Part 2 CCT Overview
Coal-fired Power Generation Technologies (Gasification Technologies)

2B1. Hydrogen-from-Coal Process (HYCOL)
Research and development: HYCOL Association [Idemitsu Kosan Co., Ltd. ; Osaka Gas Co., Ltd.;J-POWER; Tokyo Gas Co., Ltd.; Toho Gas Co., Ltd.; Nikko Kyoseki Co., Ltd.; The Japan Steel Works, Ltd.;
Hitachi Ltd.; and Mitsui Coal Liquefaction Co., Ltd.]
Project type: NEDO entrusted projectTechnology Overview

1. Background and process overview
The Hydrogen-from-Coal Process (HYCOL) is a gasification(2) Slag self-coating technology for the water-cooled tubes wastechnology utilizing an entrained bed, in which pulverized coal isapplied. This technology prolongs the life of the tubes andgasified with oxygen under high temperatures and high pressure.

improves the reliability of the gasifier.

Through the gasifier, medium calorific gas, rich in hydrogen and(3) A swirling gas flow distributor was developed and adopted ascarbon monoxide, is obtained. The technology is called thea technology to easily and uniformly distribute coal to multiple"HYCOL process." Through the shift reaction, the gas yields

burners.

carbon monoxide and converts steam to carbon dioxide and(4) Ash in coal is melted in the gasification furnace. The meltedhydrogen. After separating the carbon dioxide, the gas is purified

ash is discharged through the slag hole located in the furnace’s

to become high-purity hydrogen.

hearth. As a result of the swirling gas flow, a high temperature isHydrogen is used in oil refineries and in the chemical industry, as

maintained at the slag hole, ensuring a smooth flow of slag.

well as in the coal liquefaction process. On the other hand, the(5) The unreacted char discharged along with gas from thegas containing carbon monoxide is expected to be used widely

gasification furnace is separated by a cyclone or other suchas a raw material for synthetic chemical products, as a fuel for

device to recycle the material to the gasification furnace in afuel cells, and as a fuel in various industries.

high-temperature, high-pressure state, thus ensuring a complete

The HYCOL process has the following features:reaction.

(1) The process uses a dry-feed, one-chamber, two-stage(6) Ash in the coal is recovered as slag, which does not eluteswirling-entrained-bed gasification furnace. Pulverized coal,toxic components. Combined with the advantage of an easypressurized in a lock hopper, is fed, to the gasification furnace via

recovery of the sulfur and nitrogen components, in the form ofburners in a swirling mode. Four burners are utilized in each

H2S and NH3, respectively, the ash recovery also significantly

stage. The oxygen feed and the gasification rate at the upper

contributes to a reduction in the environmental burden.

stage and lower stage are separately controlled. Throughout theCoal that has a lower fuel ratio (fixed carbon to volatile matter) isoperation, high thermal efficiency is attained, and heavy load

more easily gasified.

gasification is performed.
2. Progress and development results

3. Issues and feasibility of practical application

The HYCOL association (made up of the nine above-listed

The development of a coal gasification fuel cell system (IGFC) forprivate companies) carried out the research and development ofpower generation utilizing HYCOL technology began in 1995,

the pilot plant, under entrustment from NEDO. Five private(EAGLE Project).

companies (Hitachi Ltd., Babcock-Hitachi K.K., Asahi Glass Co.,
Ltd., Shinagawa Refractories Co., Ltd., and NGK Spark Plug Co.,
Ltd.) carried out the basic study on the structure of the furnaceand on the materials, also under entrustment from NEDO.
For establishing the process, a pilot plant was constructed at
Sodegaura, Chiba. The operational study of the pilot plant wasconducted from 1991 to 1994. The performance target wasachieved, and the world’s most advanced gasification furnacetechnology was established.

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Clean Coal Technologies in Japan

Water-washingprocess

Gasification process

Gasification
furnace

Water-washingtowerLockhopper

Coal

Pulverized
coalapparatus

Product gas incineration process

BoilerPretreatment process

Incineration
Wastefurnace
heat boiler
Distributor
Desulfurization unit

Lockhopper

Air heater

Recycled gascompressor
Ash treatment process

Fig. 1 Process flowchart of pilot plant

Pilot plant: Specifications and target performance
Coal throughput

Max. 50 tons/day

Gasification agent

OxygenGasification pressure

30 kg/cm2(G)Gasification temperature

1,500-1,800 C

O2/Coal0.8-0.9 (weight ratio)

Produced gas volume

Approximately 91 kNm3/dayOGas composition

CO61%(design)

H231%CO23%Carbon conversion

98% or greater

Cold gas efficiency

78% or greater

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