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
– Backgrounds of this study
 What is “Co-production” technology
 Application of Co-production technologies
in Steel industry
 Introduction
– Low-temperature Gasification Plant
– CO2 Recovery and Utilization System
 Results
of the case studies
 Conclusion
Recycle-oriented Society
Kyoto Protocol (Reduction of GHGs)
Industrial symbiosis
Industry A
Industry A
Energy,
Resources
Energy,
Resources
Industry B
Industry B
Industry C
Industry C
Individually optimization
To maximize energy, resource,
environmental efficiency
Example of “Industrial symbiosis”
Jurong Island, Singapore
Products
consumer
To develop Jurong Island
Pacific Region
Wastes
Oilinto a World-Class Chemicals Hub in the Asia
Environment
Chemicals
Medicine
Fuel Oil
Recycle Hubﾞ
Recycled
materials
H2 , Syngas
High press. Steam
Elec. Power
Fuels
（value chain
cluster）
Final wastes
CO2, Exhaust heat
consumer
Environment
Locations of key industries
Steel works
Refineries – Petroleum industry
Ethylene plants – Petrochemical industry
LNG tanks
Potentials to develop industrial
symbiosis
What is co-production technology?
- Technologies for Industrial symbiosis
(1) Existing System
Fuels，Energy
Raw materials
Power Generation
Manufacturing Pro.
Main products
・Goods
・Electricity
・Materials
Large amount of waste heat
(2) Co-production System
Fuels，Energy
Power Generation
Manufacturing Pro.
Raw materials
Wastes
Main products
・Goods
・Electricity
・Materials
Little waste heat
Newly Energy
Saving Process
Co-products
・Fuels
・Chemicals
・Steam etc.
Conventional
Co-generation
Energy efficiency
Capacity
operating
rate
Environment
Energy efficiecy
Capacity
operating
Exergy
rate
Material
Environment
Co-production
Energy efficiency
Capacity
operating
Exergy ratio
Material
Environment
Industry A
Exergy
Material
Industry A
Energy,
Resources
Energy,
Resources
Industry B
Industry C
Industry B
Industry C
Goal and scope
・ To investigate environmental impacts of Co-production
technologies (for Industrial symbiosis)
• Gasification plant
• Dry ice (cryogenic energy ) production plant
with CHP
Steel works
・ To expand system boundary to evaluate total
environmental impacts
Methodology
1． To investigate where to apply co-production technologies
・Industries (capacity, location)
・Waste heat distribution
・Demand and supply of products, energy
2．To conduct LCA for co-production technologies
- CO2 emissions3．To optimize the transport of products by Linear
Planning method
4．To investigate total environmental impacts
1st Step
2nd Step
3rd Step
To assess the reduction
potential of environmental
impacts by co-production
technology.
To assess the reduction
potential of environmental
impacts in a industrial cluster
scale.
To assess the reduction
potential of environmental
impacts in a regional
(country) scale.
To compare with current
technology.
To investigate the demand and
supply of energy and products.
To develop database.
To develop a model
Power stations
Grid mix
Conventional
process
Co-production technology
Demand
and Supply
Electricity
Steel plant with co-production process
Fuel gas
Demand
and Supply
Current technology
To integrate with other
tools.
Where to apply co-production technologies?
- Waste heat distribution in industries in Japan
Others
Paper pulp
Electricity
Ceramic
Waste
incin.
9%
Chemical
Steel
Waste heat amount
Waste heat distribution
Apply Co-production
technology to Steel industry
Waste heat distribution in steel works
3000
Tcal/year
2500
2000
冷却水
Water
固体
Solid
ガス
Gas
1500
1000
500
2
0℃ 00
℃
～
30
0℃ 300
℃
～
40
0℃ 400
℃
～
50
0℃ 500
～ ℃
60
6
0℃ 00
℃
～
70
70 0℃
0℃
以
上
20
0℃
10
10
～
以
下
0
0℃
Exhaust gas from
Coke oven, BFG
etc
COG
LDG etc
Co-production technology (1)
High efficiency gasification plant with
high-temperature waste heat (600℃)
High-temperature
Waste heat
Methanol
Tar
1t
Waste heat
at 873 K
1300 Mcal
Gasification
Gas
CO/H2＝2
8300Mcal
5810 Mcal
or
Electricity
plant
Steam
Methanol: easy for storage,
Utilizing waste heat
ICFG : Internally Circulating Fluidized-bed Gasifier
Feedstock
(Fuel or Wastes)
Synthesis Gas
Combustion Gas
Gasification
Chamber
Char-Combustion
Chamber
Fluidizing medium
descending zone
Heat Recovery
Chamber
Heat Transfer
Tubes
Fluidizing medium &
Pyrolysis Residue
(Char, Tar)
Steam
Air
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
DI
CHP
Electricity:
0.176 kWh
Dry ice production
process
1kg
Co-production technology (2)
Compressor
CO2 gas from
co-production
processes
Gas Cooler
Liquefier
Sub-cooler
Liquefied
CO2 tank
Flash
tank
Cooling
Tower
High-stage
expander
Chemical
Heat
Pump
Dry-Ice
Dry-Ice
press
Low-stage
expander
CO2 emission intensity (kg-CO2/kg)
LCA for Co-production technologies
0.25
0.2
0.15
0.1
0.05
0
Dry ice
Dry ice (co(conventional) production)
Methanol
Methanol (co(conventional) production)
Fig. CO2 emission intensity for co-products (kg-CO2/kg)
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
ＣＯ2 emissions at synthesis
process
ＣＯ2 emissions at the transport
stage
0.013
0.019
Co-production
0
0.15
0.22
conventional
0.1
0.2
0.3
0.4
CO2 Emissions（ｋｇ－CO2）
Fig. CO2 emission intensity of methanol
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
(200μm/div)
Low temperature crushing of PP － Conventional technology
PP pellet：
1 kg
Crushed PP：1 kg
CO2 emissions：
2.33 kg-CO2
Liquefied N2：
9.68 kg
Low temperature crushing of PP － by dry ice
PP pellet：
1 kg
Dry ice：
3 kg
Δ2.10 kg-CO2
Crushed PP：1 kg
CO2
emissions：
0.23 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;
[email protected]