Journal of Power and Vol. 5, No.

2, 2011

Energy
Systems
Improving Efficiency of Thermal Power
Generation in Japan*
Toshihiro SANO**
**Thermal Power Department
Tokyo Electric Power Company
1-5-3 Uchisaiwai-cho, Chiyoda-ku, Tokyo, JAPAN

Abstract
In order to combat global warming, attention has been increasingly shifting towards
nuclear and renewable energy such as wind and solar power generation as feasible
power resource alternatives. The electric power suppliers of Japan are aiming to
increase the amount of nuclear and non-fossil fuel power generation by over 50%
of total power generation by 2020. However, this does not translate into the
complete eradication of the traditional model as the remaining half will still depend
on fossil fuel-based thermal power generation. Given these circumstances, Japan
has aggressively implemented further measures to enhance the efficiency of
thermal power generation.

Key words: High Efficiency, Steam Power Generation, Combined Cycle Power
Generation, USC Steam Power Generation, IGCC

*Received 12 Oct., 2010 (No. 10-231-5)
[DOI: 10.1299/jpes.5.146]
Copyright © 2011 by JSME
1. Introduction
1.1 Thermal Power Generation
The conviction that global warming prevention and the generation of nuclear power and
renewable energies such as wind and solar power are inextricably linked is an idea that has
recently been gathering force. Regardless, thermal power generation still remains as the
major source of power supply and accounts for approximately 60% of total power supply in
Japan. Thus, efficiency improvement of thermal power generation has been deemed
indispensible in order to achieve CO2 emissions reduction. Further, since Japan has few
natural resources and depends greatly on imports for energy resources, the impact of the
recent rise in fuel prices has been extreme. For the effective utilization of fossil fuels,
technology for improving the efficiency of the thermal power generation has become
increasingly important from both environmental and economical perspectives.
Figure 1 shows an international comparison of the efficiency of thermal power
generation. From the 1990s, Japan has attained the highest level of thermal efficiency, a
level it still maintains along with UK/Ireland. This has been achieved via the enthusiastic
introduction of the highly efficient combined cycle power generation from the mid 1980s
along with the state of the art efficient steam power generation facilities (Boiler/Turbine).
Figure 2 depicts the lifecycle CO2 emissions from different types of power sources. It
shows the amount of CO2 emitted during the process of burning fuel to generate power, as
well as the amount of CO2 emissions from all other types of energy usage, such as from the
extraction of raw materials, construction of power generating facilities, fuel transportation
and refining, and plant operations and maintenance. Liquefied Natural Gas (LNG) has the

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smallest CO2 emissions per calorific value, and the combined cycle power generation has a
20 to 30% higher thermal efficiency compared to the steam power generation. That is why
LNG-fired combined cycle thermal generation has the least CO2 emission intensity among
all thermal power generation.

45%

43% Japan

Thermal Efficiency(%) - LHV

41% Nordic France
Countries

39% UK/Ireland

37% USA

South Korea Germany

35%
Australia
33%
India
31%
China
29%
1990 1992 1994 1996 1998 2000 2002 2004 2006

Fig.1 International Comparison of thermal power generation efficiency (1)

1.0
CO2 Emission intensity （kg-CO2/kWh）

0.8 Fuel Combustion for power generation

0.6

0.4

0.2 Construction/Operation
of facilities

0.0
Photovoltaic
LNG Combined

LNG Combined

LNG Combined
LNG
Coal

Wind

Nuclear
Oil

(1,100℃-class)

(1,300℃-class)

(1,500℃-class)

Fig.2 Lifecycle CO2 emissions (2)

After the two oil crises, which highlighted our vulnerability due to our nation’s lack of
energy resources, we have strived to enhance our energy security through utilizing the “best
mix” of power sources. We have diversified our power and fuel sources where we were
previously dependent mainly on oil-fired thermal power generation. Coal is available in
abundance and is relatively inexpensive and LNG has superior environmental performance.
Thus coal-fired thermal power and the LNG combined cycle are the two main sources of
our thermal power generation. Further technological development to increase the thermal
efficiency and subsequent aggressive implementation are desired for these two different
technologies.

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Energy Systems

1.2 Improving Efficiency of Thermal Power Generation

Figure 3 depicts the output trend of steam conditions and the efficiency of TEPCO’s
thermal power generation. In the late 1950s, the main source was steam power generation
with its thermal efficiency being around 39% (LHV). After the Second World War, Japan’s
thermal power generation increased in efficiency and capacity. This was achieved via
repeated improvements of the steam conditions (pressure and temperature) by bringing in
and absorbing the latest technologies from Europe and the United States. In the 1970s, the
capacity and efficiency reached 1,000MW and 43%, respectively. Japanese technology for
thermal efficiency improvement has since then surpassed that of Europe and the United
States. At present, the efficiency of the latest coal-fired Ultra Super Critical (USC) thermal
power plant has reached 45%.

1,000MW Steam Power Generation

1000
Output
800
Unit Output (MW)

710MW
600
600 Combined Cycle Power Generation
500
400 350 350 360 380
175 265
165MW
200 125MW

Steam Temperature (deg-C)

24.1MPa 24.5MPa
25 Steam
Steam Pressure (MPa)

Condition
600℃
600
20 566℃ 566℃

538℃ 16.6MPa 550

15
12.5MPa
10 500

65
Gross Efficiency (LHV%)

Thermal 61%
Combined Cycle Power Generation 59%
60 Efficiency
55 54% 55%

50 47%
44.6% 45.2%
45 42.2% 42.7% 43.2%
39.4% Steam Power Generation
40
35
1950 1960 1970 1980 1990 2000 2010 2020

Fig.3 Output, Steam Condition and efficiency trend of TEPCO’s thermal power generation

In 1985, TEPCO has introduced its first combined cycle power generation. Its thermal
efficiency of 47% has largely surpassed that of the conventional steam generation at that
time. Further, for the combined cycle, the gas turbine inlet temperature which is equivalent
to the steam conditions for the conventional steam power generation was increased. The
Advanced Combined Cycle (ACC) with an efficiency of 54% was introduced. The gas
turbine inlet temperature was increased from 1,100 deg-C to 1,300 deg-C. Further, in 2007,
the “More Advanced Combined Cycle” (MACC) with a gas turbine inlet temperature of
1,500 deg-C commenced commercial operations. Its thermal efficiency had reached 59%.
Now, the total capacity of the combined cycle generation of TEPCO is approximately
13,000MW and accounts for one third of TEPCO’s total thermal generation capacity. As a
result of the vigorous implementation of the combined cycle generation, the average
efficiency of TEPCO’s thermal power generation was 46.9% (LHV) in the fiscal year 2009,
which is amongst the top levels in Japan.

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In this paper, the features of the steam and combined cycle generation and the trend of the
latest efficiency improvement technologies have been introduced.

2. Development of a Steam Power Generation Facility

2.1 Features of the Steam Power Generation
For steam power generation, as shown in Fig. 4, fuel is burned in the boiler to produce
high temperature and high pressure steam. This steam rotates the steam turbine and the
generator to generate electricity. Then, the steam is cooled until it condenses into water at
the condenser and is then resent to the boiler. Sea water is the primary cooling source for
the condenser. Various types of fuel not only coal, oil, and LNG, but also extremely heavy
residual oil (such as asphalt) can be used for the boiler. Recently, there are also approaches
to utilizing biomass fuel by mixing them with coal at coal-fired thermal power plants.

Stack
Boiler Turbine
Fuel Storage
Tank

Flue Gas
Transformer
Steam Generator
LNG
Carrier Vaporizer

Air
Water
Fuel Gas Electricity

Cooling Water

Fig.4 Outline of Steam Power Generation

2.2 Transition of Steam Power Generation and its Environmental Measures

In 1960s, with the further development of the Japanese economy, many power stations
were built to meet the rapid growth of electricity demand. As oil became increasingly cheap
and available in abundance, fuel for thermal power generation was converted from coal to
heavy and crude oil. After experiencing the two oil crises in the 1970s, the weakness of
Japans energy policy, which relied almost exclusively on Middle East oil resources, had
become apparent. From the viewpoint of energy security, in order to realize the “best mix”
of power sources, nuclear, LNG thermal and coal thermal power generation were introduced
as substitutes to oil-fired thermal generation.
In 1970, the Minami Yokohama Power Plant which started operation in 1970 was the
world’s first LNG-fired power plant. At that time, social controversy concerning air
pollution was beginning to peak. The utilization of LNG as a fuel source had since then
expanded with its dust and sulfur oxide (SOx) emissions-free superior environmental
characteristics.
On the other hand, coal-fired thermal power generation became necessary in order to
comply with strict environmental regulations borne from anti-pollutant environmental
legislation. However, given its abundance in many diverse sources, coal is being
reconsidered, especially in the politically stable countries of the Pacific Rim.
Japan leads the world not only in thermal efficiency but also in technologies for
environmental measures. As shown in Fig. 5, Japan’s NOx and SOx emission intensity is
the lowest in the world. As for counter measures against SOx emissions, the use of
low-sulfur heavy oil and high quality coal and the installation of the wet lime-gypsum
method high performance flue gas desulfurization unit for coal- fired thermal power

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generation were implemented. In considering NOx emissions, excluding those originating

from the fuel, NOx is also produced through the oxidation of nitrogen found in combustion
air. These types of emissions are known as thermal NOx. The major countermeasures
against NOx emissions are realizing reductions via the improvement of the combustion
method and the implementation of a low-NOx burner and removal by installing a catalysis
flue gas denitration facility. The major countermeasures against dust emitted from burning
oil and coal, is the installation of an electrostatic precipitator.

[g/kWh] SOx Emmision Intensity NOx Emmision Intensity

4

3.5 3.4 3.3

3.2
3.1
3 2.9

2.5

2
1.6
1.5 1.4 1.4
1.2 1.2
1 0.7 0.8 0.8
0.6
0.5 0.2 0.2
0.09 0.14
0
Canada France Germany Italy UK USA 6Nations Japan TEPCO
('05) ('05) ('05) ('05) ('05) ('05) Average ('08) ('09)
('05)

Fig.5 International Comparison of SOx, NOx emission intensity (3), (4)

2.3 Implementation of Efficiency Improvement Technology for Steam Power

Generation
Thermal efficiency for steam power generation was improved by increasing its capacity
and temperature and the pressure of steam conditions.
By increasing its capacity and enlarging the equipment, the thermal efficiency increases.
This is because the radiation loss from the surface of the boiler relatively decreases and also
the decrease of the tip loss of the steam turbine caused by the steam passing through the gap
between the rotating blades and the casing without producing power. The unit capacity
increased from around 350MW in the 1960s, to 600MW in the 1970s and has now reached
1,000MW. Figure 6 reveals the incremental temperature and pressure improvements of
steam power generation in Japan. The steam conditions had been improved in the order of
sub-critical, Super Critical (SC) and Ultra Super Critical (USC) steam conditions. When
water is pressurized above a certain pressure and heated to increase its temperature, there is
a phenomenon where the water suddenly changes to steam. This point is called the critical
point of water (22.12 MPa, 374.15 deg-C). Steam conditions over this critical pressure are
called SC and within SC, steam conditions with the temperature exceeding 566 deg-C are
classified as USC.
With the introduction of SC steam conditions, the boiler has developed from the
traditional drum circulating type to the one-through type which consists only of groups of
many long tubes. Due to the SC steam conditions where the water suddenly changes into
steam when it reaches a certain temperature, the drum which acts as a kettle has been
eliminated. Water entering a tube will be preheated, evaporated and super heated and steam
will come out of the exit of the tube.

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650
620℃
50

Steam Temperature (deg-C)

Main Steam Pressure (MPa)
610℃
600℃
593℃
600
40 566℃

538℃ T 31MPa
550
30 24. 1MPa

20
18. 6MPa
16. 6MPa
P 500

10 450

0 400
1950 1960 1970 1980 1990 2000 2010
Year of commercial operation
Fig.6 Trend of Steam Temperature and Pressure for Japanese Steam Power Generation

After the 1970s, the steam conditions had not changed for quite a while, but the effort to
improve efficiency continued via capacity enlargements and the development of the
highly efficient steam turbine blades. From the 1980s, construction of coal- fired power
generation was promoted in order to take advantage of the abundant and cheap coal.
However, as coal-fired power generation required more in-house loads in order to operate
the equipment necessary for environmental measures and have more CO2 emission intensity
compared to the LNG and oil-fired power generation, there was an increasing demand
towards efficiency improvements via increasing its steam conditions. Further, with the
development of new materials able to resist high temperatures, the USC technology was
realized. The first coal-fired USC plant for TEPCO is the Hitachinaka Power Station Unit
One which commenced operations in 2003. Further, in 2004, the Hirono Power Station Unit
Five began commercial operations. Currently, two more units, namely, Hitachinaka Unit
Two and Hirono Unit Six are under construction. Further, the spread of coal-fired USC
power generation has expanded throughout Japan and now accounts for half of all coal-fired
generation in the nation. Table 1 shows the number USC Power Stations in Japan.

2.3.1 Example of USC Power Plant in Japan - Hitachinaka

In order to enhance energy security and minimize generation costs, TEPCO’s coal-fired
Hitachinaka Unit One (1,000MW) commenced commercial operations in December 2003.
For TEPCO, it had been about 30 years since the last large scale coal-firing power plant was
constructed. In order to increase the thermal efficiency and decrease CO2 emissions, the
USC steam conditions of 24.5MPa, 600/600 deg-C was adopted. It achieved a thermal
efficiency of 45% (LHV) which is the highest class in terms of coal-fired steam power
generation levels. Maximum efforts were put forth towards environmental preservation.
Highly efficient and reliable denitrifying facility and electrostatic precipitator and
desulphurization facility had been installed for the flue gas treatment. Further, woody
biomass fuel which is a kind of natural and renewable energy is scheduled to be utilized as
fuel for Unit One from fiscal year 2012. When implemented, it would reduce the annual
CO2 emissions by about 110 kilo tons.
The construction of Unit Two (1,000MW) has started in October 2009. Commercial
operations are scheduled to commence from December 2013. Although the Unit Two’s
steam conditions are the same as those for Unit One, operability improvements and
operating cost reductions are being made. It will also be able to cope with more different
types of coal than Unit One. Figure 7 is a bird’s eye depiction of Units One and Two.

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Table 1 USC Power Stations in Japan

Steam Condition
Station Name Output Year of commercial
Company Pressure Temperature
Unit No. operation
MW MPa deg-C
Tomato-Atsuma 4 Hokkaido 700 25.0 600/600 Jun-02
Noshiro 2 Tohoku 600 24.1 566/593 Dec-94
Haramachi 1 Tohoku 1,000 24.5 566/593 Jul-97
Haramachi 2 Tohoku 1,000 24.5 600/600 Jul-98
Hitachinaka 1 Tokyo 1,000 24.5 600/600 Dec-03
Hitachinaka 2 Tokyo 1,000 24.5 600/600 Dec-13(Schedule)
Hirono 5 Tokyo 600 24.5 600/600 Jul-04
Hirono 6 Tokyo 600 24.5 600/600 Dec-13(Schedule)
Hekinan 3 Chubu 700 24.1 538/593 Apr-93
Hekinan 4 Chubu 1,000 24.1 566/593 Nov-01
Hekinan 5 Chubu 1,000 24.1 566/593 Nov-02
Nanao Ohta 1 Hokuriku 500 24.1 566/593 Mar-95
Nanao Ohta 2 Hokuriku 700 24.1 593/593 Jul-98
Tsuruga 2 Hokuriku 700 24.1 593/593 Sep-00
Maizuru 1 Kansai 900 24.5 595/595 Aug-04
Maizuru 2 Kansai 900 24.5 595/595 Aug-10(Schedule)
Misumi 1 Chugoku 1,000 24.5 600/600 Jun-98
Tachibanawan 1 Shikoku 700 24.1 566/593 Jun-00
Reihoku 2 Kyushu 700 24.1 593/593 Jun-03
Matuura 2 J-Power 1,000 24.1 593/593 Jul-97
Tachibanawan 1 J-Power 1,050 25.0 600/610 Jul-00
Tachibanawan 2 J-Power 1,050 25.0 600/610 Dec-00
Isogo 1 J-Power 600 25.0 600/610 Apr-02
Isogo 2 J-Power 600 25.0 600/620 Jul-09

Fig.7 Hitachinaka Power Station

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2.3.2 Example of USC Power Plant in Japan - Hirono

TEPCO’s Hirono Power Station was a heavy oil-fired steam power generation plant
located at Hamadori along the coast of the Fukushima Prefecture. Units Five and Six have
been constructed in an extension area of about 14ha which is extremely small for a
coal-fired steam power generation unit. With these two units, the total output of Hirono
Power Station will come to 4,400MW making it TEPCO’s second largest thermal power
station. Units Five and Six will also possess the highest global standards of thermal
efficiency, steam conditions and environmental measures the same as Hitachinaka Power
Station. When the master plan was put together during the 1990s, the electricity
liberalization and competition with the IPPs had begun. In order to reduce construction and
operational costs, optimizations of the following facility were thoroughly implemented:
・ Size reduction of the boiler furnace by limiting the variety of design coal
・ Simplifying the number of duct systems into a single system
・ Optimization of the start up system in order to eliminate the boiler recirculation pump
・ Tandem compound steam turbine
・ Two cylinder steam turbines made up of high and intermediate combined turbine
cylinders and a single low-pressure turbine cylinder
・ World's longest 48-inch last stage steel blades for 3,000 rpm turbines
Further, due to the limited land space and shallow surrounding sea areas, it was difficult
to dock coal carrier ships. Thus, the Onahama Coal Center was built as coal transshipping
station 30 km south of the power station. Coal from the carrier ship is initially unloaded and
stocked at the Onahama Coal Center and then transported to its final destination via a
designated domestic vessel. The operation of the Coal Center was started in conjunction
with the operations of Unit Five. The overview of Hirono Unit Five is shown in Figure 8.

Fig.8 Hirono Power Station

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3. Development of a Combined Cycle Power Generation Facility

3.1 Features of the Combined Cycle Power Generation
The gas turbine which is the heart of the current combined cycle power generation was
previously used as an independent prime mover for power generation. Compared to steam
power generation, the gas turbine can easily change its load of a certain amount and is
capable of rapid starts and stops. Although it is also capable of adjust to demand
fluctuations, its efficiency was significantly low compared to steam power generation due to
the large energy loss of high temperature exhaust gas. That is why it was used only during
emergencies or peak hours in Japan.
But in foreign countries, many of them were implemented as they are easy to construct
within a short period of time, construction costs are low and there are minimal location
restrictions as there is no need for vast amounts of cooling water for the condenser and
operations are relatively easily managed compared to steam power generation. During this
period, the gas turbine inlet temperature has increased to 1,100 deg-C, a resulting level
considered to be satisfactory and reliable. Figure 9 outlines the structure of the combined
cycle generation. The exhaust gas from the gas turbine, after rotating the gas turbine, is lead
to the heat recovery steam generator to produce steam to rotate the steam turbine. Although
the temperature of the steam is limited to 600 deg-C due to material constraints for steam
power generation, the combined cycle generation can effectively utilize the energy of the
fuel, by utilizing the thermal energy in high temperature regions at the gas turbine and the
low temperature regions at the steam turbine.

Air Fuel Exhaust Gas Exhaust Gas

Gas Turbine
Power HRSG
Generation
Gas Generator
Compressor Air Fuel
Turbine
Steam
Exhaust Gas Generator Generator Turbine

Boiler
Steam Power
Generation Gas
Compressor
Turbine
Cooling Cooling
Water Water
Combined Cycle Power
Condenser Condenser
Generation
Fuel Pump Pump

Fig. 9 Outline of Combined Cycle Power Generation

Further, environmentally speaking, the combined cycle power generation is superior. As

power output is shared amongst the gas turbine and the steam turbine, the thermal effluent
from the condenser of the steam turbine is about 50-60% lower compared to that of steam
power generation of the same capacity.
The features of the combined cycle generation is that it is able to start and stop within a
very short time frame taking advantage of the mobility of the gas turbine. The load curve of
the combined cycle power generation is shown in Figure 10. Where around three hours is
necessary for a 1,000MW steam power generation unit to reach base load operations from
start up after an eight hour stop, it only takes around one hour for the combined cycle
generation unit from the same eight hour stop.

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100
100

Speed (%)

Load (%)
0 0
GT Start Synchronize Base Load

Aprox 60 Minutes
Fig.10 Start up Schedule of C/C Power Generation

3.2 Efficiency Improvement Technologies for Combined Cycle Power Generation

The combined cycle generation has been introduced throughout the world with the
recognition of the 1,100 deg-C class gas turbine. The thermal efficiency of the 1,100 deg-C
class combined cycle is 47% (LHV) and surpassed the efficiency of the steam power
generation by over 3-4% at that time. Thus, large combined cycle power plants for utilities
were built in many places in Japan since 1984.
Since then, with dramatic thermal efficiency and environmental feature improvements
achieved by increasing its gas turbine inlet temperature and developing the dry low-NOx
combustor, LNG combined cycle power plants were built in sequence through out Japan.
Now, there is a 1,500 deg-C combined cycle power plant with one of the world’s highest
thermal efficiency of 59% (LHV) already in commercial operation. Figure 11 is the heat
balance diagram of the latest 1,500 deg-C class combined cycle power generation.
Condenser
Turbine
Steam

33%
53%
53%
20%
Electricity

59%
Heat Recovery Energy

39%
Gas Turbine
Fuel (LNG)

100%
61%
GT Exhaust

H
53% R
S
8% G

Exhaust Gas

Fig.11 Heat Balance Diagram of MACC

The most important indicator for the combined cycle power generation is the gas turbine
inlet temperature of the gas turbine which dominates the thermal efficiency of the combined
cycle power generation. The history of improving the efficiency of the combined cycle

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power generation can be said to be the history of increasing the gas turbine inlet
temperature of the gas turbine. The combined cycle power generation can be categorized
into three distinct generational phases with this gas turbine inlet temperature.
Within TEPCO, in order to distinguish these three generation phases, we call the first
generation phase with the 1,100 deg-C class, CC (Combined Cycle), the second generation
phase with 1,300 deg-C class, ACC (Advanced Combined Cycle) and the third generation
phase with 1,500 deg-C class, MACC (More Advanced Combined Cycle). Table 2 shows
the 1,100 deg-C and 1,300 deg-C combined cycle power plants of TEPCO.

Table 2 TEPCO‘s CC and ACC power stations

Yoko-
Futtsu Shina-
hama Chiba 1 Chiba 2 Futtsu 3
1&2 gawa 1
7&8

Number of Unit 14 8 4 4 4 3

Unit Output (MW) 165 350 360 360 380 380

Group Output (MW) 2,000 2,800 1,440 1,440 1,520 1,140

Design Thermal
47.2 54.1 54.2 54.2 55.3 55.3
Efficiency (%LHV)
Year of Commercial 1986 /
1998 2000 2000 2003 2003
Operation 1988

GT Type 9E 9FA M701F 9FA 9FA+e 9FA+e

Just after the World War II, the buckets of the gas turbines were made of steel and used
without any cooling or coatings. The gas turbines for the CC power generation increased its
gas turbine inlet temperature to 1,100 deg-C by utilizing the technologies employed in
aviation engines such as nickel super alloy, blade cooling technology and thermal barrier
coatings. Since then, the combined cycle power generation has become economically
feasible and has spread widely throughout the world. Further, for TEPCO, Futtsu Power
Station Groups One and Two (2,000MW) commenced operations in 1985 and achieved a
thermal efficiency of 47% (LHV).
Further, for the ACC power generation, the construction of a 1,300 deg-C class gas
turbine was realized through several technical developments. Concerning the material
technology, enhancement of high temperature creep strength was created by improving the
crystal structure and chemical components of the nickel supper alloy for buckets. As for the
cooling technology, a cooling efficiency increase was realized by adopting the return flow
cooling with a sophisticated cooling passage within the turbine buckets compared to the one
through cooling of the previous 1,100 deg-C class gas turbine. With the realization of the
1,300 deg-C class gas turbine, the thermal efficiency of ACC power generation dramatically
increased to 54% (LHV). Starting from the Yokohama Power Station Group Seven and
Eight (2,800MW), many ACC power plants were constructed. Further technological
improvements for the thermal barrier coating to protect the buckets from the hot exhaust gas
were made after ACC power generation was implemented.
As for the MACC power generation, additional high temperature strength enhancement
of the metallic material and usage of steam which has a higher cooling ability than air for
the cooling of combustors, buckets and nozzles allows for the further increase of the gas
turbine inlet temperature. With the 1,500 deg-C gas turbine, the thermal efficiency of the

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MACC power generation reached 59% (LHV). TEPCO’s Kawasaki Power Station Group
One and Futtsu Power Station Group Four commenced commercial operations from 2007
and 2008, respectively. Furthermore, the implementation of a 1,600 deg-C class More
Advanced Combined CycleⅡ(MACCⅡ) power generation which has increased its gas
turbine inlet temperature with the bucket cooling and coating technology improvement has
been planned for the Kawasaki Power Station Group Two and the replacement of the Goi
Power Station. Table 3 shows the latest ultra-high efficient combined power stations in
Japan.

Table 3 Latest Combined Cycle Power Stations in Japan

Kawasaki 2-1 Himeji No.2 Kawasaki 2-2,3 Goi 1

(Tokyo) (Kansai) (Tokyo) (Tokyo)

Number of Unit 1 6 2 3

Unit Output (MW) 500 486.5 710 710

Group Output (MW) 1,920 2,919 1,920 2,130

Design Thermal
about 59 about 60 about 61 about 61
Efficiency (%LHV)

Year of Commercial
2013 2013-2015 2016-2017 2021-2023
Operation

GT Type 1,500℃-class 1,600℃-class 1,600℃-class 1,600℃-class

3.2.1 Kawasaki Power Station Group 1 and 2

TEPCO’s Kawasaki Power Station Group One commenced its commercial operations
from June 2007. It was the first 1,500 deg-C class MACC power generation in Japan and
achieved a thermal efficiency of 59% (LHV) which is the highest level in the world. Group
One (500MW x 3 stages, total 1,500MW) implements the MHI’s 701G2 gas turbine. The
key features of this gas turbine are that the combustors are steam cooled. In February 2009,
the entire Group One began commercial operations and from February 2010, steam from
Group One was supplied to 10 companies in the Chidori-Yako industrial complex of
Kawasaki City.

Fig.12 Kawasaki Power Station

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Along with the construction of Group One, demolition of the former One to Six units was
done at the same time. After the demolition, construction of Group Two was started from
October 2009. Stage One of Group Two will be MACC power generation (500MW x 1
stage, MHI’s 701G2 gas turbine) and is planned to be commercially operated from February
2013. On the other hand, Stages Two and Three of Group Two are planned to be the 1,600
deg-C MACCⅡ (710MW x 2 stages, Group Two total 1,920MW) with a thermal efficiency
of 61% (LHV). They are scheduled to begin commercial operations from 2016 and 2017,
respectively. Figure 12 depicts the future Kawasaki Power Station Groups One and Two.

3.2.2 Futtsu Power Station Group 4

At Futtsu Power Station, Groups One and Two (2,000MW) which are the pioneering CC
within Japan, and Group Three ACC power generation (1,520MW) are under commercial
operations. Further, adjacent to Group Three, Group Four MACC power generation
facilities (507MW x 3 stages, total 1,520MW) are under construction. Group Four
implements GE’s 9H gas turbine. The key features of the 9H gas turbine is that it adopts
steam cooling for the 1st and 2nd stage buckets and nozzles.
Construction of Group Four was started from September 2004. The first gas turbine and
the heat recovery steam generator were delivered on site in August and September of 2006,
respectively. The commissioning of Stage One, the first of the Group Four, was started in
November 2007. After various tests and tuning such as change over of the steam supply for
the bucket and nozzle steam cooling which is special for the 9H type, Stage One
commenced commercial operations in July 2008. The entire commercial operations of
Group Four are scheduled for October 2010. A bird’s eye view of Futtsu Power Station is
shown in Fig. 13.

Fig.13 Futtsu Power Station

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3.3 Effective Use of Coal

From an energy security and economical perspective, as coal is available in abundance
and is relatively inexpensive, it is considered to be a promising fuel source for both now and
in the future. However, it is not possible to burn coal in the combustor of the gas turbines.
The use of coal was limited to such activities as pulverized coal-fired steam power
generation.
The technology to improve the thermal efficiency of coal-fired power generation is called
the “Integrated Coal Gasification Combined Cycle” (IGCC). Coal is gasified at the
gasification furnace which enables it to be used as fuel for an efficient gas turbine combined
cycle power generation. Figure 14 is an outline of the IGCC.
The commercial application of the IGCC with a 1,500 deg-C class gas turbine is assumed
to have a net efficiency between 48 to 50% (LHV). At present, the demonstration of the
IGCC is on going as a national project. This project is located in Nakoso of Fukushima
Prefecture and managed by Clean Coal Power R&D CO., LTD. (CCP), an institution which
funded mainly by TEPCO together with nine other Japanese Utilities and J-power. The air
blown IGCC, which is unique to Japan, has a higher net efficiency compared to the oxygen
blown IGCC of USA and Europe. The CCP was established in June 2001. After three years
of design and environmental impact assessment and another three years of construction and
commissioning of the 250MW IGCC with a 1,200 deg-C class gas turbine was started from
2007. It has achieved a net efficiency of 42.9% (LHV) and has successfully operated
continuously for 2,039 hours in 2008. Currently, it is in its third year of testing and is
accumulating a great deal of know-how. TEPCO has dispatched numbers of engineers to
CCP in order to acquire experience in construction, operations and maintenance for the
preparation of the commercialization of the IGCC.

Fig.14 Outline of IGCC

4. Future Prospects
The electric power suppliers of Japan are aiming to increase the rate of nuclear and
non-fossil fuel power generation to over 50% of the total power generation by 2020.
However, this means that the remaining half will still be fossil fuel-based thermal power
generation. Further, thermal power generation’s role in adjusting to the fluctuation of solar
and wind power generation output affected by the weather will still be significant. Further
efficiency improvements of the thermal power generation are necessary in order to meet
increasing environmental and economical demands while maintaining a stable supply of
energy.
In March 2008, the Resource and Energy Agency in the Ministry of Economy, Trade and

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Energy Systems

Industry, announced the “Cool Earth - Innovative Energy Technology Program”. Out of the
21 prioritized technologies, 1,700 deg-C class combined cycle power generation for “high
efficient natural gas fired power generation” and IGCC and Advanced Ultra Super Critical
power generation (A-USC) for the “high efficient coal fired generation” was chosen for this
program. The 1,700-deg-C class gas turbine is expected to be applied to not only the
LNG-fired combined cycle power generation but also to IGCC power generation.
It is strongly desired that the issues connected to each technical development be resolved
and further implementations of thermal efficiency improvements be steadily realized.

References
(1) INTERNATIONAL COMPARISON OF FOSSIL POWER EFFICIENCY AND CO2
INTENSITY (2009) (ECOFYS)
(2) Central Research Institute of Electric Power Industry
(3) OECD [Environmental Data Compendium 2006/2007]
(4) IEA [Energy Balances of OECD Countries 2010 Edition]

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