Part 2 CCT Overview
Co-production Systems

7A2. Co-production Systems
Technology overview

1. Feasibility of fuel co-production power generation systems
Conventional attempts to develop innovative processes within aand assembling peripheral plants to produce various products,

single industry face limitations. To continue the reduction of CO2enhances the unification of industries centered on a core plant,emissions, it is necessary to comprehensively review existing

thus forming an industrial coal complex based on a new materialenergy and material production systems and to develop

and energy production system. This unification of industries

technologies that optimize the individual processes and thewould advance existing industrial systems to a next-generation,interface between processes. This will not only improve thehybrid industrial system.

conversion efficiency and conserve energy, but will also

The core technology for that type of fuel co-production power

fundamentally and systematically change energy and materialgeneration system is coal gasification technology. By combining a

production systems.

high-efficiency power generation system, such as IGFC, with a

The "fuel co-production power generation system," which

process to co-produce storable fuel, the normalization of the load

produces power, fuel, and chemicals from coal, improves the total

to the gasification reactor and a significant reduction of CO2

energy use efficiency through the unification of industries throughemissions are attained.

the construction of an industrial coal complex.

Furthermore, the waste heat in the industrial coal complex is

In the power, iron and steel, and chemical industries, where large

utilized to recover chemicals from coal through endothermic

amounts of coal are consumed to produce energy, structuring areactions, thus further improving energy efficiency and enhancing

core plant that produces energy and chemicals simultaneously,

the industrial coal complex.

Steam boiler in new or existing facility

SteamSTGTFC

Gasification Center
Coal + Biomass(Waste,waste plastics,
oil-based residue, etc.)

CoalCoalPower

H2, CO

Fluidized-bed
gasification furnace

Spouted-bed
gasification furnace

Thermaldecomposition furnace

Process steam
H2

Non-reacted
gas

Fuel for heating

For fuel cell power generation,refineries, chemical plants

For hydrogen production

DME market

DMEFor petrochemical plants
Propylene
C2 distillateC4 distillate

H2, COH2

For hydrogenation anddesulfurization at ironworks

H2, COFor iron works
BTX, etc.
For petrochemical plants
CH4

Petrochemical plants, gas companies
Fig. 1 Energy flow

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Clean Coal Technologies in Japan

2. Co-produced fuel and raw materials for chemicals
There are overseas examples of fuel and chemicals being co-anticipated that DME, which has applications as a raw material

produced along with power through coal gasification, withfor clean fuel and for propylene production, will be produced asproduction varying depending on the needs of the relatedwill hydrogen, for which demand is expected to increase for use

companies, like Sasol’s production of synthetic fuel (GTL) in

as a fuel for fuel cells and for the coming hydrogen-oriented

South Africa and Eastman Chemical Company’s production ofsociety.

acetyl chemicals in the U.S. Other examples of chemical

Clean gas for iron works is also expected to be produced tosynthesis with coal gasification include the production ofrespond to changes in the energy balance at iron works of themethanol and methane in China, Europe, and the U.S. It isfuture.

3. Co-production systems
The co-production system produces both materials and energy toas power and fuel, while also producing materials shall besignificantly reduce the exergy loss that occurs mainly in theencouraged from the perspectives of creating new energy

combustion stage, and achieves an innovative and effective use

markets and also creating new industries.

of energy.

Coal co-production systems focused on coal gasification will be

The co-production system is a new production system thatable to solve environmental issues through a significant reduction

combines aspects of the conventional system, which aims toin CO2 emissions by realizing the development of high grade andimprove energy conversion efficiencies, and the cogeneration

comprehensive coal utilization technology. That type of systemsystem, which effectively uses the generated thermal energy totechnology development would trigger strong technologicalthe maximum extent possible, but goes one step further byinnovation in the coal utilization field, and vigorous innovation is

producing both energy and materials in order to significantly

expected

reduce their consumption. The co-production system, which

encourage the structuring of a recycling-oriented society.

should stimulate the economy, is also clean, thereby solving bothInternationally, the development of co-production systems shouldenergy issues and environmental concerns simultaneously.

be an important technological issue that addresses global

Consequently, co-production systems that produce energy, suchenvironmental issues.

toincreaseinternational

competitiveness

FuelPower generation in existing steam turbine power generation systems
Power
Fuel for power
generation

Power Steam

IGCC for industrial complex
Private power generation at iron works GT-CC
Cooperative thermal power company GT-CC
BTX, etc.

OutsidesaleSteamGas
Recovered steam

Iron works
Fuel for heatingGas, power, steam, BTX, etc.

Shift reaction

Coal yard
waste

Process steam
Fuel for heating

Residue oil

H2/CO > 2
H2 separation
HydrogenDME production

Non-reacted gas

Fluidized-bed
gasification
reactorIndustrial petroleum complex

Spouted bed gasification reactor Gas
Thermal decomposition reactor

Un-recovered gas
For hydrogenation

Outside saleFig. 2 Power generation, steam, fuel for process heating, hydrogen, and DME energy supply system in an iron works facility

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