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Journal of Cleaner Production 11 (2003) 473479

www.cleanerproduction.net

Market opportunities for coal gasification in China


T. Attwood , V. Fung, W.W. Clark
Global Greenlife Institute, 7A/F International Industrial Building 501-503, Castle Peak Road, Kln, Hong Kong, PR China

Abstract

Coal gasification is a technology that has been around for 200 yr. With the recent technology advances in the past 20 yr, it has
become an option for the clean production of power and other energy forms. China will continue to be the largest user of coal in
the world. Coal is the source of energy in almost every area of everyday life in China. This paper is an overview of the prospects
of coal gasification in China. It discusses the opening of Chinese markets to more private sector participation. In particular the
paper focuses on the energy sector and coal as the both an economic development variable and a factor in climate change. Clean
coal technologies can be apart of the production cycle in China and hence can impact the Chinese economy in a positive manner
as well as lower the current high levels of atmospheric pollution. Proven integrated gasification combined cycle (IGCC) technologies
in new production methods and applications can provide China with its rising energy needs and reduce the SOX, NOX and particu-
lates in the atmosphere. The results of IGCC can support the Chinese economy as it moves into the future.
2002 Published by Elsevier Science Ltd.

Keywords: Coal; Gasification; Clean production; Markets; Economy; Business

1. General background capitalism. Investment markets are to become more


open to private participation, however, either with
China is the worlds largest producer and user of coal. government regulation or direct government investment
Due to the greater than 10% economic growth during and partnership [12].
the 1980s and 1990s the Chinese demand for coal grew All of these changes will be dramatic and the impact
to exceed 1.2 billion tons per year. With the economic is just uncertain. In addition to the uncertainties of the
slow down in Asia since the late 1990s, the economic economic future there is also the importance of political
growth in China has been reduced to 57% per year from stability. All three of Chinas top leaders will be turning
its 8% over the prior 5 yr. In the energy sector and coal over power in the next 2 yr to the next generation who
in particular, this slow down in GDP has resulted in a are often educated in the west. If younger leaders, with
200 million ton per year decrease in coal use since 1999. a more western view to economics, come to power, the
With the advent of membership to the World Trade long-term outlook maybe good for bringing some con-
Organization in 2002, few can really predict the cepts of capitalism into synergy with socialism. But there
unknown and what is going to happen economically in may be an unsettling near-term impact of increased
China. unemployment that could lead to political instability and
There are predictions of continued growth and of economic slow down.
economic slow down as a result of many Chinese busi-
ness, that are not competitive ending operations and sub-
sidies ending for many industries [2]. China has 2. Coal resources and use
embarked on restructuring the financial and banking
industry under its 5 yr plan [8] and the concept of social Coal supplies 75% of Chinas energy demand and
95% of Chinas thermal electric power generation. The
State Power Corporation (SPC) of China has predicted

Corresponding author. Tel.: +852-2310-1951; fax: +852-2310- coal will continue to provide over 60% of the electrical
1955. power needs of China well past 2050. A reduction in
E-mail address: glissad@aol.com (T. Attwood). coal as a percentage of power production is predicted to

0959-6526/02/$ - see front matter 2002 Published by Elsevier Science Ltd.


doi:10.1016/S0959-6526(02)00068-9
474 T. Attwood et al. / Journal of Cleaner Production 11 (2003) 473479

come from the increased use of nuclear power. However cycle (IGCC), this technology requires high tempera-
in absolute terms coal use is projected to double over the tures. Coal, steam and oxygen (or air) are reacted
next 20 yr in terms of the fuel for power generation [9]. together to produce a gas containing Hydrogen, carbon
China has the worlds third largest coal resources. monoxide, carbon dioxide, methane and other com-
According to the China Coal Industry Yearbook 1996 pounds. This gas is cleaned to remove particulates and
[3], estimates for coal resources are 5500 billion tons, sulfur compounds. As by-products sulfur or sulfuric acid
although much of these resources are probably not can be produced. Gasification technologies can use all
recoverable. China has about 11% of the worlds recov- types of coals. It can be linked with combined cycles
erable reserves with 115 billion tons, with 55% classified (integrated combined cycle) to produce power efficiently
as bituminous (including anthracite), 29% as sub-bitum- or it can be used as a source of synthesis gas for chemi-
inous and 16% lignite [4]. Over 80% of Chinas coal cals or fuel gas for homes and industry. The technology
reserves are concentrated in the north and northwest in can produce power at efficiencies of up to 46% and can
the country. remove 99.9% of the sulfur emissions, 90% of the nitro-
The average sulfur content of the coal is 1.1% and gen emissions and 99.99% of particulate emissions. It
ash content of 17%. What this shows is that China has is the cleanest technology for producing useful energy
diverse coal resources just as does the US. In the US from coal.
the ratio of anthracite and bituminous to sub-bituminous
and lignite is 0.85 and in China this ratio is 1.2. Gener-
ally the coals in the US have a higher sulfur content and 4. Impacts on coal use in China
lower ash content than those of China. These factors will
not really influence the selection of gasification tech- In addition to the uncertain economic growth in China
nology. The diversity of gasification technologies selec- and much of the world at this time, there are other factors
ted by the US Departmant of Energy [10], for example, that will be impacting coal use and the potential for gasi-
for demonstration and ultimate application in the US fication technology. The more important impacts maybe,
markets will also be the technologies most applicable to competitiveness, transportation and environmental per-
the future Chinese market. formance.
Coal use in China can be delineated as:
4.1. Competitiveness
Coal use for power generation: 39%.
Coal use for coking: 15%. Competitiveness is important to the application of coal
Coal use for residential: 10%. gasification. As was shown in the discussion before, coal
Rail transportation: 1%. has an important role in all energy aspects of Chinese
Chemical, cement, ceramics etc.: 35%. life. The recent paper by Xianqiang [11], which was
presented at the joint US China meeting in Beijing Sep-
However, the use of coal in China is very different tember 2001, presents an excellent argument for the use
than that in the US. Over 85% of the coal used in the US of natural gas to replace coal. The paper shows as an
is for the generation of power. This significant difference example, the cost of coal to be approximately Rmb
alone is a very important aspect that can make gasifi- 0.04/1000 kcal and natural gas ranging in price from
cation a more attractive and near term technology option Rmb 0.170.212/1000 kcal. Though this places gas at
in China than in the US. In China coal is the most 45 times the cost of coal, the paper goes on to make
important energy resource and it is a resource for all the case of the long-term economic and environmental
sectors of society except transportation. The transpor- benefits out weigh the cost of the fuel.
tation sector will be increasing (how rapidly, will depend Energy efficiency can be greatly improved when using
on the business and technology issues identified at the gas instead of coal. For example the energy use can be
beginning of this paper) as the economy grows. An reduced by 50% for both the chemical industry and the
important result for Chinas shift from the use of coal residential use. This will offset the increased cost of gas
for energy production has been that the country is and contribute to a tremendous reduction in pollutants.
experiencing changes in its oil demand-going from an For example the paper summarizes a study done in
exporter of oil to an oil importer over the past 10 yr. Chongqing to replace residential and small boilers coal
The economic (as well as political) consequences of this use with gas [1]. The result was that Chongqing would
shift have been significant. become in compliance for air emissions under World
Health Organization standards [5].
3. Technology description of coal gasification What Atwood and Fung [1] and other studies do is,
confirm the current policies of China that set as a priority
Coal gasification is a technology, which converts coal the direct use of natural gas to residential markets,
into gas. Known as integrated gasification combined chemical industry raw material and finally as a thermal
T. Attwood et al. / Journal of Cleaner Production 11 (2003) 473479 475

plant fuel. Many papers presented at an International that are very poorly operated and extremely inefficient.
meeting held in Beijing in September 2001, for example, With the drop in coal demand these closures may not
made the point that there is more gas in China than orig- have as negative impact as would have been the case in
inally thought just a few years ago. In fact, the State the economy growing at its prior rate. But this has the
Development and Planning Commission (SDPC) pre- near term impact of throwing a million people out of
dicts more gas supplies than are needed to meet the work or reducing the incomes of the farmers that mine
demands of the Chinese chemical industry and there will part time.
be enough available for the increasing residential mar-
ket [9]. 4.5. Coal pricing practices
This will be a very important factor towards the devel-
opment of coal gasification projects in China. The driv- Coal pricing practices have lead to the bankruptcy of
ing force for coal gasification will be the need for gas the coal industry. Since 1992 the coal industry has run
more so than the need for power. There are many at a deficit. The pricing of coal has not reflected the
options, beside gasification, to produce power more actual cost of production.
efficiently and cleanly than are in current practice in
China. However if the natural gas is not available there 4.6. Environmental policies
is the need for gasification to supply gas. As China
develops more of its gas resources and builds more pipe- Environmental policies of the Chinese government
lines the need for coal gasification diminishes. would encourage the use of gasification technologies but
these policies would also encourage the use of the other
4.2. Geographic miss-match competing technologies. In fact in some regards the poli-
cies may inadvertently encourage the use of technologies
Geographic miss-match of coal users with coal sup- other than gasification. China has banded the use of coal
pliers has lead to a policy of larger coal power plants at with higher than 3% sulfur content and requires sulfur
the mine site and transferring power by wire. The Chi- control systems on new projects using coal with a sulfur
nese coal industry is located in the central-north, eastern- content greater than 1%.
north and west, which are great distances from the users China has been working over the past decade to
in the east and south of China. The answer seems reduce particulate emissions. This has lead to control
straightforward to locate power plants at the mining systems being placed on 60% of the power plants and a
sites. However therein lies a new problem of the water target of 80% of the plants. While this policy encourages
needs. Water is in sort supply in these regions. Generally the use of pollution control systems, the goal can be ach-
an IGCC plant may use as much as 30% less water than ieved through means other than IGCC. In fact the pre-
a conventional power plant design. This would be an vention of the use of higher sulfur coals negatively
advantage for IGCC. impacts the use of IGCC. Nevertheless IGCC has the
most superior performance and if there is no economic
4.3. Transportation bottlenecks
reward for exceeding the Chinese limits of environment
Transportation bottlenecks have caused many prob- performance it is difficult to achieve economic benefits
lems with getting the coal to the users. Coal accounts of gasification.
for the largest percentage of freight of any commodity
in China. The transportation system has not been able
to handle the coal shipping requirements. This has lead 5. Electrical power generation needs
to stockpiles at the mines. In the past it has not been a
coal production, but a coal transportation problem that Prior to the slow down in economic growth China was
has lead to some power plants to look to the international adding power generation at the rate of 17 GW per year.
markets for coal supply. With the economic slowdown In 1998 the Chinese government placed a halt on new
and the possibility of a sluggish worldwide economy this thermal generation facilities [10]. Since there were over
may provide the window to improve the rail system. The 70 GW of projects in development and construction
problem may then be where to obtain the capital to do when the moratorium was put in place new power plants
the expansion. There are some estimates of $100 billion have continued to come online. At the same time China
per year of investment required to improve the rail trans- has been retiring the older smaller inefficient local power
portation system. facilities. The moratorium is to remain in place through
January 2002. With the growing world economic slow-
4.4. Restructuring down China may be extending this date. At the present
the USEIA projects an average 5% growth in power gen-
Restructuring of the coal industry has the impact of eration each year through 2020.
the government plans to shut down 25,000 small mines The plans of the SPC include demonstration projects
476 T. Attwood et al. / Journal of Cleaner Production 11 (2003) 473479

for both IGCC and PFB. The SPC has already developed Another problem is that the fertilizer industry needs to
large CFB and super critical projects. The SPC has been restructure its product mix [7]. Over 90% of the fertilizer
working on the development of a 200400 MW IGCC produced is monofertilizer. In the US and Europe, over
demonstration project. At the current rate of develop- 80% of the fertilizer used, is compound fertilizer. China
ment of this project and based on the learning experience has set a priority to convert its fertilizer production. This
of the similar projects in the US, China would not be in conversion will require an investment $30 million for
the position to commercially deploy IGCC technology the mid-scale facility. Based on studies conducted by
till after 2010. This is only if the economic drivers for Shanghai Coke and Chemical, the replacement of the
the technology are in place. existing Chinese gasification technology with Texaco or
Ugas gasification technology, the investment would be
approximately $30 million for a mid-scale facility.
6. Mixed use applications Hence China has competing demands for funds of
investing to improve efficiency or investing to make a
One of the main advantages of gasification over com- better product. These investments would be in a site with
bustion is the ability to make a slate of products. Gasifi- a limited future of less than 1020 yr. As was already
cation can produce fuel gas with a wide range of heating discussed before in this report, the SPC is reporting that
values and this gas can be put to use in the residential China has more natural gas than will be needed for
and industrial markets. The major problem with the resi- chemical production. Enron has been developing a large
dential market is the tremendous investment required for mixed-use gasification project in Nanjing. What has lead
the pipeline transportation and distribution system. to this is the project would be dedicated to a large new
Industrial gas applications would not have as demanding chemical complex with joint foreign and Chinese owner-
investment requirements if the industry is located in an ship. This would overcome the issues of non-payment
area near the gas plant. The other industrial application that other foreign projects are experiencing in the
is the production of synthesis gas to produce chemicals. power sector.
The agricultural and farming sectors are particular sig- The other aspect is that the gas lines are not in place
nificant areas for the use of synthesis gas as well as ferti- now and if they ever do come into existence the plant
lizer derived from coal [8]. can be converted from coal to gas. The other important
The issues related to these applications are as follows. aspects of this project are that it is a new facility and it
Chemical synthesis gas production has been the pri- is very large in scale. These factors make this project
mary application of gasification in China. Luxian [6] more attractive as an opportunity for gasification than
notes that there are over 1400 fertilizer plants in China. the conversion or retrofitting existing facilities.
Over 60% of these plants are small scale (40,000 tons Fuel gas industrial applications apply to the industries
per year of fertilizer) 30% are mid scale (40,000 that are using gasifiers in China, which include steel,
100,000 tons per year) and 10% are large scale paper, ceramic, and cement. Though these industries
(100,000). To put this in perspective in the US there have old and inefficient technology they do not have the
are 50 fertilizer plants and a mid-scale is about one money to invest in new technology. With the major
million tons per year. Over 65% of the fertilizer plants changes taking place and the removal of subsidies under
in China use coal. The technology is old and very inef- the WTO, there will be many industries that will shut
ficient. China uses about twice the energy as the west to down or be restructured. Until this business shake out
produce a ton of ammonia. period has taken place it will be very difficult to predict
Texaco has successfully licensed 11 projects to use its the winners and users. Until there is a better understand-
gasifier to produce synthesis gas. Shell has been ing of this, there will be a withholding of both the
developing a project in China using its gasification tech- government and foreign investment in capital improve-
nology for synthesis gas. These are very limited projects ments. This will require significant time and consider-
in the total scheme of things. What has been more active able investment in relationship building, in operation of
has been the construction of world class million tons per offices in China and most importantly (and the most dif-
year, fertilizer projects such as in Hynan Island using ficult of all) obtain the accurate data and information.
natural gas. This will be the ultimate objective and plan The financial condition of the companies will be
of China to replace the small, old and inefficient fertil- extremely difficult to determine as well as the real mar-
izer plants with larger natural gas based and efficient ket and the transportation plans that will impact the
plants. This will probable take a 20-yr period.There industry.
maybe limited potential in regions that lack the transpor- Residential gas applications are a priority of Chinese
tation, for improvement of the existing fertilizer plants government. This is seen by the many gas pipelines
using new gasification technology. These will be limited opening up and the others under development to bring
and will require much in the way of groundwork by the both Chinese and Russian gas to the eastern cities of
foreign technology owner to identify those opportunities. China to reduce pollution. The Chinese government is
T. Attwood et al. / Journal of Cleaner Production 11 (2003) 473479 477

projecting that there are sufficient resources to bring gas 5. HTW fluid bed gasifier.
to the urban areas. There may be the need for conversion
of coal to medium Btu gas for cities in the coal produc- Both Texaco and Shell have pursed the development
ing regions. However large cities in Shanxi Province of synthesis gas projects in China. Texaco has signed 11
(largest coal producing region in China) have shut down license agreements of which six were actually built. Both
operation of the coal to gas plants and switched to natu- companies have been working closely with the SPC on
ral gas. It appears the long-term plan is to bring in natu- the development of the IGCC demonstration project.
ral gas rather than build large coal to gas plants. Again
there maybe some opportunities in areas where natural
gas may not be practical and coal could be an option. 8. Economics of gasification in China
This would require a very in-depth analysis and
obtaining information that has to date been difficult. First it may be best to address the economics of coal
gasification from what we know, the US demonstration
projects. These projects have a capital cost of $1600
7. Technical readiness $1700/kw. The technology vendors project costs of
future projects to be around $1200/kw. In comparison
As was discussed the coal resources in China are as GE indicates the cost of coal fired power plants (500
diverse as in the US with large resources of all types of MW) with the necessary pollution control systems to be
coals. There are generally no properties that are unique in the range of $800$900/kw and natural gas to be
to Chinese coals and would cause problem with the oper- about $600/kw with close to being 60% efficient. The
ation of coal gasification technologies. As was discussed, costs reported by the Chinese are $600$700 for coal
on average, the Chinese coals have less sulfur than the fired power plants with particulate controls but no other
US coals and a little higher ash content. What are most controls. Texaco conducted a feasibility study for a 400
important are the specific properties of the coals to be MW IGCC project and developed a cost of $1000/kw
used for the planned application. Chinese coals have however, not including the cost of financing during con-
been tested in Texaco, Shell, Ugas and Lurgi test facili- struction.
ties. The same variety of gasifiers that would apply to The SPC [9] did not believe this estimate to be
the US market will also apply to the Chinese market. realistic and though it should be closer to $1200/kw.
The US government has invested public funds to dem- Based on capital cost there would need to be a 2025%
onstrate Lurgi, Texaco, Destec (now called E-gas), KRW reduction in capital cost to be competitive with coal
and BGL technology. This represents fixed bed, fluid bed technology with control systems for nitrogen oxides, sul-
and entrained flow technologies. In addition to these fur dioxide and particulates. The coal combustion tech-
technologies there is the HTW fluid bed gasification nologies that are available today can achieve efficiencies
technology offered by a German supplier, which has in the low 40s which is comparable with the IGCC used
been in commercial operation for over 10 yr. Other tech- in these cost estimates. If the more efficient IGCC tech-
nologies are the Krupp Koppers technologies (which are nology were to be used this would add about $150/kw
no longer offered for sale) and the Lurgi fluid bed and according to the Texaco study for China. Since the
entrained flow gasifiers that have not achieved the simi- efficiencies for these cost comparisons are about the
lar levels of commercial performance. same there really would be little in the way of operating
The Lurgi fluid bed has been used in smaller scale cost benefit for IGCC.
commercial projects using wood as a feedstock. The Since the environmental performance requirements of
Gasification Association has conducted world wide sur- China can be obtained with scrubbers and there is no
veys showing the only technologies that are planing to economic benefit for better performance, the superior
be built, exclusive of demonstration projects are the performance of IGCC is not rewarded economically.
Shell and Texaco technologies. There has been little This is why all the power generation (e.g. IGCC) using
activity with the Destec technology that was purchased coals in the world exist with government subsidies. The
a few years ago by global energy. The technologies with way to overcome these economics is to use gasification
the capability to perform in a commercial environment where other technologies are not suited, as in the pro-
and having owners that provide the necessary support duction of synthesis gas from low value feedstocks such
services and possible investment include: as refinery reside and pet coke.
These are very site specific situations that are sought
1. Lurgi fixed bed (no new projects are planned in the out through the world from the vast network that Texaco
world); and Shell both have in the petroleum industry. This is
2. Texaco entrained flow gasifier; born out when reviewing the Gasification Database and
3. Shell entrained gasifier; World Market Report (2000) [9] developed by the US
4. E-gas now offered by global energy; DOE with SFA Pacific as consultants. When reviewing
478 T. Attwood et al. / Journal of Cleaner Production 11 (2003) 473479

all the recent gasification projects it is found that the gasification and to pursue such opportunities. Other
ones operating with coal and producing power are those international companies are following the lead with tar-
subsidized by the US government or the EU. Those are geted markets.
also the plans of China under its version of social capi-
talism for its demonstration IGCC project.
The economics for the production of synthesis gas are Appendix A
different in that if the natural gas is not available, gasifi-
cation is really the only option for the production of syn- Current potential applications of clean coal industry
thesis gas from materials containing carbon. Conducting production in China
an economic comparison of the production of synthesis
gas from either coal or refinery waste with the cost of March 9, 2000, Nongmin Ribao (Farmers Daily)
steam reforming natural gas is a very site-specific evalu- details four main disadvantages Chinas chemical fertil-
ation. Generally the drivers for the gasification projects izer industry faces compared with that of developed
in the world to convert the refinery waste to gas have countries:
been the need to dispose of the waste and the ability to
use lower cost crude. 1. high-concentration chemical fertilizers account for a
very low proportion;
2. the compound rate of chemical fertilizers is too low;
9. Business issues 3. the application intensity of chemical fertilizers is
much too low;
As has been described, the SPC is developing a dem- 4. chemical fertilizer producers are too dispersed and
onstration project for IGCC and would not move ahead small in scale.
with building IGCC projects until the demonstration pro-
ject is operated and evaluated. A private foreign devel- July 17, 1999, Zhongguo Huagong Bao (China
oper could certainly move ahead with IGCC as a tech- Chemical News)Solutions For Chinas Agricultural
nology option for a power facility in China. The problem Chemicalsby Mr W. Luxian, Chairman of the China
now of course is the hold on power plants, but even of Agricultural Chemicals Industry Association
greater concern is the fact that local regions in China
have not been honoring the electricity tariffs agreed upon 1. China must bring the industry into balance and pro-
for the existing independent power plants. Until the duce more herbicides and fungicides while decreasing
WTO impacts are better understood and world economic pesticides, especially the toxic kind.
outlook has improved it would be very risky to pursue 2. China agricultural chemicals industry is 2030 yr
independent power projects in China. behind the more advanced countries in technology.
Thus, more research and a more forward looking
approach is necessary. Profitability in the industry
10. Summary through better management techniques could lead to
improve chances for research funding.
China is a coal dependent economy and will remain 3. Not only do most fertilizer facilities need to change
so for a long time. It has coals similar in quality and the products they produce, their qualities must also
cost to the US. Unlike the US, coal is also the source be enlarged to fit the economy of scale.
of energy for all the sectors other than transportation. 4. There is the problem that China is importing many
This opens more economic opportunities for coal gasifi- important agricultural chemicals. This is not only
cation than in the US. However like the US, the option costly in terms of foreign exchange but damaging in
for these other opportunities is gas and with increasing that it inhibits the growth of Chinas own technologi-
finds of natural gas resources and improved efficiencies cal research. The Government should seek to establish
these non-power sector applications may be diminishing Chinas own source of raw materials and bases for
over time. mid-level manufacturing.
China is a big country like the US and due to geogra-
phy and other issues there may be the need to continue December 20, 1999 The Price Department of the State
to use coal in some locations for applications other than Development Planning Commission published a notice
for power and steam. These opportunities can only be on current prices that analyzed the state of Chinas
identified through detailed study and groundwork. Both nitrogenous-fertilizer industry.
Texaco, since early 2002, part of Chevron and also Shell The notice said effective measures to end vicious and
are involved in doing just that in China. Both companies low price competition are required for domestic
see the future economic benefits and have the network nitrogenous-fertilizer manufacturers to overcome their
as well as the resources to identify the opportunities for difficult price conditions and to strengthen themselves.
T. Attwood et al. / Journal of Cleaner Production 11 (2003) 473479 479

One of the findings that aligns with Atwood and Fung, [7] Ribao Nongmin. Farmers Daily, Nongrim; March 9, 2000.
2001 paper [1] on fertilizer. [8] Fertilizer in the agriculture sector. Peoples Republic of China,
Ministry of Agriculture Report; 1999.
[9] State Development Planning Commission (SDPC). The price
The supply of nitrogenous fertilizers was on the high department; December 20, 1999.
side, while demand is low. Therefore, the output of [10] US Department of Energy. Energy Information Agency (USEIA).
chemical fertilizers should be controlled so as to Data, web site; 1998.
maintain the balance between supply and demand. [11] Xianqiang M, Xiurui G. Improving quality in large Chinese sub-
stituting natural gas for coal. Beijing, China: International Con-
ference on Coal; 1999.
[12] Xing L, Clark WW. Social capitalism. Int J Technol Trans Com-
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[2] Chang G. The coming collapse of China. Random House: New
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[4] Chinese coal prospects to 2010, Internal Energy Agency (IEA). Asia, especially China.
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[5] Chongqing Chemical Bureau, 1997. W.W. Clark received his PhD in Anthropology at University of Califor-
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guo Huagong Bao, China Chemical News; July 17, 1999. policy issues.

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