1. Yasunari Matsuno, Ichiro Daigo, Masaru Yamashita
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

2. Topics Introduction – Backgrounds of this study
What is “Co-production” technology
Application of Co-production technologies in Steel industry
Low-temperature Gasification Plant
CO2 Recovery and Utilization System
Results of the case studies
Conclusion

3. 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
To maximize energy, resource,
environmental efficiency
Individually optimization

4. Example of “Industrial symbiosis” Jurong Island, Singapore
Oil
coal
Natural gas
Low grade oil
Fuel Oil
Steel, Cement
Recycle Hubﾞ （value chain cluster）
Environment
Final wastes CO2, Exhaust heat
Products
Wastes
Power, gas
Recycled materials H2 , Syngas High press. Steam Elec. Power Fuels
IGCC Power Plant
consumer
Final wastes
Chemicals Medicine
 To develop Jurong Island into a World-Class Chemicals Hub in the Asia Pacific Region
                                        

5. Locations of key industries
Steel works
Refineries – Petroleum industry
Ethylene plants – Petrochemical industry
LNG tanks
Potentials to develop industrial symbiosis

6. What is co-production technology?
- Technologies for Industrial symbiosis
(1) Existing System
Main products
　・Goods
　・Electricity
　・Materials
Fuels，Energy
Power Generation
Manufacturing Pro.
Raw materials
Large amount of waste heat
(2) Co-production System
Main products
　・Goods
　・Electricity
　・Materials
Fuels，Energy
Power Generation
Manufacturing Pro.
materials
Raw materials
Wastes
Little waste heat
Co-products
・Fuels
・Chemicals
・Steam etc.
Newly Energy
Saving Process

7. Industry A Industry A Industry B Industry C Industry B Industry C
Energy,
Resources
Energy,
Resources
Industry B
Industry C
Industry B
Industry C

8. 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

9. 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 emissions-
3．To optimize the transport of products by Linear Planning method
4．To investigate total environmental impacts

10. Steel plant with co-production process
1st Step
To assess the reduction potential of environmental impacts by co-production technology.
To compare with current technology.
2nd Step
To assess the reduction potential of environmental impacts in a industrial cluster scale.
To investigate the demand and supply of energy and products.
To develop a model
3rd Step
To assess the reduction potential of environmental impacts in a regional (country) scale.
To develop database.
To integrate with other tools.
Power stations
Demand and Supply
Grid mix
Conventional process
Electricity
Co-production technology
Steel plant with co-production process
Fuel gas
Demand and Supply
Current technology

11. Where to apply co-production technologies?
- Waste heat distribution in industries in Japan
Others
Paper pulp
Electricity
Ceramic
Waste
incin. 9%
Steel
Chemical
Waste heat amount
Waste heat distribution
Apply Co-production technology to Steel industry

12. Exhaust gas from Coke oven, BFG etc
Waste heat distribution in steel works
Water
Solid
Gas
Exhaust gas from Coke oven, BFG etc
COG
LDG etc

13. Methanol: easy for storage,
Co-production technology (1)
　High efficiency gasification plant with high-temperature waste heat (600℃)
High-temperature
Waste heat
Methanol
Tar 1t
Gas
5810 Mcal
CO/H2＝2
8300Mcal or
Waste heat at 873 K
1300 Mcal
Gasification
plant
Electricity
Steam
Methanol: easy for storage,
Utilizing waste heat

14. ICFG : Internally Circulating Fluidized-bed Gasifier
Synthesis Gas
Combustion Gas
Gasification
Chamber
Char-Combustion
Fluidizing medium
descending zone
Heat Recovery
Fluidizing medium &
Pyrolysis Residue
(Char, Tar)
Heat Transfer
Tubes
Steam
Air
Feedstock
(Fuel or Wastes)

15. Co-production technology (2)
　Dry Ice (cryogenic energy ) production with CHP (Utilizing waste heat)
Low temperature waste heat
Exhaust gas recovery DI
CHP
Waste heat at at 423 K 305kcal
Dry ice production process
1kg
Electricity: kWh

16. Co-production technology (2)
Compressor
Gas Cooler
Liquefier
Sub-cooler
Liquefied CO2 tank
Flash
tank
CO2 gas from co-production processes
High-stage
expander
Cooling Tower
Chemical Heat Pump
Dry-Ice
Low-stage
expander
Dry-Ice press

17. Fig. CO2 emission intensity for co-products (kg-CO2/kg)
LCA for Co-production technologies
Fig. CO2 emission intensity for co-products (kg-CO2/kg)

18. Location of steel works in Japan

19. Location of methanol consumer in Japan

20. Location of steel works and methanol consumer in Japan

21. Total CO2 emissions - Core technology
Fig. CO2 emission intensity of methanol

22. Total CO2 emission reduction potential in Japan
CO2 emission reduction potential by co-production technologies:
Methanol: ton-CO2/ton-methanol
Dry ice: 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: million ton/y
Dry ice: million ton/y

23. PP pellet (3mm diameter) Microscope of crushed pp pellet (200μm/div)
Other possible application of dry ice
Low temperature crushing of PP pellet
PP pellet (3mm diameter)
Microscope of crushed pp pellet (200μm/div)

24. Low temperature crushing of PP － Conventional technology
Crushed PP：1 kg
PP pellet：
1 kg
CO2 emissions：
2.33 kg-CO2
Liquefied N2：
9.68 kg
Δ2.10 kg-CO2
Low temperature crushing of PP　－　by dry ice
Crushed PP：1 kg
PP pellet：
1 kg
Dry ice：
3 kg
CO2 emissions：
0.23 kg-CO2
Potential demand of crushed PP: million ton/y (0.64% of total PP)
CO2 reduction potential: million ton-CO2

25. 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

26. Thank you very much for your attention.
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