application of heat pumps to cutting and washing processes
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IEA HPT Annex48 Expert Meeting of Japan
Application of Heat Pumps to
Cutting and Washing Processes
Choyu WATANABE
Chubu Electric Power Co., Inc.
Yohji UCHIYAMA
University of Tsukuba
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IEA HPT Annex48 Expert Meeting of Japan
Industry Automobile parts production
Site Gamagoori Plant, AISIN AW Co., Ltd.
Aichi Prefecture, Japan
Processes Cutting, washing
Purpose Reduction of boiler steam (fuel: crude oil)
System Waste heat recovery heat pumps
with heating capacity 22 kW (6 units)
Air-source heat pumps
with heating capacity 44 kW(8 units)
Overview
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The amount of industrial shipment of Aichi occupy approximately 15% of Japan.
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IEA HPT Annex48 Expert Meeting of Japan
Conventional system
Washing liquid
60 oC
Input energy (Gas) 1
Boiler
Heating energy
0.2
Total thermal
Efficiency =
0.2
Chiller
Cutting liquid
20 oC
Input energy
(Electric power)
1Cooling energy
2
Cooling
COP
= 2
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IEA HPT Annex48 Expert Meeting of Japan
Boiler roomGround plan of the factory
East wing
West wingCutting machines
Washing machines
Steam is supplied from the boiler
to the 300 m away washing machines. Large heat loss was caused.
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IEA HPT Annex48 Expert Meeting of Japan
Cutting liquid
20 oC
Washing liquid
60 oC
Heating
energy
3Coolingenergy
2
Input energy
(Electric power) 1 Compressor
Expansion
valve
Evaporator Condenser
Application of heat pumps to cutting and washing processes
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IEA HPT Annex48 Expert Meeting of Japan
Cutting liquid
20 oC
Washing liquid
60 oC
Heating
energy
3Coolingenergy
2
Input energy
(Electric power) 1 Compressor
Expansion
valve
Evaporator Condenser
Application of heat pumps to cutting and washing processes
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Total COP = 5
Simultaneous
cooling and heating
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IEA HPT Annex48 Expert Meeting of Japan
There were no heat pumps which were able to applied
to both cutting and washing processes in 2007.
Events until completion of the development
of the heat pumps
Cooperative development of heat pumps
by Zeneral Heat Pump Industry Co., Ltd.
and Chubu Electric Power Co., Inc. in 2008 to 2009.
Field tests of heat pumps
by AISIN AW Co., Ltd.,
Zeneral Heat Pump Industry Co., Ltd.
and Chubu Electric Power Co., Inc. in 2008 to 2009.8
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IEA HPT Annex48 Expert Meeting of Japan
1. Highly efficient hot water circulation heating (60-65oC)
2. Countermeasure against contamination of air-refrigerant heat exchangers with oil mist and dust
3. Countermeasure against unbalance between heating and cooling demands
Standard equipment of oil mist filters
Selection of the best refrigerant
Development of heat pumps was carried out.
Technical issues
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IEA HPT Annex48 Expert Meeting of Japan
Simultaneous heating & cooling operation
mode
Heating
operation
mode
Cooling
operation
mode
Switching three
operation modes
Countermeasure against unbalance between heating and cooling demands
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IEA HPT Annex48 Expert Meeting of Japan
Simultaneous heating & cooling operation mode
Heat exchanger between water and
refrigerant
CompressorCoolingenergy
2
Heating
energy
3
Heat exchanger between water and refrigerant
Input energy
(Electric power) 1
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IEA HPT Annex48 Expert Meeting of Japan
Heat exchanger between air and
refrigerant
Heating operation
mode
Heating
energy
3
Input energy
(Electric power) 1
Heat exchanger between water and refrigerant
Compressor
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IEA HPT Annex48 Expert Meeting of Japan
Cooling
operation
mode
6
Heat exchanger between water and
refrigerant
Coolingenergy
5
Input energy
(Electric power) 1
Compressor
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IEA HPT Annex48 Expert Meeting of Japan
Boiler room
East wing
West wingCutting
machines
Washing machines
The heat pump has been installed here for field tests
Ground plan of the factory
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IEA HPT Annex48 Expert Meeting of Japan
65 oC
62 oC
63 oC
温水
Washing liquid
Installation of the heat pump
Cutting liquid bath Washing liquid bathHeat Pump
Heat exchangers
One washing liquid bathSix cutting liquid baths Heat pump
Plate type heatexchanger
10 oC
15 oC
Hot water
Cold water
15
63 oC
68 oC
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IEA HPT Annex48 Expert Meeting of Japan
Field test results (temperatures)
洗浄液温度切削液温度施盤本体温度
Tem
per
atu
re(o
C)
0
10
20
30
40
50
60
70
8:00 10:00 12:00 14:00 16:00 18:00
Temperature of washing liquid ≒ 62 oC
Temperature of cutting liquid≒ Temperature of cutting machine
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IEA HPT Annex48 Expert Meeting of Japan
The developed heat pump can cope with a variation in unbalance of heating and cooling demands.
Cooling demandHeating demand
Heating &Cooling
Heating
Cooling
Time (min.)
0 10 20 30 40 50 60 70 80 90 1000
5
10
15
20
25
30
35
40
Therm
al dem
and (
kW
)
Field test results (heat demands and operation modes)
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Operationmodes
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IEA HPT Annex48 Expert Meeting of Japan
Before application of heat pumps
After application of heat pumps
Reduction achieved
Power consumption(MWh/ year)
193 (100%) <Boiler auxiliary equipment, Cooler>
570 (295%)<Heat pump>
+377 (+195%)
Fuel oil consumption(Kilo Litters/ year)
470 (100%)<Boiler fuel oil>
0 (0%)<Heat pump>
-470 (-100%)
Water consumption(KL/ year)
6,953 (100%)<Steam>
0 (0%)<Heat pump>
-6,953 (-100%)
Energy saving(Fuel oil equivalent, KL/year)
522 (100%) < Boiler, Cooler>
85 (16%)<Heat pump>
-437 (-84%)
CO2 emissions(Tons of CO2/ year)
1,364 (100%) <Boiler, Cooler>
270 (20%)<Heat pump>
-1,094 (-80%)
Effects of application of heat pumps (Energy)
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IEA HPT Annex48 Expert Meeting of Japan
Initial equipment investment cost: 91,000,000 JPY
Running cost reduction: 26,030,000 JPY/year, Pay back time: 3.5 years
Before application of heat pumps
After application of heat pumps
Reduction achieved
Investment cost
Boiler (Including piping):75,300,000 JPY
Steam heater: 10,500,000 JPY
Cooler: 50,400,000 JPYTotal: 136,200,000 JPY(100%)
Heat pump system(14 units)Total 91,000,000 JPY(66.8%)
45,200,000 JPY or 33.2%
Annualrunningcost
Electricity: 193MWh,2,340,000 JPY
Fuel oil: 470KL,28,130,000 JPY
Water: 6,953KL,2,450,000 JPY
Total: 32,920,000 JPY(100%)
Electricity:570MWh,6,890,000 JPY
Total: 6,890,00JPY(20.9%)
26,030,000 JPY or 79.1%
Effects of application of heat pumps (Cost)
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IEA HPT Annex48 Expert Meeting of Japan
Initial equipment investment cost: 91,000,000 JPY
Running cost reduction: 26,030,000 JPY/year, Pay back time: 3.5 years
Before application of heat pumps
After application of heat pumps
Reduction achieved
Investment cost
Boiler (Including piping):75,300,000 JPY
Steam heater: 10,500,000 JPY
Cooler: 50,400,000 JPYTotal: 136,200,000 JPY(100%)
Heat pump system(14 units)Total 91,000,000 JPY(66.8%)
45,200,000 JPY or 33.2%
Annualrunningcost
Electricity: 193MWh,2,340,000 JPY
Fuel oil: 470KL,28,130,000 JPY
Water: 6,953KL,2,450,000 JPY
Total: 32,920,000 JPY(100%)
Electricity:570MWh,6,890,000 JPY
Total: 6,890,00JPY(20.9%)
26,030,000 JPY or 79.1%
Effects of application of heat pumps (Cost)
When a factory is newly founded,
both initial investment and running
cost of the heat pump system are
lower than those of the conventional
steam supply system and chillers.
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IEA HPT Annex48 Expert Meeting of Japan
Heat pumps for cutting and washing processes
14 heat pumps are operatingin the plant.
Around 110 heat pumps are operating
in Japan and Japan's neighbors in 2017.
are superior in Energy saving, Economy, and Environmental conservation.
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IEA HPT Annex48 Expert Meeting of Japan 22
First List of the Best Available Technologies and
Best Practices to Improve Energy Efficiency
Internationally, the International Partnership for
Energy Efficiency Cooperation (IPEEC),
23 Mar 2016.
https://ipeec.org/publications.html
Reference documents
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IEA HPT Annex48 Expert Meeting of Japan 23
Thank you for your attention!
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