Osaka Gas Research Articles

Международная инновационная активность компаний в области систем пассивного снижения теплопритоков

The article analyzes innovative activity in the technological direction of liquefied natural gas transportation based on trends in patent activity. An analysis of the dynamics of patenting new developments in this area showed a high level of innovative activity both on the part of major market players and in relation to individual authors. The study noted bursts of patent activity in certain periods associated with the development of scientific and technological progress. The most active national markets in this area are China, Japan and South Korea, but the European patent market also has potential for scaling. An assessment of the patent portfolios of companies has identified the most significant players in the market for liquefied natural gas transportation technologies in terms of the value of technical solutions patented by these companies: Daewoo Shipbuilding and Marine Engineering, Chugoku Electric Power, Hyundai Heavy Industries, Mitsubishi Heavy Industries, Osaka Gas, Samsung Heavy Industries, Siemens. The authors give forecasts for the development of the considered technological niche in the corporate and regional context. The obtained results of the study can used in the formation of programs for the innovative development of organizations involved in the implementation of orders in the field of energy and transport.

Integration of the comprehensive Gorgon CO2 surveillance program for history matching of the Dupuy reservoir model

The Gorgon CO2 project (The Gorgon Project is operated by Chevron Australia and is a joint venture of the Australian subsidiaries of Chevron (47.3%), ExxonMobil (25%), Shell (25%), Osaka Gas (1.25%), Tokyo Gas (1%) and JERA (0.417%)) is the world’s largest operational Carbon Capture and Storage (CCS) project dedicated to greenhouse gas abatement. Since starting injection in 2019 it has successfully sequestered more than 7.5 million tonnes of CO2 equivalent (as at 31 January 2023). A comprehensive surveillance program – including reservoir pressure monitoring, 4D seismic, microseismic monitoring, distributed temperature and acoustic sensing, and InSAR surface displacement measurement – provides a wealth of data for developing history-matched static, dynamic and geomechanical models that are instrumental in the operation and development planning of the field. In comparison to modelling of conventional hydrocarbon reservoirs, in which maximising production and ultimate recovery are typically the focus, developing and selecting a suite of representative CCS models requires consideration of an additional set of factors. These factors include modelling CO2 plume movement, managing reservoir pressure at key locations and accommodating geomechanical constraints. This paper will explore these differences, and how the various sources of surveillance data have been integrated into the modelling process to better understand and predict the dynamic behaviour of the Dupuy reservoir.

Concurrent 15. Presentation for: Technological advances in biosecurity monitoring

Presented on Wednesday 18 May: Session 15 Biosecurity tools are a key aspect of an effective biosecurity system, however, existing surveillance and monitoring programs are often expensive, resource intense, reliant on special expertise, long-term and deliver variable results. Advances in innovation and technology provide opportunity to improve program efficiency, reliability and cost-effectiveness. Chevron Australia developed and deployed tools to help monitor and identify non-indigenous species on Barrow Island, a Class A Nature Reserve and home to the Gorgon Natural Gas Project, operated by Chevron Australia and a joint venture of the Australian subsidiaries of Chevron (47.3%), ExxonMobil (25%), Shell (25%), Osaka Gas (1.25%), Tokyo Gas (1%) and JERA (0.417%). Tools include: The PAWS® (Print Acquisition for Wildlife Sensors) pest identification sensor pad and PAWS® live capture devices for rodent detection and monitoring, EARS (Environmental Acoustic Recognition Sensor) devices that record the male Asian house gecko’s call and can be adapted to incorporate other species if required, LAMP (Loop Mediated Isothermal Amplification) assay to identify Asian house gecko scats or tissue samples with an in situ molecular tool, Gecko identification application (app) enabling the workforce to participate in citizen science programs. These technological advances have helped to improve surveillance and biosecurity programs on Barrow Island, realising benefits including: longer monitoring periods for lower costs, resulting in greater confidence in surveillance outcomes, in situ diagnostics providing more rapid identification to enact an immediate response; deployment of live capture devices, reducing non-target captures (consequently, a more ethical tool); wider workforce participation. While these innovative tools target species likely to threaten Barrow Island’s unique biodiversity, the technology can be adapted for other environmental monitoring programs. To access the presentation click the link on the right. To read the full paper click here

ESG Poster ESG11: Lighting the way

Poster ESG11 Historically, Chevron Australia Pty Ltd have utilised Mobile Diesel Lighting Towers (MDLTs), with ‘turtle friendly’ luminaires at the Gorgon natural gas project (located on Barrow Island, Western Australia), operated by Chevron Australia on behalf of a joint venture of the Australian subsidiaries of Chevron (47.3%), ExxonMobil (25%), Shell (25%), Osaka Gas (1.25%), Tokyo Gas (1%) and JERA (0.417%). MDLTs are a known, relatively safe and reliable light source that can be utilised in most locations, though they emit noise, odour, vibrations, waste hydrocarbons and CO2 as well as requiring regular refuelling and general engine maintenance. With recent and significant improvements in solar energy harvest, and battery storage efficiencies, Mobile Solar Lighting Towers (MSLTs) have technical and performance characteristics that are comparable, and in many instances superior, to MDLTs. In addition to these characteristics, Chevron Australia has successfully worked with its Australian supplier, conducting trials on site to introduce a range of additional design and performance improvements. These improvements include simple Human–Machine Interface (HMI) touch screen interface allowing remote automation through WiFi or 4G, real-time battery and performance monitoring, CCTV, geofencing and GPS tracking. The benefits of replacing just 25 owned MDLTs with solar includes the abatement of over 600 tonnes of CO2 and direct operational cost savings of almost A$50 000 per year (not including indirect cost savings or avoided carbon emissions costs). Further, net present value calculations demonstrate a financial benefit exceeding A$1 000 000 over 5 years when the solar towers are leased compared with maintaining existing or purchasing new diesel units. These MSLT units are delivering environmental benefits, direct and indirect financial savings, and reduced health, safety and environment risk, which have been welcomed by the on-site workforce. To access the poster click the link on the right. To read the full paper click here

Technological advances in biosecurity monitoring

Biosecurity tools are a key aspect of an effective biosecurity system, however, existing surveillance and monitoring programs are often expensive, resource intense, reliant on special expertise, long-term and deliver variable results. Advances in innovation and technology provide opportunity to improve program efficiency, reliability and cost-effectiveness. Chevron Australia developed and deployed tools to help monitor and identify non-indigenous species on Barrow Island, a Class A Nature Reserve and home to the Gorgon Natural Gas Project, operated by Chevron Australia and a joint venture of the Australian subsidiaries of Chevron (47.3%), ExxonMobil (25%), Shell (25%), Osaka Gas (1.25%), Tokyo Gas (1%) and JERA (0.417%). Tools include: The PAWS® (Print Acquisition for Wildlife Sensors) pest identification sensor pad and PAWS® live capture devices for rodent detection and monitoring, EARS (Environmental Acoustic Recognition Sensor) devices that record the male Asian house gecko’s call and can be adapted to incorporate other species if required, LAMP (Loop Mediated Isothermal Amplification) assay to identify Asian house gecko scats or tissue samples with an in situ molecular tool, Gecko identification application (app) enabling the workforce to participate in citizen science programs. These technological advances have helped to improve surveillance and biosecurity programs on Barrow Island, realising benefits including: longer monitoring periods for lower costs, resulting in greater confidence in surveillance outcomes, in situ diagnostics providing more rapid identification to enact an immediate response; deployment of live capture devices, reducing non-target captures (consequently, a more ethical tool); wider workforce participation. While these innovative tools target species likely to threaten Barrow Island’s unique biodiversity, the technology can be adapted for other environmental monitoring programs.

Lighting the way

Historically, Chevron Australia Pty Ltd have utilised Mobile Diesel Lighting Towers (MDLTs), with ‘turtle friendly’ luminaires at the Gorgon natural gas project (located on Barrow Island, Western Australia), operated by Chevron Australia on behalf of a joint venture of the Australian subsidiaries of Chevron (47.3%), ExxonMobil (25%), Shell (25%), Osaka Gas (1.25%), Tokyo Gas (1%) and JERA (0.417%). MDLTs are a known, relatively safe and reliable light source that can be utilised in most locations, though they emit noise, odour, vibrations, waste hydrocarbons and CO2 as well as requiring regular refuelling and general engine maintenance. With recent and significant improvements in solar energy harvest, and battery storage efficiencies, Mobile Solar Lighting Towers (MSLTs) have technical and performance characteristics that are comparable, and in many instances superior, to MDLTs. In addition to these characteristics, Chevron Australia has successfully worked with its Australian supplier, conducting trials on site to introduce a range of additional design and performance improvements. These improvements include simple Human–Machine Interface (HMI) touch screen interface allowing remote automation through WiFi or 4G, real-time battery and performance monitoring, CCTV, geofencing and GPS tracking. The benefits of replacing just 25 owned MDLTs with solar includes the abatement of over 600 tonnes of CO2 and direct operational cost savings of almost A$50 000 per year (not including indirect cost savings or avoided carbon emissions costs). Further, net present value calculations demonstrate a financial benefit exceeding A$1 000 000 over 5 years when the solar towers are leased compared with maintaining existing or purchasing new diesel units. These MSLT units are delivering environmental benefits, direct and indirect financial savings, and reduced health, safety and environment risk, which have been welcomed by the on-site workforce.

Field Test Result of Residential SOFC CHP System Over 10 Years, 89000 Hours

The maximum operating time, without stack replacement, residential SOFC power generation unit (manufactured by Kyocera in 2009), which was installed by Osaka Gas in a house in 2009, has exceeded over 10 years, 89,000 power generating hours. It may be the first data as a SOFC system to succeed in operating in the actual field for 10 years. We will report performance results for 10 years. In 2004, Osaka Gas and Kyocera started joint development of residential SOFC CHP system and from 2007, we conducted series of field test in the SOFC demonstration project operated by NEDO and NEF. At that time, various technical issues still remained, and after joint development with Aisin and Toyota Motor, it was mass-produced and commercialized in 2012. We also mention current status of residential SOFC (Manufactured by Aisin, Stack supplied by Kyocera), which have sold more than total 80,000 units at Osaka Gas.

Field Test Result of Residential SOFC CHP System Over 10 Years, 89000 Hours

The maxmum operating time without stack replacement, residential SOFC power generation unit (manufactured by Kyocera in 2009), which was installed by Osaka Gas in a house in 2009, has exceeded over 10 years, 89000 power generating hours. In 2004, Osaka Gas and Kyocera started joint development of residential SOFC CHP system and from 2007, we conducted series of field tests in the SOFC demonstration project operated by NEDO and NEF. At that time, various technical issues remained, and after joint development with Aisin and Toyota Motor, it was mass-produced and commercialized in 2012. We also mention the current status of residential SOFC (Manufactured by Aisin, SOFC stack supplied by Kyocera). Osaka Gas has sold more than a total of 88,000 residential SOFC CHP systems as of October 2020.

Initiatives for Product Safety at Osaka Gas Marketing

Initiatives for Product Safety at Osaka Gas Marketing

Research on Gas Engines at Osaka Gas

Research on Gas Engines at Osaka Gas

Progress of SOFC Residential CHP System: Over 50,000 Units Market Experience of Osaka Gas

Osaka Gas began selling the second-generation residential SOFC CHP “ENE-FARM type S” in April 2016, which was developed in collaboration with Aisin Seiki, Kyocera and Noritz. In April 2018, power efficiency when the rated output can be stably is improved 53.5 % (net AC, LHV) from 52.0 % (net AC, LHV). The cumulative sales volume of Osaka Gas’s the residential fuel cell CHP system as in March 2019 was over 100,000. The cumulative number of SOFC-type was more than half. We have been trying to improve its quality and specifications, and reduce its cost. For example, we have improved the merchantability by adding a self-sustaining power generation function and using the Internet. ENE-FARM type S performed at approximately 2,000 customer homes though a power failure occurred mainly in Osaka due to Typhoon in 2018. It was an opportunity that one of the benefits in residential CHP was socially recognized.

Development and Commercialization of New Residential SOFC CHP System

Osaka Gas began selling the new version residential SOFC CHP system “ENE-FARM type S” in April 2016, which is developed in collaboration with Osaka Gas, Aisin Seiki, Kyocera and Noritz. Kyocera manufactures SOFC stacks, Aisin Seiki manufactures power generation units, and Noritz manufactures boiler and remote-control units. The electrical efficiency is 52% (net AC, LHV), whereas that of the previous model was 46.5%.The previous system comprised two units: a power generation unit and a heat recovery unit. The latter unit contained the hot-water storage tank and the boiler. The new power generation unit contains the hot-water storage tank. This tank is configured for connection to a normal household boiler. The system size is minimized to facilitate its use as a residential CHP system. Moreover, it is possible to install the new system in a housing complex, where the available space is limited. This feature expands the market for this system because the previous model could only be installed in a single-family house. To achieve the high electrical efficiency of 52% (net AC, LHV) and the cost reduction, three technical issues were addressed. The first was the improvement of the fuel cell performance, the second was the optimization of the fuel utilization rate, and the third was the improvement in durability. Kyocera reduced the internal electrical resistance of the fuel cell stack. In addition, a new coating technology, i.e., electropainting, which is developed by Osaka Gas and Kyocera, was used for current collectors. Consequently, both an increase in power density (reducing the number of cells) and an improvement in the electrical efficiency have been achieved. Current collectors are oxidized at a high temperature because they comprise stainless steel. Their durability has been considerably improved by the electropainting coating technology. Aisin Seiki optimized the system controls, resulting in enhanced electrical efficiency. Osaka Gas conducted field tests in the Kansai area in Japan. We installed the systems in the houses of several employees for evaluating the system behavior. The results made it possible to accelerate product development. In accordance with the liberalization of the power market in Japan in April 2016, if customers use natural gas provided by Osaka Gas, the electrical power from the unit can be sold back to Osaka Gas. We consider that 2016 is a transition period for residential CHP from the market introduction stage to the autonomous market spread stage. We are currently focusing on achieving further developments in the technology, which will enable cost reduction and higher power generation efficiency in order to maximize the target market.

Development and Commercialization of New Residential SOFC CHP System

In April 2016, Osaka Gas began the marketing of “ENE-FARM type S,” which was an advanced version of the residential SOFC CHP system. Osaka Gas developed this system in collaboration with Aisin Seiki, Kyocera, and Noritz. The electrical efficiency of the new model was 52 % (net AC, LHV), whereas that of the previous model was 46.5 %. The system size was minimized to facilitate its use as a residential CHP system. We reduced the maintenance, stack, and system costs. In this paper, we describe the developments and features of new residential SOFC CHP system.

New Steel Plate for Liquefied-Natural-Gas Storage Tank

This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper SPE 183286, “New Steel Plate for LNG Storage Tank,” by T. Kagaya, H. Furuya, T. Kamo, Y. Takahashi, H. Wakamatsu, and T. Nagao, Nippon Steel and Sumitomo Metal; H. Nishigami and S. Tomita, Osaka Gas; and S. Hirai and M. Mitsumoto, Toyo Kanetsu, prepared for the 2016 Abu Dhabi International Petroleum Exhibition and Conference, Abu Dhabi, 7–10 November. The paper has not been peer reviewed. For more than 50 years, 9% Ni steel with excellent mechanical properties at a cryogenic temperature of less than –162°C has been used as inner-tank material for liquefied-natural-gas (LNG) storage tanks. However, a reduction of the nickel content in steel can save construction costs of LNG storage tanks. A new steel plate for LNG storage tanks has been developed by optimizing chemical composition and applying recent thermomechanical-control-process (TMCP) technology. Introduction With demand for LNG rising, construction of above-ground LNG storage tanks is expected to increase. 9% Ni steel plate has excellent strength and cryogenic toughness. For LNG storage tanks, a double-integrity structure has been proposed to prevent peremptory destruction (Fig. 1). Although a high safety standard is demanded for such steel plates, in terms of saving construction costs of LNG tanks, a reduction in the amount of nickel used was desired. The new steel plate, equivalent to conventional 9% Ni steel, has been developed by adopting a TMCP to obtain the refined microstructure and a large amount of retained austenite. Development of New Steel Concept. In the development of the new steel, key technologies are application of the TMCP and optimization of chemical compositions. The properties of the base plate and welded joint of the new steel are equivalent to those of 9% Ni steel, with excellent brittle-crack-initiation resistance and brittle-crack-propagation-arresting capability. A TMCP is a production process wherein the rolling temperature and cooling rate after rolling are controlled. TMCP technology, which improves strength, toughness, and weldability, was developed for use in shipbuilding steel or line-pipe steel. TMCP technology has been applied to plates for offshore structures, high-rise buildings, bridges, and several other structural applications. Microstructures obtained with TCMP technology are finer than those obtained with conventional processes. The production process of the new steel is a combination of controlled rolling, accelerated cooling, and appropriate heat treatment (intermediate heat treatment, known as lamellarizing). A very fine martensitic microstructure is formed by controlling the previous austenite grain size in the heating process and rolling conditions in the uncrystallized zone and quenching in the accelerated cooling process after rolling. Retained austenite, which improves toughness, is also formed by lamellarizing and tempering after direct quenching. The amount of retained austenite of the new steel is greater than that of 9% Ni steel.

5-14.大阪ガス/英国ガスにおける石炭水添ガス化プロセスの開発(Session(5)実用化を迎える石炭利用技術)

5-14.大阪ガス/英国ガスにおける石炭水添ガス化プロセスの開発(Session(5)実用化を迎える石炭利用技術)

Activities for high-efficiency small gas engines

Interest in the potential of natural gas is growing, owing to its low CO2 emissions per unit of heat produced, and to the development of techniques for the exploitation of shale gas. Research and development relating to natural gas is also being pursued in view of its potential to increase Japan’s energy security, because deposits are found around the world.Osaka Gas is pursuing the medium-to-long term development of gas engines. Increasing compression ratio, improving combustion under lean combustion conditions, and increasing specific output will be key to improving thermal efficiency. This paper summarizes the results of tests Osaka Gas to date with a view to improving the efficiency of small gas engines.First, tests with downsizing through forced induction were conducted. A naturally aspirated gas engine with a displacement of 3318 cm3 was fitted with a high-efficiency turbocharger, and performance tests were conducted at brake mean effective pressure (BMEP). It was found that thermal efficiency under lean conditions reached 40%, but that NOx emissions exceeded 1500ppm. When exhaust gas recirculation (EGR) was applied with a view to reducing NOx emissions, at the EGR limit (EGR ratio 18%), thermal efficiency was around 39% (NOx 500ppm). With stoichiometric combustion, at the EGR limit, thermal efficiency reached a maximum of 39%.Next, the effectiveness of multi-point ignition, pre-chamber spark plugs and homogeneous charge compression ignition (HCCI) in improving lean/diluted combustion were studied, and each was found to improve stability, extend the lean limit and increase thermal efficiency under lean combustion conditions.Studies were also conducted in relation to the dedicated EGR system proposed by Southwest Research Institute (SwRI) as a means of improving EGR. It was determined that around 9% H2, which has a combustion-promoting effect, was produced under conditions where the equivalence ratio was 1.5.

(Invited) Development of the Battery-Driven SnO2 Thin Film Gas Sensor

We have developed a micro methane sensor obtained by laminating “nano-columnar structure SnO2 thin film" and catalyst layer on the circular diaphragm support layer with a built-in thin film heater. Ultra-low power consumption (0.06mW) required for 5 year battery operation was achieved by separating the functional elements of gas sensors, optimizing the materials and structures in charge of each function, microminiaturizing, and driving with low power ultra-short pulse. Furthermore, this sensor has realized higher sensitivity and higher selectivity than conventional methane sensors. In May 2015, Osaka Gas released the world's first battery-driven city gas alarm equipped with this sensor.

The engineer was hiding the entrepreneur: Shimomura Kotaro and the Belgian connections of the Osaka Gas Company

The engineer was hiding the entrepreneur: Shimomura Kotaro and the Belgian connections of the Osaka Gas Company

High Durability Electrodeposition Painting for SOFC Metal Interconnector

Osaka Gas Co., Ltd. has been developing electrodeposition painting method for SOFC metal interconnector coating since 2010. Although the general electrodeposition painting was mainly consisted of resin with small amount of ceramics as a pigment, we have successfully increased the amount of ceramics in the coating and this method was adopted to SOFC metal interconnector coating. Generally, SOFC interconnector had the complex structure with the gas flow path. This method had the advantage of coating thickness uniformity regardless of the interconnector structure and mass productivity. We have investigated to enhance the durability of the SOFC interconnector with this method.In addition, we aimed to reduce the cost of the metal interconnector by using the normal stainless steel, not stainless steel specially designed for the SOFC component. The composition of Co-Mn spinel-type oxide widely used in this field was selected as the coating ceramics. As is often the case with interconnector, the protective coating needed to be partially coated. The wet coating method like electrodeposition painting needed to be fired after coating to remove the resin and sinter the spinel-type oxide. From the standpoint of processing cost, it was desirable to be fired in air, but non coated area was severely oxidized and Cr2O3 layer showing high ASR was formed on the surface of the stainless steel. In order to prevent the oxidation of non-coated area and sinter the spinel powder enough, two steps of firing have been normally taken: the resin was removed in air first, then the Co-Mn spinel powder was sintered in the reduction atmosphere. This process cost tends to be high due to changing atmosphere. However, our electrodeposition painting method did not need to be fired in two steps because its resin was acrylate resin which was removed completely even in the reduction atmosphere. Cross section images of the post anneal coating showed the dense structure and the uniform layer thickness. ASR test over 10,000hr showed excellent durability at the both of the continuous condition and thermal cycle condition. The Cr diffusion from the stainless steel was also evaluated, it showed the high prevention of Cr diffusion. The variability of coating weight were quite small, it was concluded that this electrodeposition painting method is suitable for mass production.

Gorgon Project: environmental acoustic recognition sensor (EARS)

The Asian house gecko (Hemidactylus frenatus) presents a significant risk to the unique environment of Barrow Island, the location of the Chevron-operated Gorgon Project. The island’s climate would suit the establishment of this non-indigenous species, which could displace the five known native gecko species. Originating in Asia, this pest has spread to almost 9 new locations by hitchhiking on international vessels and cargo. To help detect possible gecko activity on the Gorgon Project, a unique device has been developed to specifically detect the sound of the gecko call. EARS can detect the sound of a gecko’s call from up to 2 m away. Connected to a wireless network, it sends an alert when a call is registered detailing time, location, and a sound file to aid detection. Placed on cargo and vessels travelling to Barrow, it is also deployed in Australian supply bases, international fabrication yards, and marine offloading facilities on the island. EARS provide Gorgon Quarantine with a constant presence and are particularly useful for detecting nocturnal species. It complements Gorgon’s existing quarantine surveillance programs and is one of many measures to ensure Barrow Island remains free from non-indigenous species. The Gorgon Project is operated by an Australian subsidiary of Chevron and is a joint venture of the Australian subsidiaries of Chevron (47.3%), ExxonMobil (25%), Shell (25%), Osaka Gas (1.25%), Tokyo Gas (1%) and Chubu Electric Power (0.417%).