September, 2008 - ジェトロ（日本貿易振興機構） | … 2008 JAPAN EXTERNAL TRADE ORGANIZATION (JETRO) JAPAN CONSULTING INSTITUTE (JCI) 1 I. Necessary of Energy Conservation

September, 2008

JAPAN EXTERNAL TRADE ORGANIZATION (JETRO) JAPAN CONSULTING INSTITUTE (JCI)

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I. Necessary of Energy Conservation

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1. Importance of Energy Conservation / Mitigation of Global Warming

(1) Reduction of Product Cost The cost of products which consume more energy for production will be higher. In order to lower the manufacturing cost, it will be essential to reduce the energy consumed for the production.

The energy consumption must be reduced to the minimum from the view point of lowering production cost and CO2 emission.

Lower Energy Consumption Reduction of Product Cost

(2) Preservation of Energy Resources

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Ⅱ. Typical Technologies for Energy Utilization

Ⅱ-1 Steps to promote the Energy Saving

Ⅱ-2 Heat Pump System

Ⅱ-3 Gas Cogeneration System

Ⅱ-4 Thermal Storage System

Ⅱ-5 Biomass Energy

Ⅱ-6 Electric energy Saving System

Ⅱ-7 Reuse of Solid Waste from Food Industry

Ⅱ-8 Heat Recovery System

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Ⅱ-1 Steps to promote the Energy Saving Product

No. Product/technology Function Features Manufactures

Ⅱ-1-PE-1 Operation Improvement without investment Energy saving Step A No cost/Low cost - (Energy Management by

the Owner)

Ⅱ-1-PE-2 Equipment Improvement with small investment Energy saving Step B Introduction of Heat/Gas Recovery

Equipment - (Energy Management by

the Owner)

Ⅱ-1-PE-3 Dramatic Improvement with large investment Energy saving Step C Introduction of New Process of production - (Energy Management by

the Owner)

Ⅱ-2 Heat Pump System Product


Ⅱ-2-ME-1 Absorption type Heat Pump / Refrigerator

Absorption type Smaller electric power consumption

HITACHI

Ⅱ-2-ME-2 Vapor Compression Heat Pump (1) Steam supply from outer source

(2) Lower waste energy is utilized (3) Vapor compression technology

Ⅱ-2-ME-3 Compression Type Heat Pump-Ecocute Mechanical Type Economical hot water production with cheaper electricity at night

Ⅱ-2-ME-4 Case Study for Application of Heat Pump

Drinking Alcohol Production Factory 60% Energy saving as equivalent of Diesel Fuel

Ⅱ-3. Gas Cogeneration System

Product No. Product/technology Function Features Manufactures

Ⅱ-3-PE-1 Typical Gas Cogeneration System

Ⅱ-3-PE-2 Gas Engine Systems Gas Engine High efficiency of electricity generation, Low temperature waste gas

MHI, IHI

Ⅱ-3-PE-3 Gas Turbine System Gas Turbine Medium level of efficiency of generation,

High temperature of flue gas leads steam heat recovery

MHI, IHI, Toshiba,

Ⅱ-3-PE-4 Case Study for Co-generation Application

Application of Gas engine co-generation to Hotel

14% Energy Saving by reducing power purchase Low temperatuer

Niigata Engine Co.,Ltd Mitsui Engineering & Shipyard Co.,ltd

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Ⅱ-4. Thermal Storage System Product


Ⅱ-4-PE-1 Ice Storage System Effective Utilization of marginal electricity

Ⅱ-4-PE-2 Case Study for the Ice Storage System Air conditioning for the building

Reduction of Peak demand of electricity 60%

Ⅱ-5. Biomass Energy


Ⅱ-5-PE-1 Utilization of Bio Diesel Fuel (BDF) from Jatropha Oil

BDF (Bio Diesel Fuel)

Saving diesel oil : 5~30%

Ⅱ-6. Electric energy Saving System


Ⅱ-6-ME-1 Amorphous Metal Transformer Low electrical resistance loss

Reduction of no load loss HITACHI

Ⅱ-6-ME-2

General Purpose Inverter motors applied for various equipment

• Fan, Pump, • Conveyer, Truck • Crane, Elevator

HITACHI Toshiba Mitsubishi Fuji Electric Systems

Ⅱ-7. Reuse of Solid Waste from Food Industry


Ⅱ-7-PE-1 Case study for Waste cashew nut shell Gasification System

Saving electricity 26,000 MWh/y

Ⅱ-7-PE-2 Reuse of Roasted &Grinded Coffee Bean Waste - Manufacturing of Activated Carbon

Carbonization Heating energy saving by consolidation of the 3 processes into the large kiln and by recovery of the waste gas from the kiln

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Ⅱ-8. Heat Recovery System Product


Ⅱ-8-ME-1 Typical Heat Recovery Boiler System for Heat Source

Energy saving Steam is applied to use for the power generation, the process steam and/or the direct heating and cooling plant.

Takahashikikan Co.,ltd.

Ⅱ-8-ME-2 Typical Heat Recovery Boiler System from Meltdown Incinerator


Hirakawa Guidom Corporation.

Ⅱ-8-ME-3 Typical Heat Recovery Boiler System from Rotary Kiln


Hirakawa Guidom Corporation.

Ⅱ-8-ME-4 Typical Heat Recovery Boiler System from Non-Ferrous metal Roasting


Takuma Co., ltd

Ⅲ Advanced Technologies for Energy and Environment Conservation in Japan

Ⅲ-1. Power Generation

Ⅲ-2. Renewable Energy

Ⅲ-3. Steel manufacturing

Ⅲ-4. Nonferrous metal manufacturing

Ⅲ-5. Cement manufacturing

Ⅲ-6. Chemical (Ammonia) production

Ⅲ-7. Chemical (Caustic Soda) production

Ⅲ-8. Chemical (Naphtha Decomposition) production

Ⅲ-9. Refinery & Petrochemical Technologies

Ⅲ-10. Geothermal Technologies

Ⅲ-11. Environmental Technologies

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Ⅲ-1．Power Generation Product

No. Product/technology Function Features of the Technology Manufactures

Ⅲ- 1 - PE Production Equipments

Ⅲ- 1 - PE-1

High temperature ultra-supercritical steam turbine

Steam turbine High temperature supercritical variable pressure operation, High efficiency Flexible operation

Mitsubishi Heavy Industries, Ltd.

Ⅲ- 1 - PE-2

Large capacity high temperature ultra supercritical /supercritical pressure coal-fired power plant

Coal-fired power generation

High temperature supercritical variable pressure operation, High efficiency (η～approx.45%) Flexible operation Environmentally friendly

Mitsubishi Heavy Industries, Ltd. Hitachi, Ltd IHI Corporation

Ⅲ- 1 - PE-3 Large capacity advanced Gas turbine Combined Cycle

Gas-fired power plant

High efficiency (η52 %, ηLHV ～approx.58 %)

Max. single shaft output ～approx.500MW


Ⅲ- 1 - PE-4 Barge-mounted combined cycle plant Gas/oil- fired power plant

Barge mounted GTCC IHI Corporation

Ⅲ- 1 - PE-5

Medium capacity gas turbine power plant

Ditto Aero-derivative gas turbine plant High efficiency with simple cycle, applicable to combined cycle Compact, Simple installation

IHI Corporation

Ⅲ- 1 - PE-6 Small capacity Gas turbine & generator package

Ditto Medium capacity gas turbine plant Suitable for both combined cycle and simple cycle High fuel flexibility

Hitachi, Ltd.

Ⅲ- 1 - PE-7 Pressurized fluidized bed boiler combined cycle Plant


Suitable for wide range coal firing High efficiency (η～approx.43%) Environmentally friendly (inbed DeNOx, DeSOx)

IHI Corporation

Ⅲ- 1 - PE-8 Diesel power generation plant Oil-fired power

plant Diesel engine plant Suitable for cogeneration High efficiency (η～approx.45 %)

Mitsui Engineering & Shipbuilding Co., Ltd.

Ⅲ- 1 - PE-9 Advanced gas engine Gas-fired power

plant Gas engine plant High efficiency (η～approx.42 %)

IHI Corporation

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Ⅲ- 1 - PE-10

Cogeneration (Power and heat generation)

Gas, oil, coal-firedpower & heat generation

Gas engine, diesel, gas turbine, steam turbine, fuel cell High energy efficiency (ηE～approx.85 %)

Ⅲ- 1 - ME Machinery Equipment

Ⅲ- 1 - ME-1 Roll mill type coal pulvelizer Coal-fired boiler auxiliary

Pulvelizer with stationary/rotary separator Mitsubishi Heavy Industries, Ltd

Ⅲ- 1 - ME-2 Low Nox burner for coal firing Ditto Low NOx high efficiency coal burner Mitsubishi Heavy Industries, Ltd

Ⅲ- 1 - ME-3 Variable pitch control axial flow fan Ditto Axial flow fan for FDF, IDF, PAF Mitsubishi Heavy Industries, Ltd

Ⅲ- 1 - ME-4

Dry Selective Catalytic NOx Removal System

Ditto Selective catalytic DeNOx equipment Mitsubishi Heavy Industries, Ltd IHI Corporation Hitachi, Ltd.

Ⅲ- 1 - ME-5 Super amorphous Transmission Distribution

Amorphous metal transformer Higher efficiency than conventional transformer

Hitachi, Ltd.

Ⅲ- 1 - FP Future/Developing Technologies

Ⅲ- 1 - FP-1 Integrated coal gasification combined cycle


High efficiency power generation with gas turbine (η～approx.50 %)


Ⅲ- 1 - FP-2 Integrated coal gasification fuel cell combined cycle

Ditto High efficiency power generation with fuel cell and gas turbine (η～approx.60 %)

Electric Power Development Co., Ltd. (J-Power)

Ⅲ- 1 - FP-3 SOFC-GT combined cycle plant Gas-fired power

plant Fuel cell-GT combined cycle plant High efficiency (η～approx.65 %)


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Ultra supercritical pressure coal–fired power generation system

1000MW High temperature ultra supercritical pressure coal–fired power plant

(Source: HP of MHI)

Pressurized fluidized bed boiler combined cycle plant system

360MW Pressurized fluidized bed boiler combined cycle plant system

(Source: HP of Kyushu EPC)

III-1 Power Generation (Coal-fired )

1ry & 2ry Cyclones Pressure vessel Electrostatic precipitator

Fluidized bed boiler

Coal bunker

DeNOx equipment

Exhaust gas feedwater heater

Gas turbine

Cal slurry pump

Steam turbine

(Source: HP of Toshiba)

(Source: Catalogue of IHI)

III-1-PE-2

III-1-PE-7

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Integrated coal gasification combined cycle system

(Source: HP of MHI)

250MW Integrated coal gasification combined cycle plant

(Source: HP of MHI)

Coal gasification SOFC combined cycle

Coal gasification SOFC (Solid Oxide Fuel Cell) combined cycle (Source: HP of MHI)

Coal gasification SOFC (Solid Oxide Fuel Cell) combined cycle plant

(Source: HP of MHI)

III-1 Power Generation (Coal-fired)

Pulverizer

Coal bunker

Coal gasifier Heat exchange

Oxygen/air

Slag Char

Filter

Sulfur removal device

Inverter Steam turbine

Condenser

Exhaust gas

Compressor

Gas turbine HRSG

Coal

Coal gasifier Filter

Gas turbine

Steam turbine

HRSGChimney

Coal gasifier

Coal feed system

Coal gas

Porous filter

Combustor

Gypsum Wet DeSOx

AirStack

N2

O2

Char

Air Air separating unit

Air compressor

III-1-FP-1

III-1-FP-3

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Natural gas-fired combined cycle plant system

(Source: HP of Toshiba)

Gas turbine for 455MW single-shaft Natural gas-fired combined cycle plant

(Source: HP of MHI)

SOFC-GT combined cycle (being developed)

(Source: HP of MHI)

SOFC-gas turbine combined cycle package for DPHC

(Source: HP of MHI)

III-1 Power Generation (Natural Gas-fired)

SOFC module SOFC cell tube

Recirculation device

Inverter

Combustor

Gas turbine

Heat exchanger

Fuel

Air

III-1-PE-3

III-1-FP-3

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III-1-PE-8 Diesel Engine power generation

(Model: Mitsubishi 18KU34)

III-1-PE-9 Gas engine power generation

(Model: Mitsubishi)

Gas turbine cogeneration (heat/power ratio controllable type)

Process steam

Feedwater

Fuel

Superheated t

Generator

Compressor

Turbine

Gas turbine

Power Air

Heat recovery boiler

Stack

Exhaust gas

Combustor

Distributed Power & Heat Cogeneration

III-1-PE-10

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Ⅲ-2 Renewable Energy Product



Ⅲ- 2 - PE-1 Photovoltaic cell (Crystal Silicon Type)

Solar cell Made of solar grade silicon wafer crystallized by casting method or produced from single crystals of high purity silicon

Fuji Electric System Kyosera, SHARP

Ⅲ- 2 - PE-2

Photovoltaic cell (Amorphous-micro crystal silicon type)

Solar cell a-Si –micro crystalline thin film PVC Material and production energy saving PVC High efficiency with high temperature Clean power generation


Ⅲ- 2 - PE-3

Wind turbine generator Wind turbine plant

Variable pitch control wind turbine for high efficiency and reliability over wide range of wind speed Large capacity ～2400kW Clean power generation

Mitsubishi Heavy Industries, Ltd. Kyocera Fuji Electric Systems SANYO

Ⅲ- 2 - PE-4 Water turbine Hydraulic

turbine plant Water turbine for utility use suitable for power generation Mitsubishi Heavy Industries,

Ltd. Toshiba Hitachi

Ⅲ- 2 - PE-5

Hydro-power generation system

Ditto Small capacity water turbine suitable for DG Applicable: small river/river maintenance, sewage, agriculture channel, industrial plant Capacity ～approx.250kW Clean power generation

Toshiba Corporation Fuji Electric System Hitachi

Ⅲ- 2 - PE-6 Municipal waste incineration Power Generation

Incineration Power Plant

Power generation from the municipal waste

Ⅲ- 2 - PE-7

Ocean thermal energy conversion (OTEC)

Ocean thermal power plant

Power generation with ocean thermal energy , hot spring, waste water energy conversion and others for high temperature heat source and deep sea water for heat sink Clean power generation

Xenesys Inc.

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Photovoltaic cell power generation Amorphous-micro-crystal silicon type

III-2 Renewable Energy Power Generation Technologies

Photovoltaic cell power generation Crystal Silicon type

Model : FUJI ELECTRIC

Model : FUJI ELECTRIC Model : Mitsubishi Heavy Industries

Storage Batteries Power generation can supply the stable power output by charging and discharging the batteries.

Power Conditioner Direct current is changed to alternating current for general use.

This is a stand-alone hybrid system of 100kW PV power generation system, which includes 100kW PV and 689kWh batteries, and 25kW micro hydroelectric power generation using an induction generator (NEDO project)

User

PE-1 PE-2

PE- 1 & 2

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Vertical Axis Wind Turbine Giromill type Velocity of wind: 5- 10 m/sec

(Low-Medium) Direction of wind : All fluctuated

direction Output : ~1.5 kW

Vertical Axis Wind Turbine Darrieus type Velocity of wind: 8- 10 m/sec

(Medium) Direction of wind : All fluctuated

direction Output : ~1000 kW

Horizontal Axis Wind Turbine Three bladed large scale

Velocity of wind: 10- 20 m/sec (High)

Direction of wind : Direction control system is needed

Output : 500~2000 kW

PE-3 Wind Turbine

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Type Pelton Water Turbine Output ≤100MW Install Site Large River, High head Purpose Middle Scale Utility

Type Francis Water Turbine Output ≤300MW Install Site Large River, Middle head Purpose Large Scale Utility

Type Micro Water Turbine Output ≤100kW Install Site ・Agriculture Water way ・Factory Wastage ・Canal, etc. Purpose On-site Power supply

PE-4

Runner Needle ValveNozzle

A. Water tank B. Penstock C. Penstock adaptor flange D. Valve E. Generator F. Turbine


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Horizontal shaft propeller type water turbine generator

Source: Fuji Electric Systems Co. Ltd.

PE- 5

Model : Mitsubishi Heavy Industries

Refuse incineration power generation

PE- 6

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Ⅲ-3. Steel manufacturing Product



Ⅲ- 3 - PE-1

Blast furnace gas (BFG) firing gas turbine combined cycle

Waste heat recovery Power generation

High efficiency BFG combined cycle Low calorie gas (BFG) is used. More than 1.5 times power generation than conventional method High reliability is proven Clean power generation without additional fuel


Ⅲ- 3 - PE-2 Pulverized coal injection into blast furnace

Coal injection to blast furnace

Coal injection into blast furnace Less use of cokes

JFE Engineering Corporation

Ⅲ- 3 - PE-3 Blast furnace top pressure power generation equipment

Energy recovery power generation

BFG top pressure expansion turbine Approx. 30% energy is recoverable Clean power generation without fuel combustion

Mitsui Engineering & Shipbuilding Co., Ltd.

Ⅲ- 3 - PE-4

Direct current arc furnace with water-cooled furnace wall

Arc furnace Direct current arc furnace Simple structure with single electrode Less power consumption than three phase alternative current arc furnace


Ⅲ- 3 - PE-5

Continuous casting machine Continuous casting

Continuous casting machine Lower power consumption than conventional system

Hitachi, Ltd. JFE Steel Corporation Nippon Steel Corporation

Ⅲ- 3 - PE-6 Hot slab direct transfer rolling machine

Slab transfer Hot slab direct transfer machine Continuous casting with less fuel consumption

Nippon Steel Corporation

Ⅲ- 3 - PE-7 Continuous annealing furnace Continuous

annealing Continuous annealing furnace Less annealing time Higher productivity

Toshiba Corporation

Ⅲ- 3 - PE-8 Wire-rod coil convection heat treatment furnace

Ditto Convection coil annealing furnace Rapid heating and cooling Less fuel consumption by about 25%

Ⅲ- 3 - PE-9 Tube low-temperature forge-welding Forge welding Pipe/Tube forge-weld manufacturing

Low temperature welding method Less power consumption

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Ⅲ- 3 - PE-10 High frequency electric melting furnace

High frequency electric melting

HF Electric melting furnace Less power consumption by more than 10%


Ⅲ- 3 - PE-11 Cast iron electric melting groove typeinduction furnace

Ditto Cast iron melting furnace Higher productibity by about 10% Less power consumption by about 20 %

Fuji Electric Thermo Systems Co., Ltd.

Ⅲ- 3 - PE-12 High energy efficiency type alloy refining furnace

Alloy iron furnace Pelletized ore utilization electric furnace Less energy saving Reduction of cokes


Ⅲ- 3 - PE-13 High efficient ignition equipment for sintering kiln

Ignition equipment

Sintering equipment with high efficient burner Less coke oven gas consumption


Ⅲ- 3 - PE-ME Machinery Equipment

Ⅲ- 3 - PE-ME-1 Coke oven coal humidity conditioningequipment

Moisture control of cokes

Humidity controlled cokes oven Less coal consumption


Ⅲ- 3 - PE-ME-2 Cokes dry quenching equipment Heat recovery by

cokes dry quenching

CDQ cokes oven Approx.150kWh/t-coke is recoverable


Ⅲ- 3 - PE-ME-3 Heat recovery from sintering machinecooler

Heat recovery Heat recovery from sintered iron Heat consumption is approx. 60,000kal/t- iron

Sumitomo Metal Industries, Ltd.

Ⅲ- 3 - PE-ME-4 Heat recovery from sintering furnace exhaust gas

Ditto Heat recovery from sintering exhaust gas Recovery of steam is about 30,000kcal/t-sintering ore

JFE Engineering

Ⅲ- 3 - PE-ME-5 Air heating furnace exhaust heat recovery equipment

Heating recovery Air heating furnace heat recovery Blast furnace exhaust heat is recovered by about 40 to 50 %


Ⅲ- 3 - PE-ME-6 Energy recovery from converter furnace exhaust

Waste gas/Heat recovery

Energy recovery from converter furnace exhaust gas 200,000kcal / t-crude steel is recoverable


Ⅲ- 3 - PE-ME-7 Heat recovery from converter exhaust gas

Heat recovery Heat recovery from converter exhaust gas 30,000kcal/t-molten steel is recoverable

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III-3 Steel Manufacturing Process

PE- Sintering material supply equipment PE-1 PE-4 Direct current arc furnace with PE-6 Hot slab direct transfer rolling PE-7 Continuous annealing furnace

PE-2 Pulverized coal injection into blast

Blast furnace gas (BFG) firing gas turbine combined cycle PE-5 Continuous casting machine PE-8 Wire-rod coil convection heat treatment PE

PE-13 High efficient ignition equipment for P PE-10 High frequency electric melting furnace PE-9 Tube low-temperature forge-welding

ME-1 Coke oven coal humidity conditioning

E-3 Blast furnace top pressure

power generation equipment PE-11 Cast iron electric melting groove type

ME-2 Cokes dry quenching equipment PE-12 High energy efficiency type alloy refining ME-3 Heat recovery from sintering machine

cooler ME-6 Energy recovery from converter furnace

exhaust

ME-4 SF exhaust heat recovery equipment

ME-5 AHF exhaust heat recovery equipment

Blast furnace gas holder

Factory

Dust catcher Venturi scrubber Raw

coal Coke

Gas separating unit Generator

Oxygen, secondary raw material Scrap iron

Coke furnace

Molten iron Air heating furnace Blast furnace

Sintering machine

Powder coke

Coke oven

Coke car Coke at 200°C

High pressure steam

Low pressure steam Exhaust heat boiler

Exhaust duster

Turbine

Generator Condenser Belt conveyor

Deaerator

Circulation blower Cyclone Pure water tank

Electric furnace

Scrap iron

Molten steel

Converter Continuous casting equipment

Billet

Bloom

Slab

Heating furnace

Major products Rail Steel sheet pile Section steel Bar

Wire rod

Plank

Hot rolled coil Hot rolled plank

Cold rolled coil Cold rolled steel sheet Steel sheet for plating Welded steel pipe Pipe steel pipe

Seamless steel pie

Cast iron products Seamless steel pipe manufacturing equipment

Welded steel pipe manufacturing equipment

Cold strip mill

Hot strip mill

Plank mill

Rolling

Strip steel mill

Looping mill

Straightforward Rolling

Soaking pit Ingot making mill

Uniform heating furnace

◎Energy consumption ratio for each process (There are portions for which energy consumption can not be expressed by a numerical value, therefore the total of each process is not always 100%.)

◎Energy saving ratio per primary unit fuel by introducing energy saving equipments (average)

◎Electric power saving ratio by exhaust heat power generation

Petroleum fuel Non petroleum fuel Electric power Steam

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Ⅲ-4. Non-Ferrous Metal Manufacturing Technologies Product

No. Product / technology Functional group Features of the Technology Manufacturers

Ⅲ- 4 - ME-1 Flash Copper Smelting Furnace Energy saving Copper smelting furnace Max.50% energy saving is possible

ME-1

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Ⅲ-5. Cement Manufacturing Technologies Product



Ⅲ- 5 - PE-1 Vertical roller mill Raw material

grinding Vertical roller mill Power consumption is less than ball mill with classifier by about 30%

Kawasaki Heavy Industries, Ltd. IHI Corporation Kobe Steel, Ltd.

Ⅲ- 5 - PE-2 Suspension pre-heater Rotary kiln heatrecovery

Suspension Pre-heater Power generation with heat exhaust heat

Ⅲ- 5 - PE-3

NSP method (calciner) cement Kiln

Cement calcinations

NSP method calciner 1.5 to 2.0 times more productive than conventional SP system

Mitsubishi Heavy Industries, Ltd. Kawasaki Heavy Industries, Ltd. IHI Corporation Kobe Steel, Ltd.

Ⅲ- 5 - PE-4 Vertical roller mill Coal grinding Vertical roller mill 20 to 50% more productivity than ball mill

Ⅲ- 5 - PE-5 Pre-crusher Clinker crusher Roller press pre-crusher

15 to 26% less power consumption Ishikawajima Plant Engineering & Construction Co., Ltd.

Ⅲ- 5 - PE-6 Pre-Grinder Clinker grinder Vertical roller pre-grinder Production capacity is almost doubled

Kawasaki Heavy Industries, Ltd. IHI Corporation

Ⅲ- 5 - PE-7 Highly efficient cement separator

Cement Separator About 40% less power consumption than with conventional separator

Taiheiyo Engineering Corporation IHI Corporation

Ⅲ- 5 - PE-8 Highly efficient clinker cooler Clinker Clinker cooler More than 5% higher heat recovery

Babcock-Hitachi K. K.

Ⅲ- 5 - PE-9 NSP method cement Kiln – Fluidized bed pre-calcining

Cement kiln Fluidized bed pre-calcining Fuel consumption is decreased to 750kcal/kg-cl


Ⅲ- 5 - PE-10 Shaft Type Cement Kiln Cement kiln Shaft type cement kiln 10 to 25% less energy consumption than SP method

Kawasaki Heavy Industries, Ltd.

Ⅲ- 5 - PE-11

Vertical roller mill for grindingclinker

Clinker grinder Vertical roller mill 17 to 19kWh/t-clinker less power consumption for crushing

Mitsubishi Heavy Industries, Ltd. Kawasaki Heavy Industries, Ltd. IHI Corporation Kobe Steel, Ltd.

Ⅲ- 5 - PE-12 Vertical roller mill for slag grinding

Slag grinder Vertical roller mill About 20% less power consumption than ball tube mill method

Mitsubishi Heavy Industries, Ltd. Kawasaki Heavy Industries, Ltd. IHI Corporation

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Ⅲ- 5 - PE-13 Utilization of town waste as material and fuel for cement -Eco cement plant

Utilization of town waste

Eco-cement Cost for disposing of burned ash is eliminated

Taiheiyo Cement Corporation

Ⅲ- 5 - PE-14 New type clinker cooler Clinker cooler Clinker cooler -combined cooling system More heat recovery by 2% than high efficient cooler

Babcock-Hitachi K. K.


Ⅲ- 5 - ME-1 Coarse coal recirculation of vertical roller mill

Vertical roller mill

Coarse coal recirculation Power consumption of fan is less by about 20 %

Ⅲ- 5 - ME-2

5-stage cyclone suspension pre-Heater

Energy recovery by NSP plant

5 stage pre-heater Heat consumption is less by about 3%

Mitsubishi Heavy Industries, Ltd., Kawasaki Heavy Industries, Ltd., IHI Corporation, Kobe Steel, Ltd.

Ⅲ- 5 - ME-3

Low pressure loss suspension pre-Heater

Suspension pre-heater

Low pressure loss suspension pre-heater Power consumption of NSP fan is decreased to about a half

Mitsubishi Heavy Industries, Ltd., Kawasaki Heavy Industries, Ltd., IHI Corporation, Kobe Steel, Ltd.

Ⅲ- 5 - ME-4 Utilization of used tires as fuel for calcinations

Use of tire as fuel for calcinations

Used tire utilization kiln Fuel consumption is reduced by about 13%

Taiheiyo Cement Corporation

Ⅲ- 5 - ME-5 Power generation with wasteheat from suspension heater exhaust gas

Exhaust heat utilization

Power generation 6,500kW power generation for 3,000t/d cement plant

Kawasaki Heavy Industries, Ltd.,Takuma Co., Ltd.

Ⅲ- 5 - ME-6 Utilization of Used Plastics asfuel for Calcinations

Fuel for calcinations

Used plastics utilization Coal fuel is saved by 20 to 30%

Tokuyama Corporation

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②⑬⑯

⑭③ ⑳

⑰⑱

⑩④

⑥ ⑲○21

⑪

⑨⑮

① ⑥⑦

⑧

⑫

PE-1 Vertical roller mill PE-2 Suspension pre-heater PE-5 Pre-crusher

PE-12 Vertical roller mill for slag grinding PE-3 NSP method (calciner) cement Kiln PE-6 Pre-Grinder

ME-1 Coarse coal recirculation of vertical roller mill

PE-4 Vertical roller mill PE-7 Highly efficient cement separator

PE-8 Highly efficient clinker cooler PE-11 Vertical roller mill for grinding clinker PE-9 NSP method cement Kiln – Fluidized bed pre-calcining

PE-10 Shaft Type Cement Kiln

PE-13 Utilization of town waste as material and fuel for cement

PE-14 New type clinker cooler

ME-2 5-stage cyclone suspension pre-Heater

ME-4 Low pressure loss suspension pre-Heater

ME-5 Utilization of used tires as fuel for calcinations

ME-6 Power generation with waste heat

ME-6 Utilization of Used Plastics as fuel for Calcinations

Raw material crashing process

◎Energy consumption ratio for each process (There are portions for which energy consumption can not be expressed by a numerical value, therefore the total of each process is not always 100%.)


◎Electric power saving ratio by exhaust heat power generation

Fuel Electric power

Lime stone

Clay

Quartzite

Blast furnace slag

Electric dust collector

Raw material silo

Vertical raw material crashing mill

Boiler

Cooling tower

Sintering process

Blending silo

Turbine Cement exhaust gas generator

SP tower Vertical coal pulverizer

Bag dust filter Chimney

Chimney

Chimney

Cyclone Kiln

Clinker cooler Clinker

crasher

Electrostatic precipitator

Boiler

Finishing process

Clinker silo

Lime

Spare mill

Air separator

Finishing mill

Bag packing and shipment

Cement silo

Cement silo

Cement bag packer Shipment by truck (bags)

Shipment by truck (bulk)

Shipment by cement only ship (bulk)

(Power generation and others) (Power generation and others)

Fuel Electric power

III-5 Cement Manufacturing Process

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Ⅲ-6. Chemical (Ammonia) production Product



Ⅲ- 6 - PE-1 Urea production technology Urea synthesis Urea plant

30% less power consumption than total recycle system

Toyo Engineering Corporation

Ⅲ- 6 - PE-2 Exhaust heat recovery heat exchanger type primary reformer

Reformer exhaust heat recovery

Ammonia plant primary reformer About 10% reduction of fuel consumption

Ⅲ- 6 - PE-3 High conversion rate synthetic reactor

Ammonia synthesis Ammonia synthetic reactor About 0.14×104kcal/t-NH3

Ⅲ- 6 - PE-4 Low differential pressure synthetic reactor

Ammonia synthesis Ammonia synthetic reactor Steam consumption is reduced by 0.17×104

kcal/t-NH3

Ⅲ- 6 - PE-5 Isothermal CO conversion reactor CO conversion H2

production CO conversion reactor for ammonia plant Fuel consumption is reduced by 0.1×104

kcal/t-NH3

Ⅲ- 6 - PE-6 CO oxidizing reactor CO oxidizing to CO2 CO converter for ammonia plant

Fuel consumption is reduced by 0.07×104

kcal/t-NH3

Ⅲ- 6 - PE-7

Ammonia manufacturing plant integrated with high-pressure coal gasification power plant

Coal gasification Ammonia manufacturing plant integrated with power generation plant Fuel consumption is reduced by 2.1×104

kcal/t-NH3


Ⅲ- 6 - ME-1 Synthesized gas compressor outletheat recovery system

Heat recovery from synthesized gas

Heat recovery system of ammonia plant About 0.05×104kcal/t-NH3 is recovered

Osaka Petrochemical Industries, Ltd.

Ⅲ- 6 - ME-2 Membrane separation hydrogen recovery system

Recovery of H2 from synthesized gas

H2 recovery system of Ammonia plant Energy consumption is reduced by 0.14×104

kcal/t-NH3

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Ⅲ- 6 - ME-3 High-pressure water power recovery turbine

Power recovery from highpressure water

Water turbine of ammonia plant Steam consumption is reduced by 0.04×104

kcal/t-NH3

Ⅲ- 6 - ME-4 Pre-reformer for ammonia-reforming process

Pre-reforming of natural gas

Ammonia plant Energy consumption is reduced by 0.15×104

kcal/t-NH3

Ⅲ- 6 - ME-5

Exhaust heat recovery system for primary reformer

Heat recovery from combustion gas

Ammonia plant Energy consumption is reduced by 0.2 to 03×104kcal/t-NH3

Toyo Engineering Corporation Sumitomo Chemical Engineering Co., Ltd.

Ⅲ- 6 - ME-6 Gas turbine-driven compressor for ammonia plant

Energy saving Ammonia plant Energy consumption is reduced by 0.3 to 04× 104kcal/t-NH3

27

PE-1 Urea production technology PE-2 Exhaust heat recovery heat exchanger

type primary reformer

PE-6 CO oxidizing reactor

PE-3 High conversion rate synthetic reactor

PE-4 Low differential pressure synthetic reactor PE-7 Ammonia manufacturing plant integrated with high-pressure coal gasification power

plant

ME-3 High-pressure water power recovery turbine

ME-1 Synthesized gas compressor outlet heat recovery

system

ME-4 Pre-reformer for ammonia-reforming

process

ME-2 Synthesized gas compressor outlet heat recovery

system

ME-5 Exhaust heat recovery system for primary reformer

ME=6 Gas turbine-driveｎcompressor for ammonia plant

PE-5 Isothermal CO conversion reactor

◎Energy consumption ratio for each process


Fuel Electric power

Fuel Electric power

Gasification (reforming) process

Raw material

Heating furnace

Steam Boiler feed water

Steam drum

Steam Air

Secondary reformer

Primary reformer

Fuel

CO2 conversion tower

CO conversion process Gas refining process

CO2 absorbing tower

CO2 stripper

Methanator

Synthetic process

Ammonia synthetic tower

Purge

compress

Flash gas

Separator

Product ammonia

Note: In case of CA-PE-7+, both steam and electric power are reduced by 100% because no reformer is necessary.

III-6 Chemical (Ammonia) production

28

Ⅲ-7. Chemical (Caustic Soda) production


Ⅲ- 7 - PE-1 Quadruple effect-type concentrationfor electrolytic caustic soda with barrier membrane

Improvement of energy efficiency

Caustic soda plant Steam consumption is reduced by 0.7 t/t-NH3

Ⅲ- 7 - PE-2 Electrolyzer with ion-exchange membrane

Energy saving Electrolyzer Electric power consumption is reduced by 131kWh/t-NaOH from conventional electrolyzer

Tosoh Corporation

Ⅲ- 7 - PE-3 Saline solution electrolyzer with ion-exchange membrane

Energy saving Electrolyzer Electric power consumption is reduced by 257kWh/t-NaOH from asbestos barrier electrolyzer

Asahi Kasei Corporation


Ⅲ- 7 - ME-1 Brine preheater with salt water electrolytic heat recovery

Energy saving Electrolyzer Steam consumption is reduced by 0.17 t/t-NaOH

Ⅲ- 7 - ME-2 Active cathode for electrolysis with ion-exchange membrane

Energy saving Electrolyzer Electric power consumption is reduced by 150kWh/t-NaOH from conventional electrolyzer

29

PE-2 Electrolyzer with ion-exchange membrane PE-1 Quadruple effect-type concentration for electrolytic caustic soda with barrier membrane

PE-3 Saline solution electrolyzer with ion-exchange membrane ME-1 Brine preheater with salt water electrolytic heat recovery ME-2 Active cathode for electrolysis with ion-exchange membrane

◎Energy consumption ratio for each process


Steam Electric power

Steam Electric power

Caustic soda manufacturing process

Raw material salt refining process

Raw material salt

Raw material salt melting and refining

Saturated salt

Refining for ion exchange ????

Chlorine

Anode liquid tank

Electrolytic process

Anode Cathode

Anode chamber Cathode chamber

Electrolytic vessel

Hydrogen

Concentration process

Cathode liquid tank

Steam

Caustic soda

Water

Evaporating system

Caustic soda

Cooling water

condenser

III-7 Chemical (Caustic Soda) Prduction

30

Ⅲ-8. Chemical (Naphtha Decomposition) production


Ⅲ- 8 - ME-1 Packing for quench tower tray Energy saving Naphtha-decomposer Steam consumption is reduced by 0.35/t/t-ethylene

Ⅲ- 8 - ME-2 Turbo expander for methane tower top gas line

Energy saving Ethylene plant Steam consumption is reduced by 0.12/t/t-ethylene

Showa Denko K.K.

Ⅲ- 8 - ME-3 Cold thermal energy recovery from methane-separating tower bottom liquid

Energy saving Ethylene plant Power consumption is reduced by 40.4kWh/t-ethylene

Idemitsu Kosan Co., Ltd.

31

ME-1 Packing for quench tower tray ME-2 Turbo expander for methane tower top gas line ME-3 Cold thermal energy recovery from methane-separating tower bottom liquid


Fuel Steam Electric power

Naphtha decomposing manufacturing process

High pressure steam

Steam super heater

Naphtha ★Steam

Decomposing furnace

Common stack

Heavy oil cracking tower

Cracked heavy oil refining tower

Cracked heavy oil

Light heavy oil refining tower

Separated gas

Alkali cleaning tower

Compressor (1 - 3 stages)

Light constituent separating tower

Water stripper

Decomposed gas water removing

tower

Four stages

Hydrogen Methane Off gas

Ethane removing tower

Acetylene

Water reaction

tower

Methane removing tower (methane

decomposing tower)

Stripper propylene tower

Acetylene water reaction tower Propylene tower

Ethylene tower Green oil decomposing tower

Ethylene intermediate tank

Recycled ethane Propylene C3LPG

Propane removing tower

Pentane removing tower

C4 -C

5 separating tower

C4 residual Separated gasoline Rerunning tower Separated kerosene

C5 residual Separated heavy oil

◎Energy consumption of consumption ratio for each energy

Fuel, Steam Electric power

Decomposed gas cooling tower (quench tower)

Steam★

III-8 Chemical (Naphtha Decomposition) Production

32



Ⅲ- 9 - PE-1

Pinch technology all sectors

Cost & Energy Saving ① Check on the entire plant from broad perspective② Find the optimum energy-consumption target

value from thermo dynamic standing point ③ Achieve Highly efficient energy-consumption

plant

JGC Corporation

Ⅲ- 9 - PE-2 WIN TRAY High-Throughput and High-Efficiency Extraction Column

Liquid-liquid extraction operation

① High throughput ② High efficiency extraction

JGC Corporation

Ⅲ- 9 - PE-3 Hydro-carbon vapor recovery system

Hydrocarbon recovery

Absorber/ absorber tank for gasoline shipping facility Nichiyo Engineering Corporation

Ⅲ- 9 - PE-4 Dense loading technology Hydrogen

desulphurization, decomposer

Fixed bed reactor, Catalyst, High density filing, filler About 30% production improvement

Nichiyo Engineering Corporation

Ⅲ- 9 - PE-5 ACES21 UREA PROCESS Cost & Energy Saving This system reduces the number of components in the urea synthesis loop to simplify the system

Toyo Engineering

Ⅲ- 9 - PE-6 Integration of Gas Turbine Exhaust with Olefins Unit

Energy Saving Energy efficiency of whole plant operation will be improved by introducing of gas turbine generator to an olefins unit

Toyo Engineering

Ⅲ- 9 - PE-7 Sludge Melting System/ Ash Melting System

Energy Saving and Volume Reduction

① Energy saving through maximum heat recovery ② High volume reduction (1/25) in the form of

molten slag

JGC

Ⅲ- 9 - PE-8

Gas oil Ultra-Deep Desulfurization Process

Energy Saving and Desulfurization

① Optimal and Economical design for revamping of existing facilities

② Enhancing the reactor performance with JGC’s “High-Efficiency Internals technology”

JGC

33


Ⅲ- 9 - ME-1 Reduction in blown steam by column top steam recycle

Distillation Steam recycle Steam consumption is reduced by 15t/100,000 barrels

Ⅲ- 9 - ME-2 Power recovery of CO gas Power recovery Fluidized contact cracker Power consumption reduction by about 4.8kWh/B

Chiyoda Corporation

Ⅲ- 9 - ME-3 Power recovery system with mixed fluid condensing turbine

Power recovery Fluidized bed contact cracking

Ⅲ- 9 - ME-4 Waste heat boiler for sulfur recovery

Heat recovery Sulfur recovery equipment 0.85t-steam/t-S is obtainable

Ⅲ- 9 - ME-5 Distillation column with Intermediate reboiler

Distillation in oil refining process

Oil refinery plant

Ⅲ- 9 - ME-6 Hydrogen membrane separator Membrane separationof hydrogen

Hydrogen production apparatus Showa Yokkaichi Sekiyu Co., Ltd.

Ⅲ- 9 - ME-7 Heat pump type PP separator Propylene separation Heat pump method

Increase of power consumption is 1.02kWh/B for 20% increase of production

Chiyoda Corporation

Ⅲ- 9 - ME-8 Cogeneration using gas turbine exhaust gas as combustion air for heating furnace

Heat recovery cogeneration

Heating furnace Fuel consumption is decreased by 25%

Ⅲ- 9 - ME-9 Rotary Regenerative Burner System

Distillation Tubular furnace Energy consumption is reduced by 12 to 50%

Chiyoda Corporation

34

35

36

The composite curves, grand composite curve and total site planning enable the establishment of energy-consumption target and the optimization of level of utilities.

With Pinch Technology, case studies can be conducted during a short period prior to detailed design. Consequently, the optimum process scheme can be worked out during the shortest period, compared with the conventional processes

PE- 1Ⅲ-9. Refinery & Petrochemical Technologies

Source : JGC Corporation

37

38


Features

• High throughput

• High-efficiency extraction

• Wide operating range (low turndown ratio)

• Resistance to interface suspended substances (scum) and fouling

• Free from any clogging trouble due to polymerization components

• Simple in structure and easy to maintain

• Low investment cost

Applications Applicable to general liquid-liquid extraction operations

• Extraction of aromatics from cracked gasoline

• Extraction of organic compounds

• Increase of capacity of existing RDC (Rotating Disk Contactors),

perforated tray towers or packed towers by replacing existing trays

with WIN trays.

• Intensification of process performance


39

PE-5


Source : Toyo Engineerin Corporation

40

PE-6


Source : Toyo Engineerin Corporation

41



42

PE-8Ⅲ-9. Refinery & Petrochemical Technologies


43

Ⅲ-10. Geothermal Technologies


Ⅲ- 10 - PE -1 Geothermal Power Station Power Generation WJEC(Engineering)

Ⅲ- 10 - PE -2 Hot Water Swimming Pool Direct use of Geothermal heat energy

Ⅲ- 10 - PE -3 Heating of Greenhouse Direct use of Geothermal heat energy

Ⅲ- 10 - PE -4 Wood Processing Direct use of Geothermal heat energy

Ⅲ- 10 - PE -5 GAIA Snow Melting System Snow melting system for roads with a well bore cove-axial heat exchanger and a heat pump

Ⅲ- 10 - PE -6 Geothermal Heat-Pump System Heating the house and/or Building

Ⅲ- 10 - PE-7 Geothermal Coupled numerical reservoir simulator

Geothermal Geothermal reservoir analysis tool Accurate prediction of wellhead pressure and mass flow rate

West Japan Engineering Consultants, Inc.

44

III-10 Geothermal Technologies

Model : Hatchobaru Geothermal power station, Kyushu Electric

Source : THE GEOTHERMAL RESEARCH SOCIETY OF JAPAN


Source : Horticulture in Oita Prefecture

Hot Water Swimming Pool Geothermal Power Plant PE-1 PE-2

PE-3

45




Wood Processing

GAIA Snow Melting System

PE-4

PE-5

46



PE-6

47

Ⅲ-11. Environment Technologies


Ⅲ- 11 - PE -1 Flue Gas Cleaning System Flue Gas Cleaning IHI, Hitachi, MHI, etc., Ⅲ- 11 - PE -2 Flue Gas Desulfurization Flue Gas Cleaning IHI, Hitachi, MHI, etc., Ⅲ- 11 - PE -3 Flue Gas Denitrification Facility Flue Gas Cleaning IHI, Hitachi, MHI, etc., Ⅲ- 11 - PE -4 Eletrostatic Precipitator Flue Gas Cleaning IHI, Hitachi, MHI, etc., Ⅲ- 11 - PE -5 Ⅲ- 11 - PE -6 Ⅲ- 11 - PE-7

48

Ⅲ- 11 - PE -1 Flue Gas Clean Process

49

Ⅲ- 11 - PE -2 Flue Gas Desulfurization

50

Ⅲ- 11 - PE -3 Flue Gas Denitrification Facility

(2) Catalyst Types and Reactor Shapes

51

Ⅲ- 11 - PE -4 Eletrostatic Precipitator

Dry Eletrostatic Precipitator Wet Eletrostatic Precipitator

Gas

Electrode wash nozzle

Gas Flow Outlet

Gas Flow Inlet

Dust Collector

Dust Collector

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Documents

September, 2008 - ジェトロ（日本貿易振興機構） | … 2008 JAPAN EXTERNAL TRADE ORGANIZATION (JETRO) JAPAN CONSULTING INSTITUTE (JCI) 1 I. Necessary of Energy Conservation