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TRANSCRIPT
Industrial Heat Pump Applications in Japan
Takenobu KAIDACentral Research Institute of Electric Power Industry (CRIEPI)
Chillventa CONGRESS 2018Nuremberg, Germany
October 15, 2018
©CRIEPI
CO2 Emissions Reduction by Electrification
2
Key points for significant reduction of CO2 emissions
Low carbonization of electricity
Higher efficiency electricity usage
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
1970 1990 2010 2030 2050
CO
2em
issi
on
fac
tor
[kg-
CO
2/k
Wh
] 2011.3.11Great East Japan Earthquake & Tsunami
0.37
Under investigation
0.530 (2015)
0.352 (2010)
0
1
2
3
4
5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
CO
P
CO2 emission factor [kg-CO2/kWh]
City gas
Heavy oil A
Estimation conditions
- City gas: 0.0499 kg-CO2/MJ- Heavy oil A: 0.0693 kg-CO2/MJ- Conbustion efficiency: 0.9
Transition and target of CO2 emission factor for electricity in JapanHeat Pump (EHP) vs. Boiler regarding CO2 emissions
under the condition that the heat load is equal
©CRIEPI
56%26%
18%
Industrial6,600 PJ/year
13%
16%
13%
9%
49% Commercial2,800 PJ/year
27%
3%
27%8%
35%
Residential2,200 PJ/year
Final Energy Consumption in Japan
3
Approximately 40% of the final energy consumption is “heat.”
Industrial sector has the largest amount of energy consumption.
Residential14%
Commercial20%
Industrial43%
Transport23%
■ Space Heating■ Space Cooling■ Hot Water Heater■ Kitchen■ Lighting & Power
■ Space Heating■ Space Cooling■ Hot Water Heater■ Kitchen■ Lighting & Power
■ Heating■Material■ Lighting & Power
IndustrialHeating
Total Final Energy Consumption in Japan: 13,548 PJ (FY2015)
©CRIEPI
Commercialized IHPs in Japan
4
Sup
ply
Tem
per
atu
re [°C
]
Heating Capacity [kW]
Water-source Heat Pumps
Source: JEHC (Japan Electro-Heat Center), “Guideline for using industrial heat pump,” 2017 [in Japanese]
©CRIEPI
Commercialized IHPs in Japan
5
Heating Capacity [kW]
Sup
ply
Tem
per
atu
re [°C
]Air-source Heat Pumps
Source: JEHC (Japan Electro-Heat Center), “Guideline for using industrial heat pump,” 2017 [in Japanese]
©CRIEPI
Installation Target of IHPs by the Government
6
“The Plan for Global Warming Countermeasures”
Decided by the Cabinet on May 13, 2016
26% reduction of GHG emissions by FY2030 compared to FY2013(= 367 million ton-CO2 reduction)
The role of industrial heat pumps (IHPs)
Over 150 times spread(11 MW in FY2013 to 1,673 MW in FY2030)
1.35 million ton-CO2 reduction(= about 0.4% of total GHG emissions reduction )
0
200
400
600
800
1,000
1,200
1,400
1,600
1,800
FY2
01
3'1
4'1
5'1
6'1
7'1
8'1
9'2
0'2
1'2
2'2
3'2
4'2
5'2
6'2
7'2
8'2
9'3
0
Expected
Actual
Expected
Cu
mu
lati
ve In
stal
lati
on
Hea
tin
g C
apac
ity
[MW
]
Source: METI (Ministry of Economy, Trade and Industry) & MOE (Ministry of the Environment) Joint Meeting, Feb. 28, 2018 [in Japanese]
©CRIEPI 7
Installation Situation
©CRIEPI
Collection of Installation Cases
8
Collection from published information
Japan Electro-Heat Center (JEHC)
Heat Pump & Thermal Storage Technology Center of Japan (HPTCJ)
The Energy Conservation Center, Japan (ECCJ)
Japan Society of Refrigerating Air Conditioning Engineers (JSRAE)
Collected examples
84 examples
Installation cases of industrial heat pumps, published by Japan Electro-Heat Center (JEHC)
Voice of customer
Effects of energy, CO2
and cost reductions
System flow
Installed results (~FY2016)
84 examples: 4.9 MW(6% of government statistics)
88.1 MW
©CRIEPI
Installation Situation | Installation Year
9
After the mid-2000’s
2005- Steam-less air-conditioning system (by HP chiller & Evaporative Humidifier) [up to 50°C]
2008- High temperature hot water supply HP [up to 90°C]
2009- Hot air supply HP [up to 120°C]
2012- Steam supply HP [up to 165°C]
0
10
20
30
40
50
60
70
2001 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12 '13 '14 '15 '16 '17
Nu
mb
er
of
Inst
alla
tio
n C
ase
Cumulative Installation Case
Installation Case per Year
* 66 example cases which installation years have been published among the total number 84 of installation cases collected
©CRIEPI
0
5
10
15
20
25
30
35
Food (33) Machinery (18) Electronics (10) Chemistry (10) Agriculture& Fisheries (7)
Paper (3) Unknown (3)
Nu
mb
er o
f In
stal
lati
on
Cas
e
Heating
Heating& Cooling
Hot Water Supply
Drying
Distillation or Concentration
Air Conditioning
Installation Situation | Industry and Process
10
Food industry: the most, various process, simultaneous heating & cooling
Machinery, Electronics and Chemistry: steam-less AC for clean room
Agriculture: AC for greenhouse
Paper industry: large potential but small application
©CRIEPI
Installation Situation | Type of Heat Pump
11
Hot water supply type is used most often.
Circulation heating > Once-through heating
22
17
5
1
4
7
7
12
2
5
2
0 5 10 15 20 25 30
Air Source | Hot Water Supply HP
Water Source | Hot Water Supply HP
Air & Water Source | Hot Water Supply HP
Water Source | Hot Air Supply HP
Water Source | Steam Supply HP
Mechanical Vapor Recompression
Others (PAC, OAC, Unknown)
Number of Installation Case
Circulation Heating
Once-thorough Heating
©CRIEPI
Installation Situation | Heating Capacity & Supply Temperature
12
The required heating capacity and temperature depend on the process.
Many installations in the hundreds of kW class (700kW ≃ 1 ton/h steam boiler)
Many installations of 65°C or 90°C hot water supply
4
12
7
19
12
5
25
0 5 10 15 20 25
Q≤10 [kW]
10<Q≤50 [kW]
50<Q≤100 [kW]
100<Q≤500 [kW]
500<Q≤1,000 [kW]
1,000<Q≤3,000 [kW]
Unknown
Number of Installation Case
Heating Capacity
18
8
18
7
15
0
4
1
13
0 5 10 15 20 25
T≤50 [°C]
50<T≤60 [°C]
60<T≤70 [°C]
70<T≤80 [°C]
80<T≤90 [°C]
90<T≤110 [°C]
110<T≤120 [°C]
120<T≤130 [°C]
Unknown
Number of Installation Case
Supply Temperature
©CRIEPI
Installation Situation | Energy-saving Effects
13
Reduction of heat load by installation near process
Reduction of cooling load by simultaneous heating & cooling
Self heat recovery and high COP operation by MVR (Mechanical Vapor Recompression)
*
* *
* *
* * *
* * ** *
*
0
10
20
30
40
50
60
70
80
90
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51
Pri
mar
y En
erg
y Sa
vin
g Ef
fect
[%
]
■Simultaneous Heating & Cooling
■Mechanical Vapor Recompression (MVR)
■Waste Heat Recovery
■Others (Air Source, etc.)
* Reduction of heat load by installing near process
* 51 example cases which primary energy consumption reduction effects have been published among the total number 84 of installation cases collected
©CRIEPI 14
Case Study 1-Simultaneous Heating & Cooling-
©CRIEPI
Case 1 | Washing Process in Automobile Parts Production
15
Industry Machinery
Production Automobile parts (Differential case)
User company AISIN AW Co., Ltd.
Installed year 2010
Process Cutting (Cooling), Washing (Heating)
Application Hot Water (65°C) & Cold Water (15°C)
HP manufacturer Zeneral Heat Pump Industry Co., Ltd.
HP System AWW Heat PumpsRefrigerant: R134aHeating capacity: 476 kW(22 kW/unit × 6 units)(43 kW/unit × 8 units)
Effects CO2 reduction: 80%Primary energy reduction: 84%Energy cost reduction: 79%Payback period: 3.5 years
Outline of Installation Process and Application
Feed Material
Cutting Process
Washing Process
Assembly Process
• Coolingcutting liquid
• Heatingwashing liquid
Product (Differential Case)AWW Heat Pump(Air to Water & Water to Water)
©CRIEPI
AfterBefore
Case 1 | Washing Process in Automobile Parts Production
16
Boiler
Washing ProcessCutting Process
Cutting Liquid Washing Liquid
Chiller
Work
20°C 60°C
15°C
Steam
300m
Heat Pump
Washing ProcessCutting Process
Cutting Liquid
Work
20°C 60°C
15°C
65°C
Hot Water
Washing Liquid
Applicationof Heat Pump
Issue 1 | Low effective use of steamSteam was supplied from boiler to 300 m away washing machines. This caused large heat loss from piping. Total thermal efficiency of steam supply system was 0.2.
Issue 2 | Individual equipment installed in heating and cooling processChiller was used for cooling process. This caused hot waste heat dissipation to ambient air. Cooling COP of the chiller was 2.
Resolution | Installation of simultaneous heating & cooling heat pump near processBy installing heat pump near process, heat loss was reduced and supply temperature was decreased.And by simultaneous heating and cooling use, this heat pump could achieve total COP of 5.
©CRIEPI
Case 1 | Washing Process in Automobile Parts Production
17
Evaporator Condenser15°C
10°C
65°C
60°C
Compressor
Simultaneous Heating & Cooling Operation Mode
Evaporator15°C
10°C
Compressor
Condenser
Cooling Operation Mode
Evaporator
Condenser65°C
60°C
Compressor
Heating Operation Mode
0
5
10
15
20
25
30
35
40
0 10 20 30 40 50 60 70 80 90
Ther
mal
dem
and
[kW
]
Time [min]
Cooling demand
Heating demand
Simultaneous Heating & Cooling operation
Cooling operation Heating operation
Operation
3 operation modes
Switching operation modes and unit control can cope with unbalance between heating and cooling demand
No back-up boiler and chiller
©CRIEPI
Case 1 | Washing Process in Automobile Parts Production
18
Effects
CO2 emissions
‒ 80% reduction
‒ 1,094 ton-CO2/year reduction
Water consumption (Steam line)
‒ 100% reduction
‒ 6,953 kL-Water/year reduction
Primary energy consumption
‒ 84% reduction
‒ 437 kL-Oil/year reduction
Running cost
‒ 79% reduction
‒ 26 million JPY/year reduction
Payback period
‒ 3.5 years
One of Top 10 BATsto Improve Energy Efficiency
©CRIEPI
Other Simultaneous Heating & Cooling Application
19
Noodle production
Application of brine source heat pump hot water heater
Primary energy consumption: 35% reduction
Boiler Boiling bath Cooling bath
98°C 1°C
Boiler Boiling bath Cooling bath
98°C 1°C
Fuel Fuel
Feed Water 17°C Feed Water 17°C
Chiller
1°C
Feed Water 17°C
-5°C
1°C90°C Heat Pump
Hot Water TankIce thermal storage tank
Before
Applicationof Heat Pump
After
©CRIEPI
Summary | Simultaneous Heating & Cooling
20
Application Examples
16 examples in food industry
2 examples in machinery
Key points
Close distance of heating process and cooling process
Coping with unbalance between heating and cooling demand
‒ Resolution 1: Switching operation mode with AWW heat pump
‒ Resolution 2: Thermal storage
©CRIEPI 21
Case Study 2-MVR-
©CRIEPI
Case 2 | Concentration Process in Salt Production
22
Industry Food
Production Salt (from deep ocean water)
User company Muroto Kaiyoshinsosui Co., Ltd.
Installed year 2015
Process Concentration
Application Steam (70°C)
HP manufacturer Sasakura Engineering Co., Ltd.
HP System Mechanical Vapor Recompression (MVR)Steam temperature: 70°C (-0.07MPaG)Steam flow: 400 kg/h
Effects Primary energy reduction: 79%Energy cost reduction: 78%Payback period: 2 years (with subsidy)
Outline of Installation
3% 10% 24%
Concentration of salt
Process and Application
Feed MaterialConcentration
(RO Membrane)Concentration(Evaporation)
Crystallization Separation Shipping
• Deep Ocean Water • Reverse Osmosis Membrane
• MVR
• Steam Kettle • Centrifugal Separation
Mechanical Vapor Recompression Product (Salt)
©CRIEPI
AfterBefore
Case 2 | Concentration Process in Salt Production
23
Boiler
Steam
RO Membrane
Steam Kettlefor Concentration
Steam Kettlefor Crystallization
3%
10%
24%
Centrifugal Separator
Concentrated Water Tank
Concentrated Water Tank
Deep Ocean Water Tank
Salt+Bittern
Boiler
Steam
RO Membrane
3%
10%
24%
Centrifugal Separator
Concentrated Water Tank
Concentrated Water Tank
Deep Ocean Water Tank
Salt+Bittern
MVRApplicationof Heat Pump
Waste heat Heat recovery
©CRIEPI
After
Case 2 | Concentration Process in Salt Production
24
Salt Water100°C
Salt Water65°C
Steam 60°C
70°CSteam
Waste Heat (Steam)
Steam K
ettle
Heat Loss
Steam K
ettle
Heat Loss
Waste Heat (Steam)
Heat Recovery
110°CSteam
Electric Power
Heavy Oil
Input Energy
Input Energy
Before
Atmospheric pressure
Vacuum pressure
©CRIEPI
Case 2 | Concentration Process in Salt Production
25
Effects
Primary energy consumption
‒ 79% reduction(Evaporative concentration process)
‒ 49% reduction(Total salt production processes)
Energy cost
‒ 10 million JPY/year reduction
Payback period
‒ 2.0 years (with subsidy)
‒ 3.5 years (without subsidy)
0
0.2
0.4
0.6
0.8
1
1.2
Before After
Ene
rgy
Co
nsu
mp
tio
n [
L/kg
]
Concentration (Evaporation)CrystallizationConcentration (RO Membrane)Centrifugal Separation
▲49%
©CRIEPI
Summary | MVR
26
Application Examples
2 examples in concentration process (Salt production, Drainage treatment)
1 example in distillation process (Alcohol production)
2 examples in drying process (Tissue production, Sewage treatment)
Key points
Long time continuous process
Low BPR (Boiling Point Rising) for distillation process
Attention to corrosion or scale deposition because of direct compression
Described later(Case studies 3 & 4)
©CRIEPI 27
Case Studies 3 & 4-Indirect Self Heat Recovery-
©CRIEPI
Case 3 | Distillation Process in Dextran Production
28
Industry Chemistry
Production Dextran (Polysaccharides)
User company Meito Sangyo Co., Ltd.
Installed year 2017
Process Distillation of methanol
Application Hot water (90°C)
Contractor Kimura Chemical Plants Co., Ltd.
HP manufacturer Kobe Steel, Ltd. (KOBELCO)
HP System HEM-HR90 (× 2 units)Refrigerant: R134a+R245faHeating capacity: 800 kW
Effects CO2 reduction: 60%Primary energy reduction: 60%Energy cost reduction: 63%
Outline of Installation Process and Application
Feed Material FermentationCollection of Precipitation
Acid Hydrolysis
Collection of Precipitation
Vacuum Concentration
Spray DryingDextran
(Powder)
• Sugars • Distillation of methanol
• Distillation of methanol
Heat Pump Distillation Column Product (Dextran)
©CRIEPI
Case 3 | Distillation Process in Dextran Production
29
Boiler
City Gas
Methanol drainage 50%
Cooling Tower
Methanol 99% over
Distillate Cooler
Steam 120°C
65°C
100°C
Reboiler
Water
Distillation column
(Atmospheric pressure)
Before
Waste heat
30°C
35°C
Applicationof Heat Pump
Methanol drainage 50%
Distillate Cooler
44°C
80°C
Reboiler
Water
Distillation column
(Vacuum pressure)
After
Heat recovery
30°C 35°C
Methanol 99% over
86°C 80°C
Heat pump
Electric Power
Hot water supply HP can be used when distillation column is decompressed.
©CRIEPI
Case 3 | Distillation Process in Dextran Production
30
Why MVR was not selected?
44°C
80°C
M
M
M
M
M
M
Compressor× 6 stages
MVR
Require a special specification compressorbecause of methanol vapor compression
Require 6 stage compressors because of high BPR→ high cost and complicated operation
86°C
Heat Pump
Lower risk of methanol flammability Use a general-purpose heat pump→ lower cost and better operability
44°C
80°C
30°C 35°C
Methanol 99% over
80°C 86°C
Heat pumpHigh BPR
(ΔT=42°C)
©CRIEPI
Case 4 | Distillation Process in Bio-ethanol Production
31
Industry Chemistry
Production Bio-ethanol
User company Hokkaido Bioethanol Co., Ltd.
Installed year 2012
Process Distillation of ethanol
Application Steam (120°C)
Contractor Japan Chemical Engineering & Machinery Co., Ltd.
HP manufacturer Kobe Steel, Ltd. (KOBELCO)
HP System SGH120 (× 5 units)Refrigerant: R245faSteam flow: 2 ton/h
Effects CO2 reduction: 43%Energy cost reduction: 54%Payback period: 3.5 years
Outline of Installation Process and Application
Feed Material Liquefaction Fermentation
Distillation Dehydration Shipping
• Sugar beet• Non-standard wheat
• Steam supply • Zeolite membrane
10% 95% 99.5%
Concentration of Ethanol
Heat Pump Distillation Column
©CRIEPI
Case 4 | Distillation Process in Bio-ethanol Production
32
Boiler
Heavy Oil
Fermentation liquid 10%
Cooling Tower
Ethanol 95%
Distillate Cooler
Steam 110°C
80°C
100°C
Residual remnant
Distillation column
(Atmospheric pressure)
Before
Waste heat
Applicationof Heat Pump
Fermentation liquid 10%
Distillate Cooler
80°C
100°C
Distillation column
(Atmospheric pressure)
After
Heat recovery
60°C 65°C
Ethanol 95%
Residual remnantElectric Power
Flash TankHeat Pump
115°C
110°C
Steam 110°C
Steam supply HP is used when distillation column is not decompressed.
©CRIEPI 33
Conclusions
©CRIEPI
Conclusions
34
Installation Situation of Industrial Heat Pumps in Japan
Installation target by the government is heating capacity of 1,673 MW by FY2030.
Heating capacity of 88.1 MW was installed before FY2016.
The most have been installed in “Food industry.”
The HP type used most often is “Circulation heating hot water supply HP.”
Effective Applications
Reduction of heat load by installation near process
‒ Leads to high COP operation by low temperature lift and self heat recovery
Simultaneous heating and cooling
‒ Applied industry: Food industry, Machinery
Mechanical vapor recompression (MVR)
‒ Applied process: Concentration, Distillation, Drying
‒ In the case of high BPR for distillation, indirect self heat recovery is selected.