4. WS Effective use of thermal energy in industry_AIST_Hirano
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Transcript of 4. WS Effective use of thermal energy in industry_AIST_Hirano
National Institute of
Advanced Industrial
Science and Technology
Satoshi HIRANO
Associate Manager,
Planning
Headquarters
Bilbao, 23rd June 2016
VI CDTI-NEDO JOINT WORKSHOP
Energy consumption and the situation of waste heat in Japanese industry
#WasteHeat The Effective use of termal energy in industry
01National Institute of Advanced Industrial Science
and Technology, AIST
Organization / Company
Researchstaff
18%
14%
12%14%
18%
14%
10%
Overall Staff 8,835
Researcher 2,258
Post Doc 1,908
Visiting
Researchers 4,669
#WasteHeat The Effective use of termal energy in industry
02Heat demand in Japan (Commercial & Residential)
0
0.5
1
1.5
2
2.5
1965 1975 1985 1995 2005
Fiscal year
En
erg
y c
onsu
mp
tio
n
[EJ]
Lighting, etc
Space heating
Hot water supply
Space cooling
Cooking
0
0.5
1
1.5
2
2.5
1965 1975 1985 1995 2005
Fiscal year
Energ
y c
onsum
ption [E
J]
Lighting,
Space heating
Hot water supply
Space cooling
Cooking
End-use energy consumption in the
commercial sector in Japan
End-use energy consumption in the
residential sector in Japan
(Data source: EDMC Handbook of Energy & Economic Statistics in Japan, The Energy Conservation Center, (2013))
About 50% of the commercial use is used for
space heating and hot water supply in Japan
About 60% of the residential use is used for
space heating and hot water supply in Japan
#WasteHeat The Effective use of termal energy in industry
03Heat demand in Japan (Industrial)
0
5
10
15
1997 1998 1999 2000 2001
Fiscal year
Energ
y c
onsu
mption [E
J]
Heater BoilerCogeneration Raw materialOther
Change of the final energy consumption in
Japan according to the industrial use
Approximately 55% of energy use for the industry
are used for direct-heating and boiler heating
Half or more of the quantity of energy use
are used for heating
Where does the heat after the use go?
#WasteHeat The Effective use of termal energy in industry
04
With manufacturing, heat is released
with various forms, but the situation
is different every work site and it is
hard to see perspective
Definition of unused heat of this survey
Examples of the unused heat defined in this survey
Factual survey is necessary to
find the invisible situation
from the government statistics
#WasteHeat The Effective use of termal energy in industry
05Method of investigation
Three investigations which are executed in the 'TherMAT' Project
Literature investigation
Finding the morphology, the temperature, the caloric value, the pressure, and so on of the
unused heat in the typical factory
Questionnaire (macro investigation)
Finding the actual state of the unused heat and heat utilization of factory of the variety of
types of industry
Field study (macro investigation)
Finding the detailed state of the heat utilization in the typical factory
#WasteHeat The Effective use of termal energy in industry
06Questionnaire (macro investigation)
Questions to about 1000 factories
Energy consumption in 2012 and the by-product energy amount that was sold
Unused heat of production equipment and the incinerator (except the generator set)
The unused heat from the premises generator installation and by-product energy
Opinion about the change trend of the industrial technique and manufacturing process to five
years ahead
#WasteHeat The Effective use of termal energy in industry
07Result of the questionnaire (Temperature vs exhaust heat)
Quantity of heat of the exhaust gas according to
the temperature zone per factory
0
10
20
30
Quantity
of heat
[TJ/y
·facto
ry]
Exhaust gas temperature [ºC]
FoodPulpChemicalPetroleumCeramicSteelNonferrousMachineTransport
250-299
500
~450-499
400-459
350-399
300-349
200-249
150-199
100-149
~
99
0
20
40
60
80
100
Waste
-heat
perc
enta
ge [
%]
Type of industry
500~
450~499
400~449
350~399
300~349
250~299
200~249
150~199
100~149
~99
Food Chem Ceramic Nonfer Trans
Pulp Petroleum Steel Machine
Temperature
[°C]
Caloric percentage of the exhaust gas according
to the temperature zone of each type of
industry
#WasteHeat The Effective use of termal energy in industry
08Result of the questionnaire (Equipment vs exhaust heat)
Quantity of heat of the exhaust gas according to
the equipment per factory
Caloric percentage of the exhaust gas according
to the equipment of each type of industry
0
10
20
30
40
Quantity
of heat
[TJ/y
·facto
ry]
Equipment
Food
Pulp
Chemical
Petroleum
Ceramic
Steel
Nonferrous
Machine
Transport
Chem Heating Steam Waste Inciner OtherKiln Combus Fusion Medium Deodor Refriger
0
20
40
60
80
100
Waste
-heat
perc
enta
ge [
%]
Type of industry
Others
Refrigeratingmachine
Incinerator
Deodorizationfurnace
Waste-heatboiler
Heatingmedium boil
Steam boiler
Fusion furnace
Heating oven
Combustionfurnace
Chemicalreactor
Kiln
Food Chem Ceramic Nonfer Trans
Pulp Petroleum Steel Machine
#WasteHeat The Effective use of termal energy in industry
09Result of the questionnaire (Total exhaust heat)
Estimated total heat of the exhaust gas in Japan according to the
temperature zone of each type of industry.
0
20
40
60
80
100
Type of industry
500~450~499400~449350~399300~349250~299200~249150~199100~149~99 ºC
Food Chem Ceram Nonfer Trans
Pulp Petro Steel Machine
Tota
l heat of exhaust gas [P
J/y
ear]
#WasteHeat The Effective use of termal energy in industry
10Result of the literature investigation [1] Chemical
The heat recovery from the used steam in the heating step (evaporator), and the use for preheating of the feed
water of the steam boiler
(Data source: A collection of the all
applications to Energy Conservation
Award 2012, The Energy
Conservation Center, (2013))
Phenols
Holm aldehyde genera
Acid catalyst
Condensation
reaction, 100ºCDehydration
150ºC
Condensation
106 to 110 ºC
Used steam
Phenol resinwaterCondensation
Waste water
90ºC
Steam
Evaporator
(Before the improvement, feed
water was preheated by steam) Drainage tank
Heat exchanger
Coolingtower
Heatexchanger
Heatexchanger
Low pressureboiler
Exhaust steam
Heatexchanger Medium pressure
boiler1.2 MW
Energy reduction in the chemical factory by installing the thermal devices for exhaust-
heat recovery and efficient use
#WasteHeat The Effective use of termal energy in industry
11Result of the literature investigation [1] Chemical
Steam production by the
heat recovery of the
exhaust gas from the
deodorizing furnace for the
dryer of the sludge
The heat recovery from the
used hot water at 90ºC and
the use for preheating of
the feed water of the
steam boiler
(Data source: A collection of the all applications
to Energy Conservation Award 2012, The Energy
Conservation Center, (2013))Before After
Exhaust gas Release into the atmosphere
(400ºC)
Release into the atmosphere
Steam
Exhaust-gas steam boiler
Exhaust gas
(400ºC)
Deodorizing furnace
Deodorizingfurnace
Deodorizingfurnace
(220ºC) HeaderSteam
75 kW
Waste water tank
Primary water-tank for processing
Before AfterPrimary water-tank for processing
Boiler
Feed water
(60ºC)
(20ºC) Heat ex-changer
Waste water tank Waste water tank Waste water tank
Wastewater
Wastewater
90ºCWaste waterWaste water
186 kW X2
Feed water 90ºC
#WasteHeat The Effective use of termal energy in industry
12Result of the literature investigation [2] (Glass lens)
1. Material processing process
1.1 Raw material blending
1.2 Elementary dissolution [600ºC]
[Room temperature]
1.3 Main dissolution [1300ºC]
[Room temperature]
1.4 Quality inspection
1.5 Molding press
1.6 Adjusting [600ºC]
2. Lens processing process
2.1 Rough grinding [Room temperature]
2.2 Elementary grinding
2.3 Polishing
2.4 Quality inspection
2.5 Lens centration
2.6 Coating [300 to 400ºC]
Molding machine in the lens production of the digital camera, heat loss reduction by the
improvement of the vapor deposition machine, thermoelectric generation by the waste
heat
#WasteHeat The Effective use of termal energy in industry
13Result of the literature investigation [2] (Glass lens)
Heat radiation from the front window of the lens molding machine --> Increase in air conditioning load -
-> Thermoelectric generation by the radiation heat (8W/unit)
--> Lighting of three LED lamps/unit (Seven sets were installed in total)
(Data source: Excellent
casebook of Energy
Conservation Award 2012,
The Energy Conservation
Center, (2013))
Energy loss
Molding
Radiation heat
Increase in air-con load
Lighting
with
LED
Lamps
Thermoelectric generation by waste-heatEnergy loss from molding machines
LEDCeiling lighting is off
Thermoelectric generator
LED lamp
Heat loss by the exhaust gas,
19%, 100<T<300ºC
Heat loss by the exhaust gas,
10%, 300ºC<THeat loss from the fixture
and the furnace wall,
64%
Work, 7%
Lens
molding
machine
#WasteHeat The Effective use of termal energy in industry
14Ideas for a Japan Spain collaboration
Data sharing
Sharing and stock of the example data of the heat flow of the factories
Sharing and stock of the installation example data of the energy-saving apparatus into factories
Analysis
Analysis of the factor of the introduction of the apparatus which uses exhaust heat into
factories
Analysis of the introduction barrier
Acceleration of the introduction and spread
Development of the innovative apparatus to utilize the unused-heat with each advanced field,
and acceleration of the introduction
THANK YOU
どうも有難う御座います
ESKERRIK ASKO
GRACIAS
Satoshi HIRANO
For further information