel pipe Pipe steel pipe

Seamless steel pie

Cast iron products Seamless steel pipe manufacturing equipment

Welded steel pipe manufacturing equipment

Cold strip mill

Hot strip mill

Plank mill

Rolling

Strip steel mill

Looping mill

Straightforward Rolling

Soaking pit Ingot making mill

Uniform heating furnace

◎Energy consumption ratio for each process (There are portions for which energy consumption can not be expressed by a numerical value, therefore the total of each process is not always 100%.)

◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)

◎Electric power saving ratio by exhaust heat power generation

Petroleum fuel Non petroleum fuel Electric power Steam

2. Steel Manufacturing

2-1 Blast Furnace Gas Firing Combined Cycle Steel / iron manufacturing Waste heat recovery Power generation

1. Function

(1) Generating electricity using blast furnace gas as the fuel

(2) High power generation efficiency obtained by installing advanced BFG fired gas

turbine combined cycle

2. Features

(1) 1.5 times of electricity generation of that with conventional power plant

(2) Utilization of low calorific waste gas as the fuel. (Approx. 1000kcal/Nm3)

(3) High reliability is assured by more than 20 years of successful operation record

3. System Combined cycle plant adjusted suitable for blast furnace gas firing.


(1) Technical Features Blast furnace gas generated as the by-product of steel mill is normally used in conventional boiler or discharged via flare stack. Additional electricity can be generated with application of combined cycle.

(2) Energy Saving/CO2 Emission Reduction

Power output comparison Plant BFG-fired combined

cycle plant BFG-fired conventional

plant Coal-fired plant

Power produced

985×106 kWh 700×106 kWh 985×106 kWh

Coal fired 0 (BFG) 0 (BFG) 700,000 ton/y

CO2 emission

0 (Base) 0 (Base) 200,000 ton/y

2-2 Blast Furnace Top-pressure Power Generation Turbine

Steel/iron manufacturing Energy Recovery Expansion Turbine 1. Function

(1) Waste energy(pressure) recovery system

(2) Blast furnace gas expansion

(3) Stable plant (blast furnace) operation

2. Features (1) Power generation without combustion of any kind of fuel

(2) About 30% of energy is recoverable as electricity

(3) Simplification of plant (blast furnace) operation

3. Top pressure turbine system

Power

(Improvement)

Blast furnace gas

Blast furnace

Duster

Gas cooling system

Dust bin

Screw conveyor

Top pressure turbine

Septum valve

New

Blast furnace gas pipe

Generator

Blas

t furn

ace g

as

Cooli

ng w

ater

Dry-type dust collector (Bag filter)

Existing


(1) Technical Features High efficiency energy recovery system for blast furnace gas with expansion

turbine.

(2) Energy Saving and CO2 Emission Reduction Approx. 30% of the mechanical energy of BFG could be recovered as

electricity.

System does not use any fossil fuel, does not produce any CO2.

2- 3 Waste Heat Recovery Power Generation Power generation Heat recovery Steam turbine cogeneration

1. Function

(1) Heat recovery from exhaust (waste) gas of which temperature is higher than 250℃ with Heat Recovery Steam Generator (HRSG) to produce steam. Various kinds of hot gases are usable for the heat recovery and steam generation. Higher the gas temperature, higher efficiency is obtainable.

(2) The steam generated by the boiler is used as the driving media of the steam

turbine coupled with the boiler. Thus steam turbine generator is operated to generate the power. Unit capacity is 1,000kW and larger. Larger the unit capacity, better efficiency is obtainable.

(3) As the heat sources are exhaust gases, usually no addition of fossil fuel is

required. In case the gas temperature is low, supplemental firing is necessary.

2. System

Exhaust heat recovery power generation

Turbine generator Condenser

Low pressure steam Preheater

HRSG

Superheater

Exhaust gas Cooling tower

Vacuum pump

Cooling water

High pressure steam

Feed water

4. Energy Saving / CO2 Emission Reduction As the waste exhaust gasses are utilized, (1) Fuel consumption is basically zero. (2) CO2 emission is zero.

Comparison of power plant and cogeneration plant

Plant Power generation only Cogeneration Energy efficiency ～30 ％～80 ％ Fuel consumption 0 0 CO2 emission 0 0

2-4 Cokes Dry Quenching Equipment Steel/ Iron manufacturing Coke oven Fire extinguisher

1. Function After hot coke has been manufactured in the coke oven, this equipment (coke

dry quenching (CDQ)) cools it with inactive gas, i.e., ordinary exhaust gas, in an

airtight container so that inactive gas warmed by heat exchange will be

recovered and will be used for steam or for power generation with steam as the

heat source.

2. Features For general steelmaking plants, 7% to 8% of the energy consumption is

occupied by the area of coke. Approximately 45% of this consumption is

sensible heat of hot, or red heated, coke. This equipment recovers this sensible

heat. In the conventional method, fire of this hot coke is extinguished by watering

after being taken out from the coke oven, and the sensible heat generated at that

time was emitted into atmosphere. (The equipment is called water spray type

red-heated coke cooling equipment.)

The new equipment consists of (1) a coke cooling furnace, which contains a

spare and a cooling chamber, and (2) an exhaust gas boiler. The red-heated

coke (approximately 1,200℃) enters the spare chamber, blown there from the

top of the furnace, exchange heat with the circulating inactive gas. The inactive

gas that has become hot (800℃) converts water into steam while circulating in

the heat tube of the exhaust heat boiler. The temperature of the coke

temperature decreases to 200℃ at the output port of the furnace.

Energy Saving / CO2 Emission Reduction

When this equipment is installed, steam of 0.5 t-steam/t-coke can be recovered.

Steam of 0.5 t is equivalent to approximately 150 kWh (300 kWh/t-steam).

3. Structure/System

Cokes Dry Quenching system

Hoisting column

Hoist Charging equipment

Cyclon

Coke bucket

Coke car

Coke 200°C

Conveyor Quarrying equipment

Steam

Feed water

Gas circulating fan

Duster

Improved

2- 5 Regeneration Burner Steel/ Iron manufacturing Burner Regeneration burner

1. Function Regeneration burner is composed of minimum a pair of burners. When one

burner is in operation, the other works as heat storage type heat exchanger and

also as exhaust conduit. Thus they work as a burner and heat exchanger

interchangeably recovering the heat contained in exhaust gas.

2. Features (1) Heat is effectively recovered up to 50% contained in exhaust gas.

(2) Better combustion performance of burner

As the combustion air is heated by the heat stored in the storage body

(commonly ceramics) before combustion, stable complete combustion condition

is established.

(3) As the heat storage mass works as heat exchanger, system is simplified

3. Structure/System

Regeneration burner

Exhaust gas temperature 170°C

Exhaust gas 4 direction change valve

Heat storage mass (Honey cone ceramics type)

Heat storage burner Improvement

Abcd

Raw material crashing process

Lime stone

Clay

Quartzite

Blast furnace slag


Raw material silo

Hard type raw material crashing mill

Boiler

Cooling tower

Sintering process

Blending silo

Turbine Generator

Cement exhaust gas SP tower Hard type lime stone crashing

Bag dust collector

Chimney

Chimney

Chimney

Cyclone Kiln

Clinker cooler Clinker

crasher


Boiler

Finishing process

Clinker silo

Lime

Spare crasher

Air separator

Finishing mill

Bag packing and shipment

Cement silo

Cement bag packer Shipment by truck (bags)

Shipment by truck (bulk)

Shipment by cement only ship (bulk)

Cement silo

3. Cement Manufacturing Process

C-2 Vertical roller mill C-1 Waste heat recovery system for cement plant C-6 Pre-crusher

C-13 Vertical roller mill for slag grinding C-3 Suspension pre-heater C-7 Pre-Grinder

C-16 Coarse coal recirculation of vertical roller mill

C-4 NSP method (calciner) cement Kiln C-8 Highly efficient cement separator

C-5 Vertical roller mill C-12 Vertical roller mill for grinding clinker C-9 Highly efficient clinker cooler

C-10 NSP method cement Kiln – Fluidized bed pre-calcining

C-11 Shaft Type Cement Kiln

C-14 Utilization of town waste as material and fuel for cement

C-15 New type clinker cooler

C-17 5-stage cyclone suspension pre-Heater

C-18 Low pressure loss suspension pre-Heater

C-19 Utilization of used tires as fuel for calcinations

C-20 Power generation with waste heat

C-21 Utilization of Used Plastics as fuel for Calcinations

◎Energy consumption ratio for each process (There are portions for which energy consumption can not be expressed by a numerical value, therefore the total of each process is not always 100%.)


◎Electric power saving ratio by exhaust heat power generation

Fuel Electric

(Power generation and others) (Power generation and others)

Fuel Electric

3-1 Power Generation utilizing waste heat from cement manufacturing plant

Turbine

Electric generator

Flow of steam or water Flow of gas

Pre

-hea

ter

Kiln

Boiler

Condenser

Calciner

Clinker cooler

Sintering process Product process

Chimney

Improvement

HP/LP flasher

Dust collector

Boiler

With 3,000t/d cement plant, approx. 6,500kWpower generation is possible.

Pre

heat

pro

cess

Material process

Primary reformer

◎Energy consumption ratio for each process


Fuel Electric power

Fuel Electric power

Note: In case of CA-PE-7+, both steam and electric power are reduced by 100% because no reformer is necessary.

4. Fertilizer & Chemical Manufacturing Process - 1

F-2 Exhaust heat recovery heat exchanger type primary reformer

F-6 CO oxidizing reactor F-1 Urea production technology F-3 High conversion rate synthetic reactor

F-7 Ammonia manufacturing plant integrated with high-pressure coal gasification power plant

F-10 High-pressure water power recovery turbine

F-4 Low differential pressure synthetic reactor

F-8 Synthesized gas compressor outlet heat recovery system

F-11 Pre-reformer for ammonia-reforming process

F-9 Synthesized gas compressor outlet heat recovery system

F-12 Exhaust heat recovery system for primary reformer

F-13 Gas turbine-driveｎcompressor for ammonia plant

F-5 Isothermal CO conversion

reactor

Gasification (reforming) process

Raw material

Heating furnace

Steam Boiler feed water

Steam drum

Steam Air

Secondary reformer

Fuel

CO2 conversion tower

CO conversion process Gas refining process

CO2 absorbing tower

CO2 stripper

Methanator

Synthetic process

Ammonia synthetic tower

Purge

compressor

Flash gas

Separator

Product ammonia

F-15 Electrolyzer with ion-exchange membrane F-14 Quadruple effect-type concentration for electrolytic caustic soda with barrier membrane

F-16 Saline solution electrolyzer with ion-exchange membrane F-17 Brine preheater with salt water electrolytic heat recovery F-18 Active cathode for electrolysis with ion-exchange membrane



Steam Electric power

Steam Electric power

4. Fertilizer & Chemical Manufacturing Process - 2Caustic soda manufacturing process

Raw material salt refining process

Raw material salt

Raw material salt melting and refining

Saturated salt

Refining for ion exchange membrane

Chlorine

Anode liquid tank

Electrolytic process

Anode Cathode

Anode chamber Cathode chamber

Electrolytic vessel

Hydrogen

Concentration process

Cathode liquid tank

Steam

Caustic soda

Water

Evaporating system

Caustic soda

Cooling water

Condenser

4. Fertilizer & Chemical Manufacturing Process - 3

F-19 Packing for quench tower tray F-20 Turbo expander for methane tower top gas line F-21 Cold thermal energy recovery from methane-separating tower bottom liquid


Fuel Steam Electric power

Naphtha decomposing manufacturing process

High pressure steam

Steam super heater

Naphtha★Steam

Decomposing furnace

Common stack

Heavy oil cracking tower

Cracked heavy oil refining tower

Cracked heavy oil

Light heavy oil refining tower

Separated gas

Alkali cleaningtower

Compressor (1 - 3 stages)

Light constituent separating tower

Water stripper

Decomposed gas water removing

tower

Four stages

Hydrogen Methane Off gas

Ethane removing tower

Acetylene

Water reaction tower

Methane removing tower (methane

decomposing tower)

Stripper propylene tower

Acetylene water reaction tower Propylene tower

Ethylene tower Green oil decomposing tower

Ethylene intermediate tank

Recycled ethane Propylene C3LPG

Propane removing tower

Pentane removing tower

C4 -C

5 separating tower

C4 Residue Separated gasoline Rerunning tower Separated kerosene

C5 residual Separated heavy oil

◎Energy consumption of consumption ratio for each energy

Fuel, Steam Electric power

Decomposed gas cooling tower (quench tower)

Steam★

4-1 Urea Production Plant Fertilizer industry Urea production Synthesis section

1. Function (1) Urea Production

2. Structure / System (1) A urea plant is composed of five sections such as urea synthesis, purification,

recovery, concentration and product forming section.

(2) Major feature of this technology is in the urea synthesis section which contains

a reactor, a stripper and a carbamate condenser.

(3) Liquid ammonia is fed to the reactor via the HP Carbamate Ejector which

provides the driving force for circulation in the synthesis loop. The reactor is

operated at an N/C ratio of 3.7, 182 °C and 152 bar.

(4) Urea synthesis solution leaving the reactor is fed to the stripper where

unconverted carbamate is thermally decomposed and excess ammonia and

CO2 are efficiently separated by CO2 stripping.

(5) The stripped off gas from the stripper is fed to the Vertical Submerged

Carbamate Condenser, operated at an N/C ratio of 3.0, 180°C and 152 bar.

(6) Ammonia and CO2 gas condense to form ammonium carbamate and

subsequently urea is formed by dehydration of the carbamate in the shell side.

(7) Reaction heat of carbamate formation is recovered to generate 5 bar steam in

the tube side. A packed bed is provided at the top of the Condenser to absorb

uncondensed ammonia and CO2 gas into a recycle carbamate solution from the

MP absorption stage. Inert gas from the top of the packed bed is sent to the

purification section

3. Features (1) Ground Level Reactor: The sophisticated two-stage synthesis concept

employing a Condenser and an HP ejector enables the HP equipment in the synthesis section to be laid-out very compactly in low elevation.

(2) Less Corrosion: TOYO and Sumitomo Metal Ind., Ltd. (SMI) have jointly developed new duplex stainless steel DP28W™ for urea plant. The biggest advantage of duplex stainless steel is the excellent corrosion resistance and passivation property in urea-carbamate solution.

(3) Clean Effluents: The liquid effluents from the urea plant contaminated with NH3, CO2 and urea are processed in the process condensate stripper-urea hydrolyzer system. The process condensate leaving the system is purified to 1 ppm of urea and 1 ppm of NH3. The exhaust air from the prilling tower (or granulator) is scrubbed through a packed bed scrubber to reduce the urea dust content to 30 mg/Nm3-air.

(4) Easily revamp a conventional urea plant: Existing urea reactor can be re-utilized for conventional solution recycle process or ammonia stripping process

3. System of a total recycle CO2 stripping urea process

Urea production process (typical)

4. Energy Saving/CO2 Emission Reduction

(1) Technical Features

The operation conditions of the synthesis section have been optimized under

lower operation pressure than in the previous process. As a result, a

remarkable reduction in energy consumption has been achieved.

(2) Energy Saving/CO2 Emission Reduction

This technology realizes 30% reduction of the energy consumption in a urea

plant compared with the total recycle process and 10-20% compared with the

conventional stripping technology. As one of example, the reduction of 550,000

kcal/ton of urea can be expected by modification of the total recycle urea plant

by this technology.

Process Flow Diagram

Urea manufacturing plant

4-2 N2O (Nitrous oxide) Decomposition Plant Fertilizer industry

Decomposition of N2O (GHG) N2O decomposition plant

1. What is N2O and how much is its global warming potential? (1) Nitric acid (HNO3) is an important component for synthetic fertilizers such as

KNO3 and NaNO3. (2) N2O is undesired byproduct of HNO3 production. In order to produce nitric

acid, ammonia (NH3) is oxidized into NO with catalyst. NH3 + 2O2 → HNO3 + H2O 4NH3 + 5O2 → 4NO + 6H2O 4NH3 + 4O2 → 2N2O + 6H2O 2NH3 + 8 NO → 5N2O + 3H2O

(3) N2O is a GHG of which global warming potential is 310 times higher than CO2 which is the most popular GHG mostly produced by combustion of fossil fuel.

(4) Therefore it is effective for mitigating global warming to decompose it into non greenhouse effect gases such as N2 and O2

2. How is N2O decomposed? (1) Catalytic decomposition equipment is installed between HNO3 absorber and stack. (2) N2O is decomposed while it flows through the equipment.

N2O → N2 + (1/2)O2

3. Schematic of N2O decomposition plant

Catalytic NOx and N2O decomposing system

Fig. 1

R-1 Pinch technology

R-2 WIN TRAY R-8 Waste heat boiler for sulfur recovery

◎Energy consumption ratio for oil refining entire process Fuel and steam: 88% Electric power: 12%


◎ Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)

Fuel, steam Electric power

Fuel, steam Electric power

Fig. 2

Street asphalt

Air cooler

Alkylation

MTBE

Oil refining entire process

Crude oil normal pressure distillation system process (Fig. 2)

Crude oil

Naphtha

Kerosene

Light oil

Gas oil

Atmo

sphe

ric di

stilat

ion

Hydrotreater L naphtha

H naphtha

Gas

LPG recovery

Naphtha

Gasolineconditioner Refomed

gasoline Kerosene

Diesel Light oil

Gas LPG

Regular gasoline Premium gasoline Jet fuel

Kerosene

Diesel light oil

Methanol

Light v gas oil Heavy v gas oil

FCC gasoline FCC light oil

Heavy oil B

Asphalt Asphalt conditioner

Sulphur

(Fig.4)

Hydrotreater

Vacuume distlation

Fluid catakytic cracker

Atmospheric bottomsr

Hydrogen Generator

Hydrotreater

Vacuume residuum

FCC feed hydrotreater



Desulphurized heavy oil

Desulphurized heavy oil

Heavy

oil

conditi

oner

Heavy oil A

Heavy oil C

Lubrication oil process Sulphur recovery plant

5. Refinery Process - 1

R-9 Distillation column with Intermediate reboiler

R-12 Cogeneration using gas turbine exhaust gas as

combustion air for heating furnace

R-13 Rotary Regenerative Burner System

R-3 Hydro-carbon vapor recovery system

R-4 Dense loading technology

R-10 Hydrogen membrane separator




Common equipments Oil refining annexed equipments Hydrogen manufacturing equipments


Crude oil normal pressure distillation system process

Crude oil

Primary side reflax

Secondary side reflax

Main distillation tower

Stripper

Stripping steam Stripping

steam

Naphtha stabilizer

Gas recovery

Naphtha splitter

Recirculation tank

Light naphtha

Reboiler

Reboiler

Naphtha hydrogen treatment refining facility

Heat exchanger Heavy naphtha

Kerosene

Light light oil

Heavy light oil

Atmospheric bottoms

Fig. 3 Fig. 4

Steam

Hydrogenation desulfurization system process

Crude oil

Stripper

Recirculated hydrogen

Hydrogen

Reactor

Heating furnace

Injection water

High press. tank

Low press. tank

Fuel gas

Receiving tank

Heating furnace

Light oil

Off gas rinse

Waste water Product oil

R-6 Power recovery of CO gas R-7 Power recovery system with mixed fluid condensing turbine R-11 Heat pump type PP separator

◎Energy consumption ratio for each energy


Fuel Steam Electric

Fuel Steam Electric

5. Refinery Process - 2

◎Energy consumption ratio for each energy


Fuel Steam Electric


To oil separator

Flowing contact decomposing system process

Contact reforming system process

Reaction tower

Heating furnace Raw material naphtha

Combined feed heat exchanger

Hydrogen gas

Separator

Reformate

Stabilizer Off gas

R-5 Reduction in blown steam by column top t l

Reduced pressure distillation equipment process

Raw oil

Stripping steam

Heating furnace

Steam

Quench oil

RP residuals

Steam Flash tower by RP

Light RP oil

Wash oil Heavy RP oil

Slop oil tank

Slop oil

RP light oil

Steam generator

CO boiler

Air blower

Exhaust gas cooler Exhaust gas

treater

Raw oil

Gasoline

Main

distill

ation

towe

r Low pressure evaporator

18% recover Light oil

Heavy oil

High pressure evaporator

Medium, low pressure evaporator

6-1 Methane Fermentation System Utilization of

waste Methane fermentation

Power generation Fertilizer production

1. Function (1) Sanitary treatment of food waste and animal waste,

(2) Producing methane gas from waste to generate electricity,

(3) Producing liquid fertilizer and compost.

2. System (1) Waste is put into Methane fermentation tank through receiving facilities,

(2) Methane gas produced is supplied to gas engine to generate electricity.

(3) Digestive fluid discharged from the tank is utilized as liquid fertilizer.

(4) Waste dehydrated in receiving facilities is utilized as compost.

4. Energy Recovery & Methane/CO2 Emission Reduction

(1) From 85 ton/d of waste, 2000kWh/d electric power is produced, 35 ton/d

liquid fertilizer and 15 ton/d compost are obtained,

(2) Compared with direct landfill disposal, CH4 (GHG) emission is greatly

reduced CH4+2O2 → CO2 + 2H2O

Fermentation 2000kWh/d electric power

35 ton/d liquid fertilizer

15 ton/d compost

85 ton/d of waste

6.2 Multi-Fuel (Biomass and Waste) Fired Boiler Utilization of biomass

and waste Multi-fuel fired boiler Fluidized bed boiler

1. Function

Utilization of various low grade fuels, waste and biomass such as low grade coal,

biomass (wood, bark, pulp sludge), used tire, RPF, RDF, oil cokes and others for

power generation

2. Features (1) Clean utilization of various kinds of fuels. Owing to in-furnace DeSOx system,

independent DeSOx equipment is not required. With Low NOx combustion

system and in-duct DeNOx equipment, independent catalytic DeNOx

equipment is not required.

(2) High combustion efficiency without fine grinding of fuel.

(3) Wide operating load range and excellent dynamic performance

Fluidized bed boiler system

In-duct DeNOxBiomass Waste Coal Steam turbine

Receive, store and supplyequipment of coal, biomass, waste

Limestone storage and supply system

Ash treatment system Ash treatment system

Circulatin fluidized bed boiler

6-3 Ethanol Production from Molasses and Bagasse Bio-fuel/Food Ethanol/Sugar Ethanol production from molasses and bagasse

1. Function

(1) Production of ethanol (bio-fuel) which is useful as alternative energy resource to petroleum from byproducts in sugar manufacturing process.

(2) Ethanol is carbon neutral clean energy resource which is made from bagasse which is a kind of waste produced and molasses in sugar manufacturing process.

(3) Depending on demand, production ratio of ethanol or sugar is controlled.

2. System

The system is the integration of sugar manufacturing plant and ethanol

manufacturing plant.

Sugar manufacturing factory integrated with ethanol manufacturing facility

Ethanol manufacturing facility • Molasses ethanol • Bagasse ethanol

Sugar manufacturing factory

Sugar cane Raw material Press Cane juice Concentration Crystallization

Bagasse Molasses

Raw

mat

eria

l

Raw

mat

eria

l

Product(Sugar)

Product(Ethanol)

3. Features (1) Integration of sugar manufacturing factory and ethanol manufacturing factory. (2) Effective utilization of waste bagasse for production of ethanol. (3) Control of products quantity of sugar and ethanol on market demand.

4. Energy Saving/ CO2 Emission Reduction (1) The raw material is biomass which is carbon neutral, therefore, ethanol is

essentially CO2 free. (2) Ethanol is a CO2 free alternative fuel to petroleum.

7-1 Di-methyl Ether Production Plant Environmentally

friendly fuel Organic waste

Natural gas Bio fuel

Natural gas derived fuel

1. What is di-methyl ether? (1) Di-methyl ether (DME CH3OCH3) is the simplest of all ethers.

(2) Heating characteristics similar to natural gas.

(3) DME is currently manufactured from natural gas-derived methanol. DME can

also be manufactured from methane and syngas (hydrogen and CO gas)

which are derived from natural gas, coal, oil and biomass

(4) DME is a clean-burning alternative to liquified petroleum gas, liquified natural

gas, diesel and gasoline.

(5) DME is expected to be good fuel for vehicles because of the excellent

combustion characteristics.

2. How is DME made ? Conventional DME production uses methanol dehydration method. For mass

production of DME, DME synthesis from hydrogen and CO gas (syngas) is

developed.

(1) Catalytic Dehydration of methane 2CH3OH → CH3OCH3 + H2O

(2) DME-synthesis 3 CO + 3H2 → CH3OCH3 + CO2

2CO + 4H2 → CH3OCH3 + H2O

2CH3OH → CH3OCH3 + H2O

CO + H2O→ CO2 + H2

3. DME synthesis plant-Direct synthesis method

4. Features (1) DME can be liquefied relatively easily owing to the low vapor

pressure(0.6MPa) or high boiling point(-25.1℃), being suitable for fuel for

transportation.

(2) Biomass is usable to manufacture DME in addition to natural gas, oil and coal.

CO2 emission is less than coal and oil. In case of biomass is used as the raw

material, CO2 emission is none (carbon neutral).

(3) Combustion characteristics with engine is excellent, no smoke emission and

lower NOx emission.

Therefore, it is considered that DME will become the main fuel for vehicles.

100 ton / day DME production plant

Source: JFE HP

7-2 CO2 Recovery Plant - KM CDR Process Environment CO2 recovery CO2 utilization &

Prevention of global warming 1. Function

(1) KM-CDR process is a technology to capture CO2 from combustion gas from

utility and industrial plants developed by Mitsubishi Heavy Industries, ltd

(MHI) and Kansai Electric Power Co., Inc. (Kansai) in Japan.

(2) Recovered CO2 is used for;

①Chemical feedstock production such as urea (NH)2CO or methanol CH3OH.

②Enhanced oil or gas recovery by injecting it into the reservoirs.

③Sequestration of CO2 in geologic formations such as oil and gas reservoirs,

unmineable coal seams and deep saline reservoirs to avoid the increase of

CO2 in the atmosphere.

2. Plant system: The KM-CDR CO2 recovery plant consists of: (1) Flue gas pre-treatment plant, (2) CO2 recovery plant, and (3) Solvent regeneration section.

KM-CDR plant system

C.W.

C.W.Steam

Reboiler

C.W.

ABSORBER

Flue GasCooler

CO2Flue Gas

Outlet

Flue Gas

STRIPPER

Purity : 99.9 %

C.W.

C.W.Steam

Reboiler

C.W.

ABSORBER

Flue GasCooler

CO2Flue Gas

Outlet

Flue Gas

STRIPPER

Purity : 99.9 %

7-3 CO2 Capture & Storage System Environment CO2 capture and

storage CO2 sequestration

1. Function (1) Sequestration of CO2

CO2 in the combustion gas of fossil fuel is separated, captured and injected

into the underground aquifer for sequestration. So, no or minimum CO2 in

the combustion gas is emitted to the atmosphere. It is expected that no

secondary harm will be caused by the storage in the aquifer.

(2) Effect of CO2 sequestration The increase of CO2 content in the atmosphere is caused by mainly by

combustion of fossil fuel, therefore, it is very effective means to capture and

sequestrate the CO2 in combustion gas for preventing the increase of CO2

concentration in the atmosphere and mitigating the climate change.

2. Plant system

source: MHI HP

8-1 Absorption type Heat Pump / Refrigerator Air conditioning &

refrigeration Waste heat utilization Absorption type heat pump

(1) Types of heat pump There are two types of heat pump, one is mechanical type (vapor compression

type) and the other is absorption type.

(2) Mechanical type The main components in the system are compressor (usually driven by electric

motor), condenser (heat discharger), expansion valve and evaporator (heat

absorber). The working fluid (gaseous refrigerant) from the evaporator

compressed to a high pressure and cooled in the condenser (to liquid) is

expanded to the low pressure of the evaporator by the expansion valve

evaporating and absorbing the heat from outside (cooling the outside fluid). So,

much electrical power is consumed by the compressor.

Mechanical (vapor compression) type

heat pump

Absorption type heat pump

1

4

Heat in

Input:Electricity

Engine

Heat out

Compressor

2. Compression

3. Condensation1. Evaporation

4. Expansion

Expansion valveEvaporator CondenserExpansion valve

Heat in

Evaporator Condenser

Heat outAbsorber

Heat

Regenerator

Pump

Expansionvalve

2

3

(3) Absorption type • Main components

The main components in the system are refrigerant absorber, pump, heater

(regenerator), condenser, expansion valve of working fluid, expansion valve of

absorbent and absorber cooler.

• Cycle Absorbent (water or lithium bromide is used usually) absorbs the working

medium (ammonia or water), then the pressure of the liquid is raised by the

pump. The liquid is, then heated for boiling off the gaseous working media from

the absorbent of liquid state. The gaseous working fluid is cooled in the

condenser to liquid state dissipating heat, then, it is expanded to the evaporator

pressure by the expansion valve absorbing the outside heat. Thus the driving

force of the cycle is basically produced thermally resulting in much less electrical

power requirement than the mechanical (vapor compression) type.

(4) Energy saving and less GHG (CO2) emission with absorption type As absorption type requires less electrical or mechanical energy though

requires heat for regeneration, it is higher in efficiency especially when waste

heat is available for regeneration.

Comparison of electrical power consumption

Type of HP Mechanical HP Absorption type HP

Electrical power consumption (kWh)

Large Small

Fossil fuel required None None (waste heat)

CO2 emission Large

CO2 is produced when the electricity for compressor use

is generated.

Small

The electrical power for the pump is small

(5) Application of cogeneration As waste heat is effectively utilized in absorption type heat pump / refrigerator,

the combination of power generation and refrigeration (cogeneration) is

preferable from view point of higher energy efficiency, cheaper operating cost

and less CO2 (GHG) emission (No increase of fuel consumption and CO2

emission).

8-2 Energy Efficient Cooling System with Temperature - layered Heat Storage Tank

Food & beverage industry

Cooling system Cascade type cooling system with temperature-layered heat storage tank

1. Function

(1) High energy efficiency operation of product cooling system with high temperature difference.

(2) Reduction of power consumption of refrigerating system for carbonated drink and beer.

(3) By coupling temperature layered heat storage tank, high efficiency operation of refrigerating system is obtained.

2. System The system is composed of cascade type refrigerating unit and temperarure-layered heat storage tank.

Temperature layered heat storage tank

Cascade type Refrigerating unit

Example of cascade type refrigerating system with heat storage tank

3. Features (1) High energy efficiency for product cooling process is obtained.

(2) High energy efficiency operation of refrigerator is possible regardless of the

operation such as start-stop and load fluctuation of the production system.

(3) With operation adjusted for large temperature difference corresponding to the

temperature difference of product, the power consumption of pumps and other

auxiliaries is minimized.

(4) Suitable for strict temperature control required for such as carbonator.

(5) Cooling tower is useful for UHT cooling process of chiller temperature range.

(6) Further reduction of energy consumption is possible by utilizing natural energy.

4. Energy Saving/ CO2 Emission Reduction Approximately 30% of power consumption can be reduced from conventional

cooling system, resulting in the reduction of CO2 emission by about 30%.

8.3 Vapor Compression Heat Pump Food industry Waste heat utilization Vapor recompression

1. Function (1) Utilization of waste or used low temperature vapor (steam in most cases) for

producing higher temperature vapor required for concentration and volume reduction of commodity in production process.

(2) By recompressing low temperature vapor, steam in most cases, higher temperature steam is obtained with much less energy consumption, resulting in no fuel consumption and CO2 emission except for the power for compressor.

2. Features (1) Steam supply from outer source for heating of product for concentration and

volume reduction is not required resulting in simple compact plant system. (2) Waste energy contained in low temperature vapor is effectively utilized

resulting in energy saving for producing high temperature vapor. (3) Vapor recompression technology is useful for various manufacturing industries

including food and beverage, semiconductor, plating and others where waste liquid is discharged.

(4) Investment for installation of vapor compression equipment will be recovered within a few years or less.

3. Example of a system

Concentration system of liquid product

Evaporated steam at 100°C

Compressor

Motor

Heatingsteam at 110°C

Air

Condensed waterLow concentration solution tank

Concentrated product tank

Pre-heater

8.4 Compression Type Heat Pump-Ecocute Hot water production Effective use of

Electricity Compression heat pump

1. Function (1) Economical hot water production with cheaper electricity at night and its

storage for daytime use.

(2) Clean hot water production.

(3) Energy(electricity) storage as hot water (temperature～90°C).

2. Features (1) Refrigerant

Environmentally much more friendly substance CO2 than commonly used

materials previously such as CFC (R12) and HCFC (R22) is used as

refrigerant. Refrigerant, CO2, is stable natural substance, not manufactured

chemically.

(2) Coefficient of performance It is as high as about 5, which means “5” times energy (heat) is obtainable with

“1” input of energy (electricity to drive compressor).

The energy of “4” times of the input energy is absorbed from ambient air, a kind

of solar energy.

(3) Environmentally friendly hot water supply equipment

As the energy consumption is much less than fossil fuel combustion type, CO2

emission is much less also.

As electricity is used, no combustion gas is emitted being suitable for inside

installation.

(4) High economic performance

As the amount of electricity consumed is small and it is operated when the

electricity charge rate is low such as at night, the economic performance is

excellent. The investment is recoverable within a few years.

Unit system of Eco-cute

Atmospheric heat

Heat exchanger Heat

exchanger

Compressor

Expansion valve

Heat pump unit Heat storage unit

Hot water

Cold water

Tem

pera

ture

lay

ered

heat

sto

rage

tank

Pump

Power input : 1

Energy output ~ 5

Heat

Hot water Temperature～ 90℃

Date post:	20-Aug-2018
Category:	Documents
Upload:	vominh
View:	216 times
Download:	0 times

ADVANCED INDUSTRIAL TECHNOLOGIES FOR … · advanced industrial technologies for energy...

Documents