Current Status of Osaki

CoolGen Project
~ Oxygen-blown IGCC with
CO2 Capture Demonstration ~
Table of Contents

1. Project Background

2. Oxygen-blown Coal Gasification Technology

3. Progress of Osaki CoolGen Project

(1) Outline of Osaki CoolGen Project
(2) Progress of the Step 1
-Demonstration of Oxygen-blown IGCC-
(3) Progress of the Step 2
-Demonstration of IGCC with CO2 capture-
Table of Contents

1. Project Background

2. Oxygen-blown Coal Gasification Technology

3. Progress of Osaki CoolGen Project

(1) Outline of Osaki CoolGen Project
(2) Progress of the Step 1
-Demonstration of Oxygen-blown IGCC-
(3) Progress of the Step 2
-Demonstration of IGCC with CO2 capture-
 Outlook on World Power Generation and
CO2 Emissions
Others
Renewables etc. Wind
Gas power
40 000 Bioenergy Hydro Oil power
40 000
Electricity Generation[TWh]

Nuclear Gas Coal power

CO2 emissions[Mt-CO2]
Oil Coal
30 000 30 000

20 000 20 000

10 000 10 000

- -
2000 2015 2025 2030 2040 2000 2015 2025 2030 2040

Percentage of CO2
Percentage of coal
power generation
26% emission from coal 27%
power generation
in the world (2040) in the world
(2040)
 About 30% of the world’s energy generation will continue to use coal
 About 30% of world’s CO2 emission will be from coal energy generation
Source: IEA World Energy Outlook 2017 (New Policies Scenario)
Coal-fired Power Generation - status in Japan -

 Energy self-sufficiency in Japan ＝ approx. 6%*

 Coal-fired generation ⇒ Essential for the “Best Mix” energy policy
Energy Mix in Japan**
Demand of electric power Composition of electrical source
Saving energy
196.1TWh 1065TWh
Geothermal :1.0-1.1%
Economic growth
Biomass :3.7-4.5%
Renewable :22-24%
Wind :1.7%
PV :7.0
Nuclear:22-20%
Hydro:8.8-9.2%

966.6TWh 980.8TWh LNG:27%

Coal:26%

Oil:3%
FY2013 FY2030 FY2030

*Source : Japan’s Energy White Paper 2016

**Source : METI Long-term energy supply-demand outlook(2015.7)
Development Roadmap of High Efficiency Low
Emissions Coal Power Generation Technology in Japan
Integrated coal gasification fuel
Fuel Cell（FC） cell combined cycle (IGFC)

(MCFC) HRSG
(SOFC)

Fuel cell
Integrated coal gasification Gasifier Gas turbine Steam turbine
combined cycle（IGCC)
55%∼
HRSG CO2 reduction
about ▲30%）
1300℃ IGCC 1500℃ IGCC 1700℃ IGCC
Gasifier Gas turbine Steam turbine 46 ~ 48%
CO2 reduction
Pulverized coal fired（PCF）
about ▲15%
Super critical Ultra SC Advanced USC
boiler （SC） （USC） （A-USC）
Steam turbine 38% 39 ~ 41% 46 ~ 48%
base
Efficiency :Net / Higher heating value
Significance of Osaki CoolGen Project
Global Sustainable Development
 Efficiently use low cost coal for increased Power Demand
 Drastically reduce CO2 emissions against Global Warming

In Resources Importing Countries (as Japan)

 Coal is indispensable to achieve sustainable power supply

Development of High Efficient Clean Coal Technology

Osaki Coolgen Demonstration Project

(Step-1) Oxygen-blown IGCC

(Step-2) IGCC + CO2 Capture

(Step-3) IGFC + CO2 Capture

Table of Contents

1. Project Background

2. Oxygen-blown Coal Gasification Technology

3. Progress of Osaki CoolGen Project

(1) Outline of Osaki CoolGen Project
(2) Progress of the Step 1
-Demonstration of Oxygen-blown IGCC-
(3) Progress of the Step 2
-Demonstration of IGCC with CO2 capture-
Significance of developing Oxygen-blown type
“EAGLE” Gasifier

High efficiency and low carbonization of coal-fired power

generation and effective utilization of coal and its byproduct
Drastically to improve power generation efficiency and significantly to reduce
carbon dioxide emission.
Efficiently to capture CO2 by pre-combustion method.
To use low-grade coal(sub-bituminous coal and brown coal) and high-grade
coal(bituminous coal) for gasification.
To re-use coal ash and reduce in volume as slug of glass type

Multi-purpose uses of coal gasification gas

For the gasification gas to be widely used as synthetic fuels and chemical raw
materials.
“EAGLE” gasifier Technical Development

Scale Up
Features of EAGLE Gasifier
Oxygen-blown Two-stage Spiral-flow Gasifier
Applicable Coal Types for the “EAGLE” Gasifier
EAGLE Gasifier
EAGLE Pulverizing Coal Fired
Pulverizing Coal Fired
2.50

Coals appropriate for

Conventional
GasificationGasifier
Fixed carbon/Volatile matter [−]

2.00

1.50

1.00

：EAGLE Pilot Project

EAGLE Achievement
Achievement
Sub bituminous Coal area ◆、◆area
Bituminous Coal ：
Pilot Project
0.50
1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700
Ash Melting Temperature [℃] Source : JPOWER EAGLE brochure
Table of Contents

1. Project Background

2. Oxygen-blown Coal Gasification Technology

3. Progress of Osaki CoolGen Project

(1) Outline of Osaki CoolGen Project
(2) Progress of the Step 1
-Demonstration of Oxygen-blown IGCC-
(3) Progress of the Step 2
-Demonstration of IGCC with CO2 capture-
Project Timeline

Fiscal 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021

Environmental assessment

Feasibility study Feasibility Feasibility Feasibility

Study Study Study
1st step
Design, manufacturing, construction Demonstration
Oxygen-blown IGCC
2nd step Design, manufacturing, Demonstr-
IGCC with CO2 capture unit construction ation

3rd step Design, manufacturing, Demon-

IGFC with CO2 capture unit construction stration

CO2 transportation,
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1st
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Step Gasifier Gas clean-up unit 2nd step storage※

CO, H2 CO2

H2 rich gas
※This project does
Coal
このイメージは

このイメージは このイメージは、現在表示できません。 not include CO2

N2 このイメージは 3rd step transportation and
O2 storage
Generator
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現在表示でき

Gas Steam
Air separation Compressor turbine turbine Fuel cell
unit (AS)
Project Scheme

METI (FY2012~2015) : Ministry of Economy, Trade and Industry

NEDO(FY2016~2018) : New Energy and Industrial Technology
Development Organization

The Chugoku Electric Power Co., Inc. (Energia)

Electric Power Development Co., Ltd. (J-POWER)
Subsidy
Joint Investment

Osaki CoolGen Corporation

Table of Contents

1. Project Background

2. Oxygen-blown Coal Gasification Technology

3. Progress of Osaki CoolGen Project

(1) Outline of Osaki CoolGen Project
(2) Progress of the Step 1
-Demonstration of Oxygen-blown IGCC-
(3) Progress of the Step 2
-Demonstration of IGCC with CO2 capture-
 Oxygen-blown IGCC Process Flow (STEP-1)

Coal Coal gasification unit Gas clean-up unit

pretreatment; COS: Carbonyl sulfide
pulverized coal Syngas H2S: Hydrogen sulfide
Cyclone
blowing unit Gasifier cooler
filter
Sulfur
Coal recovery
unit
Mill

Hopper
Air

First COS Second H2S H2S Acid

Gypsum
converter absorber regenerator gas
Char recycle water water
Slag scrubber scrubber furnace

O2 N2 Combined cycle unit

Air separation unit
Air

DeNOx
Compressor
Rectifier HRSG
Stack
Water treatment unit Gas
Comp. Steam G
Air turbine turbine
Waste water Treated water Cooling Condenser
water
Sludge

Mitsubishi Hitach Power Systems, LTD JGC Corporation Diamond Engineering Co. Ltd.
Major Specifications (STEP-1)

Specification

Oxygen-Blown Single-Chamber
Coal Gasification Unit Two-Staged Spiral-Flow Entrained Bed
Coal feed ：1,180 ton/day

Wet Desulfurization Unit ： Methyl Di-Ethanol

Gas Clean-up Unit Amine (MDEA)
Sulfur Recovery Unit ： Limestone Wet Scrubbing

Air Separation Unit Pressurized Cryogenic Separation

GT (MHPS ： H100 TIT=1300°C class,

Combined Cycle Unit adopted Multi-Cluster burner）
Gross Power Output : 166MW (GT+ST)

Wastewater Treatment Unit Gas Clean-up Unit Wastewater Treatment

Complete view of IGCC (STEP-1)

Gasification
Existing Plant
Osaki PS 1-1

Gas Clean up
Combined
Cycle

Waste Water Air Separation

Treatment
Commissioning results and demonstration plan (STEP1)
FY 2015 2016 2017 2018
Individual machinery and system test
GTb no load test results
plan
Coal gasification test
Commissioning

Load dump test, Black-out test

Integrated

Load dump test, Relief valve test

Gasifier/GTb characteristic test
Automatic plant control adjustment
Test of heat run and performance
Test of automatic plant start-up/shut down
Demonstration

・Verification of basic performance

and reliability
・Verification of compatibility of
coal variety
・Verification of controllability

Power generation Gasifier Continuous

Gross output Operating hours Operating hours
Operating data
(As of May 31)
640,982 MWh 5,524 h 2,168 h
Demonstration Targets and Results (STEP-1)
item Target Result
Basic
Net efficiency Net efficiency
performance 40.5% (HHV) 40.8% (HHV) Achieved
(Plant efficiency)
Basic SOx : 8ppm SOx : <8ppm
performance NOx : 5ppm NOx : <5ppm
Achieved
(environmental Particulate : 3mg/m3N Particulate : <3mg/m3N
performance) (O2 equivalent 16 %) (O2 equivalent 16 %)
Coal types Verified with a design coal
Applicable to variety coal In progress
compatibility Planning more kinds of coal
Commercial-level annual Endurance test passed 4,000h
plant availability of 70% or (accumulated time)
Plant reliability higher Continuous operation 2,168h
(5,000 hours endurance test) Continue to do endurance test In progress
Plant
Commercial-level Load change rate
controllability & (load change rate of 1-3%/min) ∼10 %/min Achieved
operability
Obtain prospect of the
Under analyzing the demonstration
Economic equivalent or less
data
performance generating cost with In progress
Continue to analyze
commercial PCF plant
Table of Contents

1. Project Background

2. Oxygen-blown Coal Gasification Technology

3. Progress of Osaki CoolGen Project

(1) Outline of Osaki CoolGen Project
(2) Progress of the Step 1
-Demonstration of Oxygen-blown IGCC-
(3) Progress of the Step 2
-Demonstration of IGCC with CO2 capture-
IGCC with CO2 Capture Flow (STEP-2) ②
CO2 Capture unit CO2 Absorber
CO2 Capture test
H2

Feed Gas 17% slipstream

Sweet Shift Reactors
CO＋H2O ⇒ CO2＋H2 CO2 syngas equivalent to
CO2, H2 15% of total CO2
Steam volume
CO2 Physical absorption
CO, H2 Capture
method
CO2 Flash Drums
CO shift Sweet Shift
IGCC
Gasifier section (Downstream of
desulfurization)
Water H2S
Scrubber absorber

Coal Sour Shift Catalyst pilot test

N2
Feed Gas Sour Shift
Sour Shift Catalyst pilot test (Upstream of
O2
desulfurization)
Steam Low Temperature
ASU Sour Shift Reactor

Gas clean up unit

Construction area of CO2 Capture plant

Incinerator
Electrical
room

Absorber
tank

CO2 absorber unit CO shift unit

Demonstration Test Targets (STEP-2)

Item Targets
Basic CO2 Capture rate : more than 90%
Performance
(CO2 capture) CO2 Purity : more than 99%

Generating To obtain a prospect of 40%(net, HHV) power generation efficiency

Plant while 90% of CO2 volume is captured in newly-installed commercial
Efficiency IGCC with 1,500°C class GT.

Operability & To establish operation procedures with load change and verify the
Reliability reliability for IGCC system combined with CO2 Capture

Evaluate cost per unit of CO2 capture on the basis of the cost per
Economic
unit shown in “Development Roadmap of CO2 Capture Technology”
performance
of the government as the benchmark.
Schedule of STEP-2 project
FY 2016 2017 2018 2019 2020
Design, manufacturing, construction Demonstration
Technical investigation, contract
▼ Start of Construction of results
Land reclamation CO2 Capture unit plan
Schedule
Design, manufacturing, construction
commissioning Demonstration

Fiscal year 2019 2020

Individual facilities & system tests
Commissioning
Demonstration

Parameter optimization
Long time reliability test
Evaluation on coal types
Performance evaluation
Construction of CO2 Capture Unit ②