Part 2 CCT Overview
Multi-Purpose Coal Utilization Technologies (Pyrolysis Technologies)

Co-production with Coal Flash Partial Hydropyrolysis
4B2. EfficientTechnology (ECOPRO)
Research and development: Japan Coal Energy Center; New Energy and Industrial
Technology Development Organization; National Institute of Advanced Industrial Science and Technology;
Nippon Steel Engineering Co.,Ltd.; Babcock Hitachi K.K.; Mitsubishi Chemical Corporation
Project type: Subsidized coal production/utilization technology promotion project
Period: 1. Coal utilization next-generation technology development survey, 1996-1999 (4 years)
2. Coal utilization commercialization technology development, 2003-2008 (6 years)Technology overview

1. Technological objective
Clean coal technology-related development solely focused on aone reactor, synthetic gas that can easily be converted for use

single industry in pursuit of a single product is reaching its limits

such as in integrated gasification combined-cycle (IGCC) powerin terms of efficiency and economy. This is necessitating thegeneration, indirect liquefaction (GTL), and chemicals, while co-development of innovative technologies that could completely

producing light oil for utilization as a feedstock for chemicals andrevolutionize energy and material production.

fuel.

Efficient Co-production with Coal Flash Partial Hydropyrolysis

The realization of a coal-based cross-industrial composite

Technology (ECOPRO) is a technology that causes pulverized

project, led by the electric power, chemical, and steel industries,

coal to react rapidly under high pressure (2-3MPa) and in awith this technology as its core will hopefully bring a dramatic

moderate hydrogen atmosphere to highly efficiently obtain, from

improvement to total energy utilization efficiency.

2. Technology overview
Figure 1 shows the total process flow of this technology. At thein hydrogen concentration (H2 in hot gas and recycle H2partial oxidation section of a coal flash partial hydropyrolsyis

combined). At that time, hot gas from the partial oxidation section

reactor, pulverized coal and recycled char are gasified withalso functions as a source of the reaction heat required at theoxygen and steam at a pressure of 2-3MPa and at a temperaturereforming section. At the reforming section, a hydrogenationof 1,500- 1,600oC to give hot gas mainly composed of CO andreaction adds H2 to primary pyrolysis, such as tar released fromH2. At the reforming section directly connected through a throat

pulverized coal, changing heavy tar-like matter to light oil. The

to the partial oxidation section, pulverized coal is injectedgas, light oil, and char produced at the partial hydropyrolysis

together with recycled H2 into the hot gas stream from the partial

reactor follow a process where, after char separation at theoxidation section to complete the reforming reaction (partialcyclone and subsequent sensible heat recovery, synthetic gashydropyrolysis) instantly under the condition of 2-3MPa in(syngas) should be formed by way of oil recovery, desulfurization,pressure, 700-900oC in temperature, and approximately 30-50%

and other gas purification processes. A portion of the syngas isDecarbonization

Shift conversion to H2
Heatrecovery

SyngasGaspurification

Chemicals

IGCC fuel

GTL fuel

City gas

Chemicals

Fuel for power generation

Reforming section
Coal reforming reaction
Gas

Heat
H2 concentration 30-50%

CoalPartialhydropyrolysis reactor

CharHeat

Coal
Light oil

Hot gasLight oil

Partial oxidation section

SteamSlagFig. 1 Process flow chart67

Clean Coal Technologies in Japan

converted into H2-rich gas, in the course of a shift reaction andThe features of this technology include:

decarbonization (CO2 recovery). After pre-heated via a heat

1. High-efficiency: The sensible heat of hot gas generated at theexchange, the gas is recycled to the partial hydropyrolysis

partial oxidation section is effectively used as a source of heatreactor’s reforming section. The final syngas product isrequired at the reforming section, providing high energy

characterized by its main composition of H2, CO, and CH4 as wellconversion efficiency.

as hydrogen-rich contents of H2/CO 1 and is used as a source

2. Flexible productivity: The reforming section temperature, asgas for IGCC, GTL, and chemicals. Light oil is mainly composedwell as the amount of hydrogen injected, can be controlled,of aromatic compounds with 1-2 rings such as benzene andallowing the freedom to change the gas/oil composition andnaphthalene, which have applications for chemical manufacturing

output ratio, thereby flexibly responding to consumers’ needs.

or fuel for power generation.

3. Economy: The cost of producing syngas can be partially offset
by the value of the of co-produced high-value-added oil.

3. Progress and development results
1) Basic partial hydropyrolysis test (1996-1999, 1kg/day)

3) Pilot plant test (2003-2008, 20t/day)Using a small-scale test unit, the pyrolysis behavior of coal underTests are being conducted using a pilot plant with a thermallythe target conditions of this technology was reviewed, confirming

self-supportable reactor combined with other ancillary processthat the hydropyrolysis of the primary tar released from the flash

units to enable forecasts for a future demonstration unit (up toheating/pyrolysis reaction of coal was successful.

1,000t/day).

2) Process development unit (PDU) test (2000-2003, 1t/day
Nippon Steel Engineering Co., Ltd. in-house research)
Using a reforming/partial oxidation-integrated PDU test unit, thebasic performance of a partial hydropyrolysis reactor as the core ofthis technology was evaluated, clarifying the reaction in the reactor.

Table 1 Development subjects for pilot plant tests
Technology to be developed

R&D topics

Verification of the reactionin the partial hydropyrolysis reactor/establishment of reactor control technology- Quantification of partial hydropyrolysis reactor reaction- Establishment of reactor conditions for optimum transition zone formation- Establishment of high-efficiency gasification (partial oxidation section) operational conditions

Development of process/factor technologies- Establishment of technology to separate/recover char from gas- Establishment of technology to recover heat from gas co-existent with oil

Total system evaluation, etc.

- Establishment of extended continuous operation technology- Establishment of scale-up approach for demonstration unit design

Table 2 Development timetable
2003

2004

2005

2006

Pilot plant test
Design/production/construction work
Testing studies
Disassembly studies
Supporting studies

References

1) H. Shimoda et al., 10th Annual Conference on Clean Coal Technology lecture collection, p. 296, 2000.
2) H. Yabe et al., 2nd Japan-Australia Coal Research Workshop Proceedings, p. 257, 2002.
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