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


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


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?


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


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


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


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


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


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]


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


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


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


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


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

[email protected]

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