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
CO
2
Recovery and Utilization System
Results of the case studies
Conclusion
To maximize energy, resource,
environmental efficiency
Recycle-oriented Society
Kyoto 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 Region
Oil
Fuel Oil
Recycle Hub
value chain
cluster
Environment
Final wastes
CO2, Exhaust heat
Products
Wastes
Recycled
materials
H2 , Syngas
High press. Steam
Elec. Power
Fuels
consumer
Environment
consumer
Chemicals
Medicine
Locations of key industries
Steel works
Refineries Petroleum industry
Ethylene plants Petrochemical industry
LNG tanks
Potentials to develop industrial
symbiosis
FuelsEnergy
Raw materials
Power Generation
Manufacturing Pro.
FuelsEnergy
Raw materials
Wastes
Power Generation
Manufacturing Pro.
Main products
Goods
Electricity
Materials
Large amount of waste heat
(1) Existing System
(2) Co-production System
Main 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
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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
2To conduct LCA for co-production technologies
- CO
2
emissions-
1To investigate where to apply co-production technologies
3To optimize the transport of products by Linear
Planning method
4To investigate total environmental impacts
Co-production technology
Current technology
11st Step st Step
To assess the reduction
potential of environmental
impacts by co-production
technology.
To compare with current
technology.
22nd Step nd 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 Step rd 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
Steel
Chemical
Waste
incin.
9%
Paper pulp
Others
Ceramic
Waste heat distribution in steel works
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Exhaust gas from

Coke oven, BFG
etc
COG
LDG etc
Water
Solid
Gas
Co-production technology (1)
High-temperature
Waste heat
High efficiency gasification plant with
high-temperature waste heat (600)
Tar
1t
Waste heat
at 873 K
1300 Mcal
Gasification
plant
Gas
Steam
CO/H
2
2
8300Mcal
Methanol
5810 Mcal
Electricity
or
Methanol: easy for storage,
Utilizing waste heat
ICFG : Internally Circulating Fluidized-bed Gasifier
Synthesis Gas Combustion Gas
Gasification
Chamber
Char-Combustion
Chamber
Fluidizing medium
descending zone
Heat Recovery
Chamber
Fluidizing medium &
Pyrolysis Residue
(Char, Tar)
Heat Transfer
Tubes
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
CHP
DI
1kg
Cooling
Tower
Chemical
Heat
Pump
Flash
tank
Compressor
CO2 gas from
co-production
processes
Liquefied
CO2 tank
High-stage
expander
Dry-Ice
press
Dry-Ice
Gas Cooler Liquefier Sub-cooler
Low-stage
expander
Co-production technology (2)
LCA for Co-production technologies
Fig. CO2 emission intensity for co-products (kg-CO2/kg)
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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
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Total CO2 emission reduction potential in Japan
CO2 emission reduction potential by co-production technologies:
Methanol: 0.34 ton-CO2/ton-methanol
Dry 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
(200m/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 PP1 kg
PP pellet
1 kg
Dry ice
3 kg
Crushed PP1 kg




CO2 emissions
2.33 kg-CO2
CO2
emissions
0.23 kg-CO2
2.10 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