JCM Model Project “Power generation by waste heat ... · PDF fileJCM Model Project...

JCM Model Project “Power generation by waste heat

recovery in cement industry”

Gen TAKAHASHIDeputy General Manager

Global Business Development

3 March 20163 March 2016

JCM Open Seminar

2

About JFE Engineering

Project Summary

Project Methodology

Reference / Another JCM Project

Group Structure

5

43,000

Net Sales (million $)

Employees29,000

JFE Steel

6,000


Employees19,000

JFE Shoji Trade

JFE Holdings(holding company) 8,500


Employees3,700

JFE Engineering

6,000


Employees

3,600

Japan Marine United

Employees: 57,500Turnover: 39 billion$

Fortune Global 500:

Ranked in 278

(FY2014) 3Copyright 2016 © JFE Engineering Corporation All Rights Reserved

Business Field

Net Sales(mil USD)

3,700 Energy Plant & PipelineSteel Structure

Environment

Industrial Machinery & Others

4Copyright 2016 © JFE Engineering Corporation All Rights Reserved

5


Project Summary

Project Methodology


JCM Model Project Summary

6

CounterpartPT Semen Indonesia

SiteTuban PlantEast Jawa

Power Generation 28MW

GHGEmission Reduction

122,000t-CO2/year

Surabaya

Tuban

appx100km

Surabaya

Jakarta

PJ Site

Copyright 2016 © JFE Engineering Corporation All Rights Reserved

Waste Heat Recovery Benefits

7

Cement Production Waste Heat from

Exhaust Gas

Cement Production Waste Heat from

Exhaust Gas

Environmentally Friendly Power

Generation

Environmentally Friendly Power

Generation

JFE’s WHR TechnologyJFE’s WHR Technology

BenefitsBenefits

No Additional Fuel Required

No Additional Fuel Required

Savings on Production Costs

Savings on Production Costs

CO2 Emission ReductionCO2 Emission Reduction

Electricity Reserve for the Community

Electricity Reserve for the Community

Reduced Consumption fromGrid-Connected Power PlantsReduced Consumption fromGrid-Connected Power Plants

Electricity Generation Using Only Waste HeatElectricity Generation Using Only Waste Heat

Available Electricity for the CommunitiesAvailable Electricity for the Communities

Apx. 20% substituted with Electricity by WHRApx. 20% substituted with Electricity by WHR


Cement Production Process

8

Waste Heat Source

Waste Heat Source

Waste Heat Source

Waste Heat Source

350ºC350ºC

400ºC400ºC


Typical System Flow

9

Clinker Production Process

Clinker Production Process

Waste Heat Recovery System

Waste Heat Recovery System


Cement Production – Baseline

10Raw MillRaw MillStackStack

EPEPClinker CoolerClinker Cooler

EPEP

StackStack

Rotary KilnRotary Kiln

Suspension Preheater




Coal-fired Power PlantCoal-fired Power Plant

Electricity

CO2 emission due to Fossil Fuel Combustion

CO2 emission due to Fossil Fuel Combustion

100%


After WHR System Installation

11Raw MillRaw MillStackStack

EPEPClinker CoolerClinker Cooler

EPEP

StackStack

Rotary KilnRotary Kiln





Coal-fired Power PlantCoal-fired Power Plant

Electricity

SP BoilerSP BoilerSP Boiler AQC BoilerAQC BoilerAQC Boiler

Turbine GeneratorTurbine Generator

Hot Exhaust Gas

Hot Exhaust Gas

Hot Exhaust GasHot Exhaust Gas

SteamSteam

SteamSteam

ElectricityReduction of grid power supply =

Reduction of CO2

20%

80%

20%


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Project Summary

Project Methodology


Eligibility Criteria

13

Criterion 1 The project utilizes waste heat from a cement production facility by waste heat recovery system (WHR) to generate electricity

Criterion 2 WHR system consists of a Suspension Preheater boiler (SP boiler) and/or Air Quenching Cooler boiler (AQC boiler), turbine generator and cooling tower

Criterion 3 WHR system utilizes only waste heat and does not utilize fossil fuels as a heat source to generate steam for power generation

Criterion 4 WHR system has not been introduced to a corresponding cement kiln of the project prior to its implementation

Criterion 5 Cement factory where the project is implemented is connected to a grid system and

the theoretical maximum electricity output of the WHR system, which is calculated

by multiplying maximum electricity output of the WHR system by the maximum hours

per year (24*365=8,760 hours), is not greater than the total amount of the

electricity imported to the cement factory from the grid system:

> During the previous year before the validation,

if the validation of the project is conducted

before the operation of the project, or

> During the previous year before the operation of

the project, if the validation of the project is

conducted after the operation of the project


A B C D E(A*B*C*D)

Quantity of Electricity Generation

Generation Capacity

(MW)

Operating day per

year (days/y)

Time(hrs/day）

Operating Rate

Electricity(MWh)

Dry Season 28 182.5 24 0.85 104,244

Rainy Season 22 182.5 24 0.85 81,906

The quantity of electricity consumption

2.4 365 24 1 21,024

The quantity of net electricity generation by the WHR system which replaced grid electricity import 165,126

REy = EGy * EFgrid

＝ 165,126 MWh/y * 0.741 tCO2 e/MWh＝ 122,358 tCO2e/y

REy = EGy * EFgrid

＝ 165,126 MWh/y * 0.741 tCO2 e/MWh＝ 122,358 tCO2e/y

Calculation of Reference Emissions

14Copyright 2016 © JFE Engineering Corporation All Rights Reserved

Reference Emissions

15

ConservativenessConservativenessElectricity consumption of WHR system is calculated by the theoretically maximum load of auxiliary equipment

=> Rated capacity of installed equipment (EGCAP) related to WHR system and max. hours/period

ReferenceReferenceReference is the situation where WHR system has not been introduced. Diffusion rate of WHR system is very low in Indonesian Cement Industry

1 plant installed / 25 plants total

The quantity of net electricity generation

The quantity of gross electricity generation by waste heat

EGAUX,y :2.4MW(EGCAP)*24h/d*365days

1.9MW(Designed capacity)*24h/d*365daysCopyright 2016 © JFE Engineering Corporation All Rights Reserved

Reference Emissions

16

REy = EGy * EFgridREy: Reference emissionsEGy: The quantity of net electricity generationEFgrid: CO2 emission factor for an Indonesian regional grid system

Determination of EGyEGy=EGGEN – EGAUXEGGEN: The quantity of gross electricity generation by waste heatEGAUX: The quantity of electricity consumption by WHR system

Determination of EGAUXEGAUX=EGCAP * 24 * 365EGCAP: The total maximum rated capacity of equipments of WHR

system

REy = EGy * EFgridREy: Reference emissionsEGy: The quantity of net electricity generationEFgrid: CO2 emission factor for an Indonesian regional grid system

Determination of EGyEGy=EGGEN – EGAUXEGGEN: The quantity of gross electricity generation by waste heatEGAUX: The quantity of electricity consumption by WHR system

Determination of EGAUXEGAUX=EGCAP * 24 * 365EGCAP: The total maximum rated capacity of equipments of WHR

system


Emission Reductions

17

Replacement of Grid Electricity GenerationReplacement of Grid Electricity Generation

Calculation of reference/project emissionsEmissions to be calculated in the methodology are those replaced by power generation of WHR system

Emission Reductions= Reference Emissions – Project Emissions

No additional fuelProject Emissions = 0

Emission Reductions = Reference Emissions Emission Reductions

= Reference Emissions


Data and parameters fixed ex ante

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EFgrid : CO2 emission factorEFgrid : CO2 emission factor

EGCAP : Total max. rated capacity of equipments of the WHR system which consumes electricity

EGCAP : Total max. rated capacity of equipments of the WHR system which consumes electricity

National Committee on Clean Development Mechanism Indonesian DNA for CDM, Updates on Emission Factors of Electricity Interconnection System(2011)

Rated capacity of all installed equipments of the WHR system which consumes electricity


Monitoring

19

EGGEN,y: Quantity of gross electricity generationEGGEN,y: Quantity of gross electricity generation

Watt meter log data are saved:every one minutein both electronic data in a server and on printed paper


Project Schedule

20

Power Generation will be envisaged in the beginning of 2017Power Generation will be envisaged in the beginning of 2017

2013 2014 2015 2016 2017

Design

Equipment

Construction

Commissioning


No.4 SP Boiler Area No.4 AQC Damper Steam Turbine

21


Project Summary

Project Methodology


Waste to Energy Plant in Yangon- JCM Model Project -

Image

Counterpart Yangon City Development Committee

Site Mingalardon area, Yangon City,MYANMAR

TechnologyWaste to Energy(WTE)Incinerator : 60ton/day

Generator : 0.7MW

GHG Emission Reduction 4,700t-CO2/year

First WTE Project with JCM

First WTE Project in Myanmar

Ground Breaking Ceremony on Oct. 10th 201522Copyright 2016 © JFE Engineering Corporation All Rights Reserved

Power generation

(exported to the grid)

Baseline vs. Project Scenario

23

MSWCH4

Reduction of CO2 emission from fossil fuel consumption at power plant

Project Scenario

CH4

Baseline Scenario

GHG Emission Reduction

CO2

CO2

Landfill Power Generation

CO2


GHG Emission Reductions

24

Reference emissions 12,198

(CH4 emissions from landfill site) 8,032

(CO2 emissions from electricity) 4,166

GHG emission reductions 4,732

Project emissions 7,466

(CO2 emissions from waste incineration) 5,263

(N2O emissions from waste incineration) 395

(CO2 emissions from electricity) 1,786

(CO2 emissions from fossil fuel consumption) 22

tCO2e/year


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Thank you for your kind attention.

JFE Engineering Corporation (Tokyo Head Office)Marunouchi Trust Tower North 19F, 1-8-1 Marunouchi, Chiyoda-ku, Tokyo 100-0005, JAPANTEL：+81-3-62120822 FAX：+81-3-62120803

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