Reduction of Environmental Impacts by Development of Industrial Symbiosis in Japan

- Case Studies for Application of Co-production Technologies in Steel Industries and its Reduction Potential

of Greenhouse Gas Emissions -

Yasunari Matsuno, Ichiro Daigo, Masaru Yamashita

and Yoshihiro Adachi

Department of Material Engineering, Graduate School of Engineering, The University of Tokyo

Topics Introduction – Backgrounds of this study What is “Co-production” technology Application of Co-production technologies

in Steel industry– Low-temperature Gasification Plant– CO2 Recovery and Utilization System

Results of the case studies Conclusion

To maximize energy, resource,environmental efficiency

Recycle-oriented SocietyKyoto Protocol (Reduction of GHGs)

Industrial symbiosis

Individually optimization

Industry A

Industry B

Industry C

Energy,Resources

Industry A

Industry B

Industry C

Energy,Resources

Example of “Industrial symbiosis”

Jurong Island, Singapore

                                        

 To develop Jurong Island into a World-Class Chemicals Hub in the Asia Pacific RegionOilco

al

Natural gas

Low

grade oil

Fuel Oil

Stee

l, C

emen

t

Recycle Hub ﾞ（ value chain

cluster ）

Environment

Final wastesCO2, Exhaust heat

Products

Wastes

Power, gas

Recycled materialsH2 , Syngas High press. SteamElec. PowerFuels

IGCC P

ower

Pla

nt

consumer

Final wastes

Environment

consumer

Chemicals Medicine

Locations of key industries

Steel works

Refineries – Petroleum industry

Ethylene plants – Petrochemical industry

LNG tanks

Potentials to develop industrial symbiosis

Fuels ， Energy

Raw materials

Power Generation

Manufacturing Pro.

Fuels ， Energy

Raw materialsWastes

Power Generation Manufacturing Pro.

Main products ・ Goods ・ Electricity ・ Materials

Large amount of waste heat

(1) Existing System

(2) Co-production SystemMain products ・ Goods ・ Electricity ・ Materials

Little waste heat

Co-products・ Fuels・ Chemicals・ Steam etc.

Newly Energy Saving Process

What is co-production technology? - Technologies for Industrial symbiosis

Exergy

Material Environment

Capacity operating rate

Energy efficiecy

Exergy

Material Environment

Capacity operating rate

Exergy

Material Environment

Capacity operating ratio

Conventional Co-generation Co-production

Energy efficiency Energy efficiency

Industry A

Industry B Industry C

Energy,Resources

Energy,Resources

Industry A

Industry B

Industry C

Goal and scope

・ To expand system boundary to evaluate total environmental impacts

・ To investigate environmental impacts of Co-production technologies (for Industrial symbiosis)

• Gasification plant• Dry ice (cryogenic energy ) production plant with CHP

Steel works

Methodology

・ Industries (capacity, location)

・ Waste heat distribution

・ Demand and supply of products, energy

2 ． To conduct LCA for co-production technologies

　 　 - CO2 emissions-

1 ． To investigate where to apply co-production technologies

3 ． To optimize the transport of products by Linear Planning method

4 ． To investigate total environmental impacts

Co-production technology

Current technology

11st Stepst Step

To assess the reduction potential of environmental impacts by co-production technology.

To compare with current technology.

22nd Stepnd Step

To assess the reduction potential of environmental impacts in a industrial cluster scale.

To investigate the demand and supply of energy and products.

To develop a model

33rd Steprd Step

To assess the reduction potential of environmental impacts in a regional (country) scale.

To develop database.

To integrate with other tools.

Power stations

Fuel gas

Steel plant with co-production process

Electricity

Demand and Supply

Grid mix

Conventional process

Demand and Supply

Where to apply co-production technologies?

- Waste heat distribution in industries in Japan

Waste heat amount Waste heat distribution

Apply Co-production technology to Steel industry

Electricity

SteelChemical

Waste incin.9%

Paper pulp

Others

Ceramic

Waste heat distribution in steel works

0

500

1000

1500

2000

2500

3000

Tcal/

year

冷却水固体ガス

Exhaust gas from Coke oven, BFG

etcCOGLDG etc

Water

Solid

Gas

Co-production technology (1)

High-temperature

Waste heat

High efficiency gasification plant with high-temperature waste heat (600 )℃

Tar1t

Waste heat at 873 K

1300 Mcal

Gasification

plant

Gas

Steam

CO/H2 ＝ 28300Mcal

Methanol5810 Mcal

Electricity

or

Methanol: easy for storage,

Utilizing waste heat

ICFG : Internally Circulating Fluidized-bed Gasifier

Synthesis Gas Combustion Gas

GasificationChamber

Char-CombustionChamber

Fluidizing mediumdescending zone Heat Recovery

Chamber

Fluidizing medium &Pyrolysis Residue (Char, Tar)

Heat TransferTubes

Steam Air

Feedstock(Fuel or Wastes)

Co-production technology (2)

Low temperature waste heat

Dry Ice (cryogenic energy ) production with CHP (Utilizing

waste heat)

Exhaust gas recovery

Waste heat at at 423 K 305kcal

Electricity: 0.176 kWh

Dry ice production process

CHPDI

1kg

Cooling Tower

Chemical Heat Pump

Flashtank

Compressor

CO2 gas from co-production processes

Liquefied CO2 tank

High-stageexpander

Dry-Ice press

Dry-Ice

Gas Cooler Liquefier Sub-cooler

Low-stageexpander

Co-production technology (2)

LCA for Co-production technologies

Fig. CO2 emission intensity for co-products (kg-CO2/kg)

0

0.05

0.1

0.15

0.2

0.25

Dry ice(conventional)

Dry ice (co-production)

Methanol(conventional)

Methanol (co-production)C

O2

emission

inte

nsity

(kg

-CO

2/kg

)

Location of steel works in Japan

Location of methanol consumer in Japan

Location of steel works and methanol consumer in Japan

Total CO2 emissions - Core technology

Fig. CO2 emission intensity of methanol

0.019

0.22

0.013

0.15

0 0.1 0.2 0.3 0.4

Co- production

conventional

CO2 Emissions CO2（ｋｇ－ ）

2 emissions at synthesisＣＯprocess

2 emissions at the transportＣＯstage

Total CO2 emission reduction potential in Japan

CO2 emission reduction potential by co-production technologies:Methanol: 0.34 ton-CO2/ton-methanolDry ice: 0.13 ton-CO2/ton-dry ice

Current demand in Japan:Methanol: 1.8 million ton/y, Dry ice: 0.24 million ton/y

Total CO2 emission reduction potential in Japan: Methanol: 0.6 million ton/y Dry ice: 0.03 million ton/y

Other possible application of dry ice

Low temperature crushing of PP pellet

PP　pellet　(3mm　diameter)

Microscope　of　crushed　pp　pellet　(200μm/div)

Low temperature crushing of PP 　－　 Conventional technology

Low temperature crushing of PP 　－　 by dry ice

PP pellet ：1 kg

Liquefied N2 ：9.68 kg

Crushed PP ： 1 kg

PP pellet ：1 kg

Dry ice ：3 kg

Crushed PP ： 1 kg

CO2 emissions ：2.33 kg-CO2

CO2 emissions ：0.23 kg-CO2

Δ2.10 kg-CO2

Potential demand of crushed PP: 0.017 million ton/y (0.64% of total PP)CO2 reduction potential: 0.036 million ton-CO2

Conclusion

• Methanol production by co-production technology (gasification plant) will reduce CO2 emissions by 91% compared with conventional technology (92% reduction in production, 90% reduction in transport)

• Total CO2 emission reduction potential in Japan by methanol production : 0.6 million ton-CO2

• Dry Ice (cryogenic energy) production by co-production technology will also reduce CO2 emissions by 64% compared with conventional technology. Total CO2 emission reduction potential in Japan is 0.03 million ton-CO2.

• Other CO2 reduction potential by applying dry ice is being investigated, such as low temperature crushing of PP pellet

Thank you very much for your attention.

For further information; matsuno@material.t.u-tokyo.ac.jp