Clean Coal Technologies in Japan
Technological Innovation in the Coal Industry
Preface 2
Part 1 CCT Classifications 3
(1) CCT Classifications in the Coal Product Cycle 3
(2) Clean Coal Technology Systems 5
(3) CCT in the Marketplace 6
(4) CCT in Japanese Industries 7
(5) Environmental Technologies 11
(6) International Cooperation 13
Part 2 CCT Overview 15
(1) Technologies for Coal Resources Development
1A1. Coal Resource Exploration Technology 15
1A2. Coal Production Technology 17
1A3. Mine Safety Technology 19
1A4. Environment-friendly Resource Development Technology--21
(2) Coal-fired Power Generation Technologies
A. Combustion Technologies
2A1. Pulverized Coal-fired Power Generation Technology
(Ultra Super Critical Steam Condition) 23
2A2. Circulating Fluidized-bed Combustion Technology (CFBC) ---25 2A3. Internal Circulating Fluidized-bed Combustion Technology (ICFBC) --26 2A4. Pressurized Internal Circulating Fluidized-bed Combustion
Technology (PICFBC) 28
2A5. Coal Partial Combustor Technology (CPC) ---------------------29
2A6. Pressurized Fluidized-bed Combustion Technology (PFBC) ---31 2A7. Advanced Pressurized Fluidized-bed Combustion
Technology (A-PFBC) 33
B. Gasification Technologies
2B1. Hydrogen-from-Coal Process (HYCOL) 35
2B2. Integrated Coal Gasification Combined Cycle (IGCC) -------37
2B3. Multi-purpose Coal Gasification Technology Development (EAGLE) --39 2B4. Integrated Coal Gasification Fuel Cell Combined Cycle
Electric Power Generating Technology (IGFC) 41
2B5. Next-generation, High-efficiency Integrated Coal Gasification Electric Power Generating Process (A-IGCC/A-IGFC) 42
(3) Iron Making and General Industry Technologies
A. Iron Making Technologies
3A1. Formed Coke Process (FCP) 43
3A2. Pulverized Coal Injection for Blast Furnaces (PCI) 45
3A3. Direct Iron Ore Smelting Reduction Process (DIOS) 47
3A4. Super Coke Oven for Productivity and Environment
Enhancement toward the 21st Century (SCOPE21) 49
3A5. Coke Dry Quenching Technology (CDQ) 51
B. General Industry Technologies
3B1. Fluidized-bed Advanced Cement Kiln System (FAKS) 53
3B2. New Scrap Recycling Process (NSR) 55
(4) Multi-purpose Coal Utilization Technologies
A. Liquefaction Technologies
4A1. Coal Liquefaction Technology Development in Japan 57
4A2. Bituminous Coal Liquefaction Technology (NEDOL) 59
4A3. Brown Coal Liquefaction Technology (BCL) 61
4A4. Dimethyl Ether Production Technology (DME) ----------------63
B. Pyrolysis Technologies
4B1. Multi-purpose Coal Conversion Technology (CPX) 65
4B2. Efficient Co-production with Coal Flash Partial
Hydropyrolysis Technology (ECOPRO) --------------------------67
C. Powdering, Fluidization, and Co-utilization Technologies
4C1. Coal Cartridge System (CCS) 69
4C2. Coal Water Mixture Production Technology (CWM) 70
4C3. Briquette Production Technology 71
4C4. Coal and Woody Biomass Co-firing Technology 73
D. De-ashing and Reforming Technologies 4D1. Hyper-coal-based High-efficiency Combustion
Technology (Hyper-coal) --------------------------------------------75
4D2. Low-rank Coal Upgrading Technology (UBC Process) 77
(5) Environmental Protection Technologies
A. CO2 Recovery Technologies
5A1. Hydrogen Production by Reaction Integrated Novel
Gasification Process (HyPr-RING) 79
5A2. CO2 Recovery and Sequestration Technology ----------------81
5A3. CO2 Conversion Technology ---------------------------------------82
5A4. Oxy-fuel Combustion (Oxygen-firing of Conventional
PCF System) 83
B. Flue Gas Treatment and Gas Cleaning Technologies
5B1. SOx Reduction Technology 85
5B2. NOx Reduction Technology 87
5B3. Simultaneous De-SOx and De-NOx Technology 89
5B4. Particulate Treatment Technology and Trace Element
Removal Technology -------------------------------------------------91
5B5. Gas Cleaning Technology ------------------------------------------93
C. Technologies to Effectively Use Coal Ash
5C1. Coal Ash Generation Process and Application Fields 95
5C2. Effective Use of Ash in Cement/Concrete ----------------------97
5C3. Effective Use of Ash in Civil Engineering/Construction and Other Applications ----------------------------------------------99
5C4. Technology to Recover Valuable Resources from Coal Ash 101
(6) Basic Technologies for Advanced Coal Utilization
6A1. Modeling and Simulation Technologies for Coal Gasification ----103
(7) Co-production Systems
7A1. Co-generation Systems 107
7A2. Co-production Systems 109
Part 3 Future Outlook for CCT 111
Definitions, Conversions 114
Preface
The New Energy and Industrial Technology Development Organization (NEDO) and the Japan Coal Energy Center (JCOAL) have jointly prepared this guide as a review of the history of "Clean Coal Technology (CCT)" in Japan, to systematically describe the present state of CCT insofar as possible, and to provide useful material for novel technological innovation. NEDO and JCOAL hope this brochure will be helpful in elucidating why Japan's CCT is an attractive technology in the ever-increasing complexity of coal utilization owing to global warming and other environmental issues. NEDO and JCOAL also hope this brochure will encourage rapid progress in CCT development and the foundation of innovative clean coal utilization systems.
As described herein, CCT development in Japan has reached the world's highest level of technological superiority, making the technology highly attractive to Asian countries that depend on coal as an energy source. In Japan, coal consumption has rapidly increased since 1998, with gross thermal power generation efficiency increasing from approximately 38% to 41% over the past dozen or so years. In addition, emissions of CO2, SOx and NOx per generated power unit from thermal power plants are far below the level of other industrialized countries. In this regard, CCT is expected to become standardized worldwide, satisfying both economic and environmental requirements by reducing CO2 emissions and maintaining GDP growth. Technological innovation has no boundaries; significant progress can be attained sustainably and progressively. Patient, consistent efforts to build on technological developments can support a continually evolving society. NEDO and JCOAL are confident this publication will contribute to CCT development and we look forward to the emergence of dramatic technological innovations in the coal industry.

CCT Classifications in the Coal Product Cycle

Cave-in prediction
Coal preparation plant Coal train
Cave-in prediction
Coal preparation plant Coal train
Exploration, mining, safety and preparation
Crushing, transportation and storage
Processing, reforming and converting
Technologies for Coal Resources Development
Coal Resource Exploration Technology Coal Production Technology
Mine Safety Technology
Environment-friendly Resource Development Technology
Anthracite |
Bituminous coal |
Brown coal | |
Specific gravity |
1.5-1.B |
1.2-1.7 |
0.B-1.5 |
Apparent specific gravity |
- |
0.75-0.B0 |
0.55-0.75 |
Specific heat |
0.22-0.24 |
0.24-0.26 |
0.26-0.2B |
Thermal conductivity (W/mK) |
- |
1.26-1.65 |
- |
Ignition point (oC) |
400-450 |
300-400 |
250-300 |
Heating value (kcal/kg(dry basis)) |
B,200-B,500 |
7,500-B,B00 |
5,500-7,500 |
Classification |
Heating value (kcal/kg(dry basis)) |
Fuel ratio |
Caking property |
Anthracite |
- |
4.0 or greater |
Non-caking |
Bituminous coal |
8,400 or greater |
1.5 or greater |
Strong-caking |
1.5 or less | |||
8,100 or greater |
1.0 or greater |
Caking | |
1.0 or less |
Weak-caking | ||
Subbituminous coal |
7,800 or greater |
1.0 or greater |
Weak-caking |
1.0 or less |
Non-caking | ||
7,300 or greater |
- |
Non-caking | |
Brown coal |
6,800 or greater |
- |
Non-caking |
5,800 or greater |
Source: TEXT report |
Source: Trade Statistics | |||
Anthracite |
Anthracite | |||
Coking coal |
Coking coal A |
Bituminous coal |
Strong-caking coal for coke |
Ash content of 8% or less |
Coking coal B |
Ash content exceeding 8% | |||
Coking coal C |
Other coal for coke |
Ash content of 8% or less | ||
Coking coal D |
Ash content exceeding 8% | |||
Steam coal |
Steam coal A |
Other |
Ash content exceeding 8% | |
Steam coal B |
Other coal |
Ash content of 8% or less | ||
Steam coal C |
Ash content exceeding 8% |
Multi-purpose Coal Utilization Technologies
Coal Gasification and
Hydrogenation
Technologieies
Liquefaction Technologies
Pyrolysis Technologies
Powdering, Fluidization and Co-utilization Technologies
De-ashing and Reforming Technologies
Basic Technologies for Advanced Coal Utilization
Hydrogen-from-Coal Process (HYCOL)
Multi-purpose Coal Gasification Technology Development (EAGLE)
Hydrogen Production by Reaction Integrated Novel Gasification Process (HyPr-RING)
Coal Liquefaction Technology
Development in Japan
Bituminous Coal Liquefaction Technology (NEDOL)
Brown Coal Liquefaction Technology (BCL)
fe Dimethyl Ether Production F Technology (DME)
Multi-purpose Coal Conversion Technology (CPX)
Efficient Co-production with Coal Flash Partial Hydropyrolysis Technology (ECOPRO)
Coal Cartridge System (CCS)
Coal Water Mixture Production Technology (CWM)
n gy
Briquette Production Technology
4C4& Coal and Woody Biomass wSP Co-firing Technology
Hyper-coal-based High-efficiency Combustion Technology (Hyper-coal)
4re>k Low-rank Coal Upgrading Technology F (UBC Process)
Modeling and Simulation Technologies for Coal Gasification

Utilization
Environmental countermeasures

2AM Coal Partial Combustor Technology (CPC)
Pulverized Coal-fired Power Generation Technology (Ultra Super Critical Steam Condition)
Circulating Fluidized-bed Combustion Technology (CFBC)
Internal Circulating Fluidized-bed Combustion Technology (ICFBC)
Pressurized Internal Circulating Fluidized-bed Combustion Technology (PICFBC)
2AM Coal Partial Combustor Technology (CPC)
Pressurized Fluidized-bed Combustion Technology (PFBC)
Advanced Pressurized Fluidized-bed Combustion Technology (A-PFBC)
Hyper-coal-based High-efficiency Combustion Technology (Hyper-coal)
Hydrogen-from-Coal Process (HYCOL)
Integrated Coal Gasification Combined Cycle (IGCC)
Integrated Coal Gasification Fuel Cell Combined Cycle Electric Power Generating Technology (IGFC)
Next-generation, High-efficiency Integrated Coal Gasification Electric Power Generating Process (A-IGCC/A-IGFC)
Formed Coke Process (FCP)
Pulverized Coal Injection for Blast Furnaces (PCI)
Direct Iron Ore Smelting Reduction Process (DIOS)
Super Coke Oven for Productivity and Environment Enhancement toward the 21st Century (SCOPE21)
Coke Dry Quenching Technology (CDQ)
Fluidized-bed Advanced Cement Kiln System (FAKS)
New Scrap Recycling Process (NSR)
Co-generation Systems Co-production Systems

Hydrogen Production by Reaction Integrated Novel Gasification Process (HyPr-RING)
CO2 Recovery and Sequestration Technology
CO2 Conversion Technology
Oxy-fuel Combustion
(Oxygen-firing of Conventional PCF System)
SOx Reduction Technology
NOx Reduction Technology
Simultaneous De-SOx and De-NOx Technology
Particulate Treatment Technology and Trace Element Removal Technology
Gas Cleaning Technology
Coal Ash Generation Process and Application Fields
Effective Use of Ash in Cement/ Concrete
Effective Use of Ash in Civil Engineering/Construction and Other Applications
Technology to Recover Valuable Resources from Coal Ash
Clean Coal Technology Systems Clean Coal Technologies in Japan
Coal cycle
Mining Crushing Preparation
Reforming
Conversion
Co mbust
Pollutant reduction
Coal preparation
Deashing, reforming and processing
Flue gas treatment
Ash utilization
Target
Conventional coal preparation techniques Technology for low emission (jig, flotation, heavy media separation) coal utilization
Preparation process control technology
Bio-briquetting
Upgrading brown coal (UBC) Carbonization briquetting Hyper-coal
Coal cartridge system (CCS) Coal liquid mixture (CWM, COM) Desulfurized CWM | ||
Handling | ||
Bituminous coal liquefaction technology (NEDOL) Brown coal liquefaction technology (BCL) Upgrading of coal-derived liquids | ||
Liquefaction | ||
Integrated coal gasification combined cycle power generation technology (IGCC) Hydrogen-from-coal process (HYCOL) Multi-purpose coal gasification technology development (EAGLE) | ||
Gasification | ||
Multi-purpose coal conversion (CPX) Efficient Co-production with coal flash partial hydropyrolysis technology (ECOPRO) | ||
Pyrolysis | ||
Topping combustion Pressurized fluidized- Fluidized-bed boiler O2/CO2 bed combustion (PFBC) combustion Fluidized-bed boiler Fluidized-bed advanced cement kiln system (FAKS) Direct iron ore smelting reduction process (DIOS) | ||
High-efficiency combustion | ||
Advanced flue gas Dry desulfurization |
Wet desulfurization |
treatment denitration | |
Denitration | |
Hot gas cleaning technology | |
Dust removal | |
Alkaline, etc. removal technology |
Coal ash utilization technologies
Target
Conventional coal preparation techniques Technology for low emission (jig, flotation, heavy media separation) coal utilization
Preparation process control technology
Bio-briquetting
Upgrading brown coal (UBC) Carbonization briquetting Hyper-coal

Degree of technological maturity
Proven reserves and R/P (ratio of reserves to production) of major energy resources
Coal |
Oil |
Natural gas |
Uranium | ||
World reserves |
9.091 trillion tons |
1,188.6 billion barrels |
180 trillion m3 |
459 million tons | |
Local reserves |
North America Latin America Europe Former Soviet Union Middle East Africa Asia Pacific |
27.8% 2.3% 7.1% 24.5% 0.0% 5.6% 32.7% |
3.9% 9.7% 1.6% 10.0% 61.7% 9.4% 3.5% |
3.9% 4.2% 2.9% 32.4% 40.6% 7.8% 7.9% |
17.1% 3.6% 2.8% 28.7% 0.2% 20.5% 27.2% |
Annual production rate |
5.54 billion tons |
29.3 billion barrels (80.3 million B/D) |
2.7 trillion m3 |
0.036 million tons | |
R/P |
164 years |
40.5 years |
66.7 years |
85 years |
Oil, natural gas, and coal data source: BP Statistics 2005 Uranium: OECD/NEA, IAEA URANIUM 2003
Oil, natural gas, and coal data source: BP Statistics 2005 Uranium: OECD/NEA, IAEA URANIUM 2003
World reserves of coal, oil, and natural gas resources
(Unit: 100 million tons oil equivalent) (Source: bp 2005) 2,010
1,099
432 99
576 1,000 Russia 0 655
Euro
576 1,000 Russia 0 655
Euro
352 127
149 Middle East
Africa 342
0 0^ South Africa
352 127
149 Middle East
7 8 India
Africa 342
0 0^ South Africa
Asia and Oceania
ÂI ictraliQ
North America ,619 1,616
China
Latin America
CCT in the Marketplace
Clean Coal Technologies in Japan
Technological difficulty
Domestic coal conversion and reforming technology Domestic coal utilization technology
P-CPC
Technological and economical difficultés remain
EAGLE
HYCOL 1 Hyper-coal
EAGLE
HYCOL 1 Hyper-coal

Melting and fiber-forming FGC melting and mixing treatment Fluidized-bed solidification material Artificial aggregate
Cost reduction technology development
Hyper coal power generation
IGFC
SCOPE21
DIOS
Formed-coke I
NSR CPX
FAKS
Melting and fiber-forming FGC melting and mixing treatment Fluidized-bed solidification material Artificial aggregate
Cost reduction technology development
Overseas demonstration (International cooperative demonstration)
Conventional technology development region
Overseas coal conversion and reforming technology Overseas coal utilization technology
Technological difficulty
Coal Production and Consumption by Country in 2004 (Total coal production worldwide: 5.508 trillion tons; Total coal consumption worldwide: 5.535 trillion tons) and Japanese Coal Imports (Japan's total coal imports: 184 million tons)
1,956
Source: IEA Coal Information 2005
5,508 5,535
25 61 161 145
250 | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
211 |
— | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
I |
\ Former USSR 66 55 Germany 402 432 China Japan ![]() South Africa Australia Source: IEA Coal Information 2005 ![]() I (production) (consumption) Coal demand trend in Japan (Unit: million tons) World 174.28 Bothers 4.65 ceramics 6.18 Chemicals 0.91 South Africa Australia 90.79 9394 11145 a bS Pulp/paper Electric power 82.19 Iron making 80.35 (Source: Coal Note 2003)
Power generation field ![]() Location of coal-fired power plants Figures in parentheses indicate power generation capacity (MW) at the end of FY2005. Nanao Ota (1,200) Toyama Shinko Kyodo (500) ![]() Sunagawa (250) Naie (350) Tomatou Atsuma (1,735) Kin (440) Ishikawa (312) Gushikawa (312) Nanao Ota (1,200) Toyama Shinko Kyodo (500) Tsuruga (1,200) Maizuru (under construction) Takasago (500) Mizushima (281) Osaki (259) Takehara (1,300) Misumi (1,000) Shin-onoda (1,000) Shimonoseki (175) Tobata Kyodo (156) Kanda (360) Minato (156) Matsuura (2,700) Matsushima (1,000) Reihoku (1,400) Sunagawa (250) Naie (350) Tomatou Atsuma (1,735) Sendai (350) Shinchi (2,000) Haramachi (2,000) Hirono (under construction) Nakoso (1,450) Hitachi Naka (1,000) Kin (440) Ishikawa (312) Gushikawa (312) Iron making field ![]()
1990' 91 ' 92 '93 ' 94 ' 95 '96 ' 97 ' 98 '99 ' 00 ' 01 ' 02 ' 03 Coal consumption in iron making sector and crude steel production |

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