COSMO OIL CO., LTD.

COSMO OIL CO., LTD.

The t rucks and buses v i t a l to d i s t r ibu t ion andtransportation use huge quantities of diesel fuel. The gasesemitted by these diesel vehicles contain sulfur oxide (SOx)and nitrogen oxide (NOx), which are produced from sulfurand nitrogen components, as well as particulate matter.These emissions contribute to serious air pollutionproblems. For this reason, the Japanese governmentestablished rules requiring that the sulfur content in dieseloil be reduced to 500 parts per million (ppm), which has ledoil companies in Japan to invest about 200 billion yen insulfur reduction facilities. However, with environmentalawareness increasing around the world, oil companies havetaken it upon themselves to set a new development targetof producing ultra-low-sulfur diesel oil with sulfur levelsunder 10 ppm.To comply with these str ict quality standards, oi l

companies sought to reduce sulfur content through the useof catalysts. However, for one company alone to developsuch a h i g h - pe r f o rmance ca t a l y s t wou ld be anoverwhelmingly demanding task. With support from NEDO,Cosmo Oil joined forces with Shimane University andKyushu University in an industry-academia collaborativeproject to demonstrate the effectiveness of adding an agentduring the catalyst production stage. Through this jointeffort, they also identified the catalyst’ s mechanism forreducing sulfur components in diesel fuel, which provided abreakthrough in the group's research and developmentefforts.As a result, the group successfully reduced sulfur levels to

under 10 ppm by tripling the catalyst’ s performance anddeveloped a new desulfurization catalyst, C-606A, whichcosts the same as conventional products. In May 2004,Cosmo Oil began using the new catalyst in four of itsrefineries, initially in its refinery in Chiba and subsequently inits refineries in Yokkaichi, Sakai, and Sakaide. Today,ultra-low-sulfur diesel oil is sold in every Cosmo Oil servicestation These ultra-low-sulfur diesel fuels greatly contributeto a cleaner environment.

November 2008

New Catalyst for Maximum Cleaning of Diesel Fuel OilNew Catalyst for Maximum Cleaning of Diesel Fuel Oil

・Development of High Performance Industrial Furnace(FY1993-FY1999)

Clean diesel fuel oil can be manufactured using C-606A catalyst (left).

Pilot plant for evaluating the desulfurization activity

Cosmo Oil’s desulfurization plant using new catalyst

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　The reason why the smell of gasoline fills the air at a gas station is simply due to the fact that liquid gasoline is gasified and is being emitted into the air. This gasified gasoline is usually referred to as “gasoline vapor”. Gasoline vapor is a type of volatile organic compound (VOC), which in turn is a type of toxic chemical substance. With regard to VOC, international efforts have been taking place to reduce the emission thereof. Even in our country as well, the revised Air Pollution Control Act has been put in effect since 2006, and emission regulations have been stipulated with regard to volatile organic compounds (VOC).　Gasoline vapor, on top of its smell, is a cause of air pollution and fires, and also leads to a loss of resources. Gasoline vapor generated in a single day at all of the gasoline stations throughout Japan is equivalent to 22 loads of large sized tanker trucks that hold 20kl each. This means that a great amount of gasoline is being released into the air without being used. If this escaping gasoline were to be used, the value of such would amount to as much as 30 billion yen per year.　With the support of the NEDO project, Tatsuno Corporation, a leading manufacturer of petrol dispensing pumps, has developed and actualized a device that liquefies and collects this gasoline vapor at the gas station. This device is anticipated to be expanded and popular ized in the creat ing of non-smel l ing , non-po l lu t ing , h igh ly sa fe and fire-preventing, and economical gas stations. As of the end of 2012, while a total of 69 units are being used, the sales of new products such as that integrating the gasoline vapor collecting device with the petrol dispensing pumps for fueling, as well as low-priced models with slightly lowered performance are being planned. Additionally, actions are being taken to develop the product in overseas markets as well.

Tatsuno Corporation

December 2012 ～ March 2013

Tatsuno Corporation

Press pump

Nozzle collecting the gasoline vapor

An Innovative Device that Prevents Leaking of Gasoline VaporAn Innovative Device that Prevents Leaking of Gasoline Vapor

・Research and Development of Toxic Chemical Substance Risk Reducing Platform Technologies / Development of Gasoline Vapor Collection Device using a Dual Membrane System (FY2006-FY2008)

The Eco Stage L liquefies and collects gasoline vapor that is generated when unloading the gasoline from a tanker truck into an underground tank.

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35

UD Trucks

UD Trucks

　Strict environmental regulations have been imposed

on diesel vehicles such as heavy duty trucks and

buses due to the large quantities of air-polluting toxic

gases they emit. To comply with these regulations, it is

essential to reduce both the particulate matter (PM)

said to have adverse effects on the human respiratory

system as well as nitrogen oxides (NOx) that cause

acid rain. Given the trade-off associated with these

two substances, as reducing the level of one increases

that of the other, development of a new exhaust gas

purification device was imperative.

　To achieve this, Nissan Diesel Motor developed a

urea-selective catalytic reduction (SCR) system, which

is based on the approach of minimizing the generation

of PM by burning fuel at high temperatures, while

selectively breaking down NOx using a purification

device so that only nitrogen gas (N2) is emitted. This

urea-SCR system requires the addition of a urea

aqueous solution, AdBlue™ (a trademark held by the

German Association of the Automotive Industry) to

ensure high-efficiency reduction reactions. However,

there are major drawbacks to using this in diesel

engines. These drawbacks include the need for

countermeasures for the change in gas components

emitted by the engine, shorter reduction reaction

periods, and infrastructures to supply the urea

aqueous solution required by the urea-SCR system.

　To address these chal lenges, Nissan Diesel

collaborated closely with its NEDO project partners

and as a result, as of March 2012 more than 47,000

Nissan Diesel heavy-duty trucks were fitted with the

urea-SCR system as standard equipment and are now

operating throughout Japan.

November 2008

Developing an Eco-Diesel Engine with Clean Exhaust GasDeveloping an Eco-Diesel Engine with Clean Exhaust Gas

・Development of High Performance Industrial Furnace (FY1993-FY1999)

AdBlue™ tank next to a diesel fuel tankThe color and size of the AdBlue™ tank filler caps differ from those of diesel fuel tank fillers.

Interior of the reduction unitThe mesh structure increases the contact area and improves reaction efficiency. NOx is removed at the surface of the mesh structure.

Urea-SCR System

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36

　Gaskets are sealing devices that are used to prevent

liquids and gases from leaking from the joints of pipes

installed in factories and power plants. Traditionally,

asbestos has been used in the product ion of

non-metallic gaskets designed for high-temperature

conditions. However, given the serious health hazards

associated with the use of this material, there is an

increasing trend toward completely discontinuing its

manufacture and use. One material that is attracting

interest as a replacement for asbestos is a material

made of exfoliated graphite and clay, which also offers

excellent heat resistance.

　The problem, however, is that gas may leak from

gaskets made of this material when the temperature

of the liquid flowing through exceeds 300℃ because

of the brittle nature of the exfoliated graphite. For

Japan Matex Co., which has been manufacturing

industrial products using exfoliated graphite, the use

of this material at high temperatures presented a huge

challenge.

　Amidst this situation, in 2006 NEDO launched the

project on Urgent Development of Fundamental

Technologies for the Practical Reduction of Asbestos

to develop measures for discontinuing the use of

asbestos. Together with the National Institute of

Advanced Industrial Science and Technology (AIST)

and other organizations selected for the project,

Japan Matex worked to accelerate research and

development by applying technologies it had acquired

through i ts own dedicated efforts as wel l as

collaborative activities with AIST in areas such as

materials development, analysis, quality assessment

and computer simulations.

　As a result of the joint project, Japan Matex was

JAPAN MATEX CO., LTD.

October 2010

able to start shipping product samples after just one

year, well ahead of the projected two-year target

shipping date. In 2007, the company launched sales of

its exfoliated graphite gaskets and had shipped more

than 46,000 gaskets by April 2011. In 2008, Japan

Matex was again selected as a member of NEDO’ s

Innovation Promotion Program. Today, the company

continues research and development efforts to

improve and refine the design of its products.

JAPAN MATEX CO., LTD.

“Clear Matex 8121ND”

Creation of a Safer Heat-resistant Material as a Replacement for AsbestosCreation of a Safer Heat-resistant Material as a Replacement for Asbestos

・Urgent Development of Fundamental Technologies for the Practical Reduction of Asbestos (FY2006),etc.

Graphite sheetAffixed to flange

Clear MatexNot affixed to flange

With conventional non-abestos gaskets, the gasket material tends to burn and stick to the pipe joint, which is very difficult to remove when replacing gaskets. With the Clear Matex exfoliated graphite gasket, burning is prevented by a coated clay membrane.

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Hokuriku Electric Power Company

Hokuriku Electric Power Company

　Used for various purposes for many years, use of asbestos is now gradually being banned due to the health risk it poses. However, many construction materials and industrial products containing asbestos are still being used, and when disposed of they are mainly buried in landfills. Thus, the safety neutralization of asbestos has become a major issue of our society.　Hokuriku Electric Power Company launched a project to develop a mobile system for on-site neutralization and disposal of insulating materials from the company's thermal power plants,to reduce risks when burying or transporting insulating materials containing asbestos and at the same time provide solutions for the difficulties currently faced in the construction of new asbestos disposal facilities , supported by NEDO, As a result, this development can be applied not only neutralizing asbestos at its own thermal plants, but one that also can be used for asbestos disposal at other large industrial facilities.　Asbestos, the fiber must be thermally processed to neutralize at temperatures above 1,500℃. By using alkaline agents, the melting temperature can be reduced to 1,050℃. Compared with melting at 1,500℃, this allows power savings of about 25% and at the same t ime provides a wider choice of furnace materials and system design methods that can be used. Because the system is mounted on a trailer that travels on public roads, Hokuriku Electric Power has also worked to resolve issues such as restrictions in trailer size and weight in accordance with the Road Transport Vehicle Act, and to determining the appropriate weight balance of the system and trailer to prevent overturning. Before using the system, the company appl ied for asbestos neutra l i zat ion certification for own three thermal power plants from the Ministry of Environment and successfully acquired certification for the plants after undergoing five

November 2011

technical screenings and other rigorous certification requirements.　Hokuriku Electric Power is now accumulating experience in the safe and stable treatment of insulating materials that contain asbestos through the use of its on-site asbestos melting and neutralization system at own certified plants. The company plans to commercialize the system in the future.(As of July. FY2012)

Melted and neutralized asbestos

On-site Processing System for Safe, Stable and Highly Efficient Neutralization of AsbestosOn-site Processing System for Safe, Stable and Highly Efficient Neutralization of Asbestos

・Urgent Development of Fundamental Technologies for the Practical Reduction of Asbestos (FY2006),etc.

Insulating material for piping. Hollow structure, bulky when packed in a bag.

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　Asbestos is a natural mineral fiber that was once

used extensively, particularly in the construction and

clothing industries, because of its outstanding heat

resistance, sound absorbency, thermal insulation

properties and wear resistance. In the 1970s and

1980s, however, the International Labor Organization

( I LO) and Wor ld Heal th Organizat ion (WHO)

announced findings that the fiber could cause cancer

and it was widely banned in Europe and the United

States. In 1975, Japan started to gradually phase its

use out, but large amounts can still be found in

buildings constructed in the mid-1970s and earlier.

　Today, as these buildings become dilapidated and

are condemned for destruction, the safe removal of

asbestos during demolition has emerged as an

increasingly important issue for the construction

industry. Through a project funded by NEDO, Taisei

Corporation began developing robots capable of

removing asbestos to reduce the risk to workers

engaged in the demolition of older buildings. Between

2006 and 2011, the company successfully developed

three robots designed for different purposes. The

company has also developed a system for recovering

asbestos-laden construction materials that have been

removed, and is now conducting on-site verification

tests.

　Once these new robots are put into use, they will

not only reduce the risk to those involved in asbestos

removal, but will also speed up such work three- to

five-fold. It is also anticipated that Taisei’s system will

reduce the disposal of waste by more than 60%. As of

April, Taisei was collaborating with asbestos removal

companies to put its robots into use as well as on a

system designed to use an existing base machine for

the robots.

TAISEI Corporation

February 2012

TAISEI Corporation

Asbestos Removal Robot Contributes to Safe and Efficient Workplace Through Remote Control and AutomationAsbestos Removal Robot Contributes to Safe and Efficient Workplace Through Remote Control and Automation

・Urgent Development of Fundamental Technologies for the Practical Reduction of Asbestos (FY2006),etc.

Asbestos-removal robot designed for use in an elevator shaft

Demonstration for stripping and removing of simulated asbestos

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Panasonic Corporation Home Appliances Company

Panasonic Corporation Home Appliances Company

　Hydrofluorocarbons (HFCs) were developed as substitutes for chlorofluorocarbons (CFCs), which had previously been thought to have no significant effects on the environment but were later implicated in the accelerated deplet ion of ozone in the Earth 's stratosphere. However, in an effort to prevent global warming, reducing the use and emissions of HFCs has become an increasing important goal as HFCs are now known to be powerful greenhouse gases that are many times more potent than carbon dioxide (CO2) in terms of global warming potential.　Panasonic Home Appliances (formerly Sanyo Corporation) is involved in the development of non-fluorinated air-conditioning systems and has long recognized the importance of using natural coolants such as CO2. In 2000, the company developed and commercially launched the Eco Cute heat pump water heater , which uses CO2 as a coolant . Though well-suited for warming applications, CO2 coolants are difficult to use in freezing/refrigeration applications. They are also particularly unsuited for use in large industrial facilities in terms of size and efficiency.　With support from NEDO, Panasonic began research and development on a CO2-based refrigeration system suitable for use in supermarket showcases. Applying its unique compressor design and other innovative technologies, the company was able to overcome challenges associated with CO2 refrigeration and develop a non-fluorinated system that offers both cooling efficiency and energy savings comparable to that of conventional CFC-alternative freezers.　Panasonic Home Appliances began selling the new CO2-based refrigeration system in September 2010. By April of this year, the system had been installed in 64 supermarkets and convenience stores throughout Japan.

December 2011

Non-Fluorinated CO2-cooled Refrigeration System for Supermarket ShowcasesNon-Fluorinated CO2-cooled Refrigeration System for Supermarket Showcases

・Development of Non-fluorinated Energy-saving Refrigeration and Air Conditioning Systems (FY2005‒FY2007),etc.

Test site: MaxValu Express Rokugodote EkimaeRefrigerator showcaseNon-fluorinated refrigeration system installed on store roof

Exhaust heat is transformed into a hot water supply by a super-cooling water heater installed between the CO2 refrigerator and showcase

The freezer showcase refrigeration system relies on exhaust heat from super-cooling CO2 refrigerators for its hot water supply.

CO2 refrigerator

CO2 super-cooling unit

Hot water tank unit

Coolant Cool and warm waterClean hot water supply

Multi-level open refrigerator showcase

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　Today, the use of fluorocarbons in air-conditioners,

refrigerators and freezers is becoming more restricted

as their emissions are one of the causes in the

depletion of the ozone layer, which absorbs harmful

u l t rav io let (UV) rays that enter our p lanet ’ s

stratosphere from outer space.

　Fluorocarbon substitutes have been developed but

are not without their own problems, one of which is

that they emit a high level of greenhouse gases.

Methods for destroying and treating HFC-23, a

particularly potent greenhouse gas, are increasingly

sought-after as a means of reducing the potential for

global warming.

　Tsukishima Kankyo Engineering addressed this

challenge through its fluorocarbon destruction system.

To destroy HFC-23, which does not decompose easily,

the system heats it to temperatures above 1,200℃

using a vortex burner and then uses cold water to

instantaneously cool it to 80℃.

　The fluorocarbon destruction system is currently in

use in Japan, South Korea, and Southeast Asia and is

already producing significant results. For example,

fluorocarbon destruct ion systems have been

responsible for 31.2% of the HFC-23 destroyed under

the Clean Development Mechanism (CDM) of the

United Nations Framework Convention on Climate

Change (UNFCCC).

Tsukishima Kankyo Engineering Ltd.

February ～ March 2012

Tsukishima Kankyo Engineering Ltd.

Destruction of HFC-23 Through Burning and CoolingDestruction of HFC-23 Through Burning and Cooling

・Development of HFC-23 Destruction Technology (FY1998‒ FY2001)

Combustion waste gashot flue gas

Downcomer tube

Cooling gas

Collectedacid

Wearplate

Hot gas is instantaneously cooled by the direct contact with the solution.

High-load combustion (vortex burner)

Fluorocarbon destruction system in operation at Asahi Glass

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Kanto Denka Kogyo Co., Ltd.

Kanto Denka Kogyo Co., Ltd.

　Semiconductors and liquid crystal displays are devic-

es indispensable to information processing and elec-

tronic devices. The cleaning process is an important

step in their manufacturing. Currently, perfluorocar-

bons (PFCs) that produce greenhouse gas emissions

of 7,000 to 23,900 times that of CO2 are being used

as a part of this cleaning process. These PFCs include

sulfur hexafluoride (SF6), hexafluoroethane (C2F6) and

octafluoropropane (C3F8).

　The amount of PFC gases emitted is small compared

to CO2, but because even minute amounts can have a

major impact on the environment, there is a great

demand for the development of cleaning gas with min-

imal greenhouse gas emissions.

　Carbonyl fluoride (COF2) is a gas that can meet this

demand. It was developed by companies such as

Kanto Denka Kogyo, which participated in NEDO’ s

project on Research and Development of Semiconduc-

tor CVD Chamber Cleaning Systems for Electronic

Device Manufacturing Using New Alternative Gases as

a Substitute for SF6, PFCs and Other Gases.

　In addition to containing elemental fluorine indis-

pensable for chemical treatment in the cleaning pro-

cess, the global warming potential (GWP) of COF2 is 1,

the same as that of CO2, which enables sharp reduc-

tions in greenhouse gas emissions. Through this NEDO

project, Kanto Denka Kogyo focused on establishing

conditions for safely using COF2, conducted continu-

ous cleaning tests with COF2 on production lines, and

verified semiconductor device performance as well as

cleaning performance.

　Prior to the project, cleaning gas development

primarily took place overseas. This project resulted in

the development of a new, eco-friendly cleaning gas in

December 2009

Japan with very low greenhouse gas emissions.

　Further reductions in the price of COF2 will play a

key role in the continued development of this applica-

tion. Kanto Denka Kogyo is striving to supply COF2 at

a lower price by optimizing operations at its dedicat-

ed plants and reassessing their conditions. Moreover,

it participates in joint research projects to establish

methods for using COF2 that are suitable for the man-

ufacturing of semiconductors, liquid crystal displays

and solar cells.

Birth of COF2: New Clean Gas for Semiconductor Manufacturing with Very Low Greenhouse Gas EffectsBirth of COF2: New Clean Gas for Semiconductor Manufacturing with Very Low Greenhouse Gas Effects

・Research and Development of Semiconductor CVD Chamber Cleaning Systems for Electronic Device Manufacturing Using New Alternative Gases as a S u b s t i t u t e f o r S F 6 , P F C s a n d O t h e r G a s e s (FY1998‒FY2002),etc.

Semiconductor manufacturing equipment used in verification tests

Global warming potential (GWP)

(SF6)

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　Materials having a history of being synthesized that

was never mass produced. When looking into the

history of development of materials in the past, there

are many substances that have taken this path.

Reasons for this vary, such as being too costly, or due

to not being able to come up with applications.

“iodinated- trifluoromethane” (CF3I) is one of these

substances. Although having been composed in the

past, it never came into the light of day.

　However, from the late 1980’s, regulations started

being imposed on use of substances such as Freon

that destroy the ozone layer, and in the late 1990’s,

regulations started being imposed on the use and

limitations of Freon substitutes and other greenhouse

effect gasses considered to cause global warming.

Tosoh F-Tech Inc., a leading manufacturer of fire

extinguishing halon, focused on this substance, and

unde r t he suppo r t o f t he NEDO p ro jec t , a

composition technology for CF3I using a vapor phase

catalyst method was developed for the first time in

the world. Later, mass production was realized as

well.

　Currently, production is taking place at an actual

plant, and the gas is domestically being used as an

etching gas for surface treatment of semiconductors

and as an air duster to blow away dust, while

overseas the gas is being used as a fire extinguishing

solution. CF3I is being considered to serve a wide

array of purposes as a Freon substitute. In the future,

starting with use as a semiconductor cleaning gas,

applications in various fields are expected to be

discovered.

　

TOSOH F-TECH INC.

February 2013

TOSOH F-TECH INC.

Mass Production of Freon/Halon Substitute with a World’s First Composition Method Mass Production of Freon/Halon Substitute with a World’s First Composition Method

・Energy Saving Freon Substituting Substance Composition Technology Development (FY2002-FY2006) (Development of Technology for Synthesizing of Substituting Substance for Etching),etc.

Tanks of CF3I manufactured by Tosoh F-Tech

Also being sold as air-dusters that blow away dust from precision machines

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KAMI ELECTRONICS IND CO., LTD.

KAMI ELECTRONICS IND CO., LTD.

　Industrial products such as automobile dashboard

components, digital cameras and mobile phones

require an excellent design and quality to satisfy con-

sumer preferences. One processing technique that

contributes to a product’s functionality is coating appli-

cation. Coatings, such as the paint that gives a prod-

uct its color, require the inclusion of organic solvents

that provide a good finish when diluted.

　Organic solvents, however, contain substances that

are toxic to the human body and ecosystem, and they

can also contribute to air pollution problems such as

photochemical smog. In Japan, chemical substances

that pose a high risk to the human body and environ-

ment, such as volatile organic compounds (VOCs), are

highly regulated to ensure their use is managed appro-

priately and that emissions are reduced.

　Taking into account the needs of society, Kami Elec-

tronic Industry, a leader in component coating tech-

niques headquartered in Miyazaki Prefecture, is com-

mitted to developing innovative coating processes

that do not use VOCs. With the support of NEDO and

the cooperation of the National Institute of Advanced

Industrial Science and Technology (AIST) and the

Industrial Technology Institute, Miyagi Prefectural Gov-

ernment (ITIM), the company has developed a coating

method that is capable of diluting and spraying paint

by using supercritical carbon dioxide (CO2) instead of

organic solvents, thereby reducing the amount of VOC

used to one-third of that in conventional methods.

Kami Electronic Industry is now using this method in

its plants. Several leading automobile interior compo-

nent manufacturers have also incorporated it into their

coating systems as well.

December 2011

From Tohoku to the World! Innovative Coating Process Reduces Use of Harmful ChemicalsFrom Tohoku to the World! Innovative Coating Process Reduces Use of Harmful Chemicals

・Development of Fundamental Technologies for Risk Reduction of Hazardous Chemical Substances/Research and Development of Innovative Coating Devices (FY2007‒FY2008)

Coating robot

Coating (1 pts.wt.)

Coating (1 pts.wt.)

Coating polymer(0.5 pts.wt.)

True solvent(0.5 pts.wt.)

Coating polymer(0.5 pts.wt.)

True solvent(0.5 pts.wt.)

Diluting solvent(1.0 pts.wt.)

VOC ingredient (VOC 0.5 pts.wt. to coating 1 pts.wt.)

To reduce the coating to a sprayable viscosity, the same amounts of diluting solvent and paint are used.

Conventional method (organic solvent coating)

Proposed method (CO2 device)

VOC ingredient(VOC 0.5 pts.wt. to coating 1 pts.wt.)

VOC use reduced to one-thirdof that in conventional methods

Diluted solvent can be replaced with just a small amount of CO2

Reduction effects of VOC used in supercritical CO2 coating method

Coated automobile interior component

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　The high performance of insulating coating films for electronic parts and wiring is becoming an increasingly important requirement for achieving compact, light-weight and reliable (long life) features in electronic parts. Generally, epoxy resin is widely used for this insulating coating film. However, the method by which the epoxy resin is produced has two problems. The first problem is that this method involves the use of phenol, which has a negative impact on the environ-ment. The second is that it also incorporates halide. As a result, the insulating protective film that is the final product will inevitably contain organic chlorine compounds, impurities that may contribute to the deterioration of the film’s quality.　One means of resolving these environmental and quality problems is Showa Denko’ s thermosetting solder resist. Through NEDO projects, which applied techniques developed by Professor Ryoji Noyori (of Nagoya University at the time) and other researchers, Showa Denko worked jointly with the National Insti-tute of Advanced Industrial Science and Technology (AIST) to develop a method for deriving epoxy com-pounds through the direct oxidation of olefin com-pounds using hydrogen peroxide as a substitute for phenol and halogen compounds.　Through the repeated review of trial production efforts and evaluation of test results in this industry-ac-ademia collaboration, a new insulating coating film with excellent long-term insulating performance was developed. Improving the catalyst and refining the process played a key role in scaling up manufacturing and reducing costs, and the group was able to pro-duce favorable results in a short period of time. Since 2007, when the first products incorporating this new insulating film were launched, the technology has been applied in a number liquid crystal panel manu-facturing processes.

Showa Denko K.K.

December 2010

Showa Denko K.K.

Development of a High-performance Insulating Coating ResinDevelopment of a High-performance Insulating Coating Resin

Halogen-free epoxy resin

・Development of Fundamental Technologies for Risk Reduct ion o f Hazardous Chemica l Substances Development of Resist Materials Using Non-phenol Resin Materials (FY2004‒FY2006)

Raw material

Hydrogen peroxide

Useful substance

Water

Metal complexes

Quaternary ammoniumhydrogen salts Phosphonic acids

Discovery of new catalysts(1996)

Insulating coating filmCopper wiring

Base film

Cross-section of printed wiring board Copper wiring (brown) is formed over base film (purple), and covered with insulating coating film (green)

Epoxidation reaction of olefin using hydrogen peroxide

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KOKONOE ELECTRIC CO., LTD. / Ritsumeikan University

KOKONOE ELECTRIC CO., LTD. Ritsumeikan University

Rare earth elements are natural resources that are indispensable for producing technologically sophisticated products. Because they only occur in certain countries, there is a risk that the supply of them may be interrupted or decrease if a diplomatic problem or other unordinary situation arises. Cerium, which is one of the rare earth elements, is a material that has been used in Japan for many years for glass surface grinding and other purposes. However, the sharp rises in the price of cerium in 2010 to 2011, during which the prices of other rare earth elements also surged, hurt the glass grinding industry. On the other hand, Ritsumeikan University and KOKONOE ELECTRIC CO.,LTD. which is a grinding tool manufacturer based in Kawasaki C i t y o f K a n a g awa P r e f e c t u r e , h a d f o rm ed a j o i n t industry-academia team before this and participated in the “Development of Substitute Materials for Rare Metals” project of NEDO, endeavored to develop a technology to dramatically reduce the consumption of cerium in glass grinding under the project and succeeded in establishing that technology and commercializing a new grinding tool (grinding pads). The newly developed grinding pad made it possible to reduce the consumption of cerium by one half. This grinding pad was commercialized in 2012, and was adopted by more than 10 companies in a little more than one year from the start of sale. It is expected that more companies will adopt the grinding pad in the future.

August 2013

A Technology that Halves the Consumption of the Rare Earth Element that Is Indispensable for Glass GrindingA Technology that Halves the Consumption of the Rare Earth Element that Is Indispensable for Glass Grinding

“Rare Metal Subst i tute Mater ia ls Development Project - Development of Technologies to Reduce the Amount of Cerium Used for Precision Grinding and the Development of Substitute Materials” (FY2009-2012)

Grinding equipment with an epoxy pad attached

Grinding pads produced by KOKONOE ELECTRIC CO., LTD. - There are more than 10 epoxy pads that differ in thickness, hardness, density, etc. and more than 10 epoxy-urethane pads that differ in thickness, hardness and density, etc. The customer can choose the most suitable pad for the purpose from among these pads.

Large epoxy grinding pad with a diameter of 1200mm(Professor Tani (left) and Mr. Nomura, head of the development staff of KOKONOE ELECTRIC CO.,LTD. (right))

Glass grinding method - The grinding pad holds the grinding material (abrasive grains) and grinds the glass surface.

Work piecesGrinding material (abrasive grains)

Grinding pads

Surface plate

Grinding pad

Glass work piece

Compressing

Slurry (grinding liquid)

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　In cities throughout Japan, many of the buildings that were built during the period of high economic growth are reaching their final years of endurance. It is not rare that these buildings do not meet the earth-quake resistance standards, and rebuilding is being hurried. Additionally, according to the “Construction Recycling Act”, dismantling operators are obligated to separate construction waste at deconstruction sites and recycle the separated materials. The, separating process is mainly done manually, and is becoming an issue in terms of efficiency and ensuring safety.　From such social background, NEDO has imple-mented the research and development project for a “Construction Waste Processing Robot System” capa-ble of safely and efficiently dismantling buildings and separating the waste thereof. The project took place in 2006-2010, and as a result, Hitachi Construction Machinery Co., Ltd. developed the “ASTACO NEO”, a construction machine having two arms, and started the sales of this in September, 2012. The two arms are asymmetrical, and are characterized in that the right arm operates as the main arm while the left arm acts as an assisting arm. A 10-13 ton attachment designed for excavators can be mounted on the end of the right arm, while the left arm is capable of being equipped with a 4 ton attachment. The array of attachments needs to grab objects with a “grappler”, cut steel frames, etc. with a “cutter”, crush concrete or asphalt with a “pressurized crusher”, and carry gravel or waste with a “bucket”, and these can be interchanged according to needs.　Prior to sales, the machine was active in Mina-mi-Sanrikucho and the city of Ishinomaki in Miyagi Pre-fecture, both of which are affected regions of the Great East Japan Earthquake, and was able to gain an operation record. The machine is scheduled to con-tinue being active in dismantling work of buildings and at scrap processing sites, etc.

December 2012

Hitachi Construction Machinery Co., LTD.

Dual-Arm Construction Machinery, Expected to be Active in Sites of Building DeconstructionDual-Arm Construction Machinery, Expected to be Active in Sites of Building Deconstruction

・“Strategic Advanced Elemental Robot Technology 　Development” Project (FY2006-FY2010)

In a dual-arm machine where one arm crushes or excavates while the other arm supports, the loads on each of the arms greatly differ. (photo taken of a proto type)

A cargo container drifted by the tsunami and blocking a road in the city was disassembled and separated on the spot to be transported. (Ishinomaki City)

Metal scraps from construction structures and foundations complicatedly intertwined with each other were finely cut and separated to be transported. (Minami-Sanrikucho)

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47

Hitachi Construction Machinery Co., LTD.Hitachi Construction Machinery Co., LTD.

JFE Engineering Corporation

JFE Engineering Corporation

　The greater part of the municipal waste in Japan is treat-ed through the use of stoker furnaces, where waste is placed on fire grates and burned. In response to the need for waste incinerators with higher energy recovery efficien-cy and lower pollution levels, JFE Engineering Corporation developed a new type of stoker furnace.　The new stoker furnace combines a combustion system capable of stable combustion through the equalization of air blowing in, a furnace shape that effectively mixes unburned and burned gases produced during the incinera-tion process to reduce the discharge of toxic gases and control technology that achieves stable combustion via a fuzzy control system.　The company has also completed development of its Hyper 21 Stoker System as part of the Research and Devel-opment on Advanced High-temperature Air Combustion Control Technology by combining high-temperature air blow and exhaust gas recirculation technologies.　To realize high-efficiency energy recovery, it is important to reduce the air ratio. However, if the value is too small, incomplete combustion occurs, resulting in the discharge of a considerable amount of toxic gases. With the new technology that has been developed, blowing in high-tem-perature air increases the stability of combustion at low-air ratios, thereby minimizing the production of toxic gases.　In April 2009, the Kunisaki Clean Center was completed in the eastern part of Hyogo Prefecture and the Hyper 21 Stoker System was put to practical use for the first time at the facility. “We have adopted stringent, high-level environ-mental standards, in view of standards required by munici-pal governments throughout Japan and in Europe,” says Tsunekazu Moriyoshi of JFE Engineering. He added, “Our new technologies will enable us to achieve our objective of adhering to these standards.”　Today, the Hyper 21 Stoker System is currently in opera-tion or under construction in ten plants in Japan. By evalu-ating feedback on the actual performance of these furnac-es, JFE Engineering will continue its efforts to develop even more efficient and cleaner waste disposal techniques.

March 2009

Achieving More Efficient, Cleaner Waste Incineration with New TechnologyAchieving More Efficient, Cleaner Waste Incineration with New Technology

・Re se a r c h a nd De v e l o pmen t o n Ad v a n c ed High-temperature Air Combustion Control Technology (FY1999‒FY2003)

Kunisaki Clean Center, the first facility to install the Hyper 21 Stoker SystemTwo furnaces are able to treat 235 tons of waste per day. Recovered heat from furnace is used to generate power and heat water.

Control room at the Kunisaki Clean Center

Inner wall of a furnace

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48

Coal is an inexpensive fuel, and the amount of its minablereserve is larger than the amount of minable reserve of anyother fossil fuel. In addition, coal is present in many countriesaround the world unlike oil, natural gas, etc., which are presentonly in certain countries. On the other hand, coal emits moreCO2 than any other fossil fuel when burned and contains largeamounts of environmentally hazardous substances such assulfur and ash.Because of these facts, efforts to develop and put into

practical use a next-generation coal-fired thermal powergeneration system with smaller coal consumption and higherpower generation efficiency than existing coal-fired thermalpower generation systems (which is called the “IntegratedCoal Gasification Combined Cycle (IGCC)”) have beenpursued using technologies of MITSUBISHI HITACHI POWERSYSTEMS, LTD. (MHPS; the company name at the time wasMitsubishi Heavy Industries, Ltd.) and making use of the NEDOproject and other projects, with electric power companiesleading the research and development.The development of the IGCC technology started in 1983

with experiments conducted at the Central Research Instituteof Electric Power Industry using 2-ton/day basic experimentequipment. In 1986, a 200-ton/day pilot plant was constructedon the premises of the Nakoso Power Station (located in IwakiCity of Fukushima Prefecture) of JOBAN JOINT POWER CO.,LTD. Within the project of NEDO. In 1991, research on theoperation of the pilot plant using the plant was started. Theresearch encountered many problems in the beginning, butultimately 789-hour continuous operation was achieved in1996, the year in which the project was completed.After completion of the project, various tests for realizing a

demonstration plant were conducted at the ComprehensiveIGCC Test Facility in the Nagasaki Research Institute ofMitsubishi Heavy Industries, Ltd. As a result, a 250,000kW-classdemonstration plant (owned by Clean Coal Power R&D Co.,L T D . ) w a s c o n s t r u c t e d o n t h e p r em i s e s o f t h eabove-mentioned Nakoso Power Station. The demonstrationplant achieved power generation efficiency on par with that ofstate-of-the-art coal-fired thermal power stations. Thereafterthe plant was taken over by JOBAN JOINT POWER CO., LTD.,and, started operation as a commercial plant on June 30,2013. In December 2013, the plant demonstrated its highreliability by achieving 3917-hour continuous operation, whichset the world record for IGCC.

MITSUBISHI HITACHI POWER SYSTEMS, LTD. JOBAN JOINT POWER CO., LTD.

December 2012

This success showed that it was possible to achievecoal-fired thermal power plants whose coal consumption isabout 20% less than that of traditional coal-fired thermalpower plants and whose power generation efficiency is 48 to50% ( in terms of LHV at the upstream end of powert r ansm i s s i on ) . Cu r ren t l y , a p l an to cons t r uc t two500,000kW-class high-efficiency demonstration plants is beingmade as part of the project for establishing power sources forhelping Fukushima recover from the effects of the earthquake(The two demonstration plants will be put into operation in theearly 2020s).

MITSUBISHI HITACHI POWER SYSTEMS, LTD. / JOBAN JOINT POWER CO., LTD.

Achieving Higher Efficiency by Gasifying Coal - “IntegratedCoal Gasification Combined Cycle (IGCC)”Achieving Higher Efficiency by Gasifying Coal - “IntegratedCoal Gasification Combined Cycle (IGCC)”

・Project for the Development of an Entrained Bed CoalGasification Power Generation Plant (FY1986-1996) ,etc.

The gasification furnace viewed from below

The demonstration plant that set the world record in continuous IGCC operation (Unit 10 of the Nakoso Power Station of JOBAN JOINT POWER CO., LTD.)

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EARTHTECHNICA Co., Ltd. / SEKISHOUTEN Co., Ltd.

EARTHTECHNICA Co., Ltd. SEKISHOUTEN Co., Ltd.

For production industries such as papermaking,steelmaking and cement industries, large burning facilitiesare indispensable. At those burning facilities, largeamounts of fossil fuels are being consumed every day.However, a new fuel that can replace fossil fuels has beenwaited for a long time, because of the experience ofresource shortages caused by the two oil crises in the1970s, the present need to alleviate global warming, andthe recent high instability of market prices of resources.One new fuel that is attracting attention as a candidate forsuch a new fuel is “Refuse Paper and Plastic Fuel (RPF).”RPF is a solid fuel produced from such materials as

difficult-to-recycle waste laminated paper coated withplastics and waste plastics that will not be decomposedby the action of the natural world after burial. RPF hasmany advantages over coal including the lower price andthe lower environmental impact in terms of the amount ofCO2 emitted (the amount of CO2 emitted by RPF is twothirds the amount of CO2 emitted by coal for the samecalorific value). For this reason, the number of companiesthat produce and sell RPF has exceeded 200, and RPF istaking root as a substitute for fossil fuels for industrialproduction. In January 2010, a JIS Standard for RPF as anindustrial product was established.The person who devised RPF is Katsushiro Seki, who is

the president of SEKISHOUTEN Co., Ltd. and the currentChairman of the Japan RPF Associat ion. From hisexperience of operating the resource collection companyhe inherited from his parents, Mr. Seki had felt that it wasvery important for Japan to dramatically reduce theamounts of wastes disposed of at final disposal plants anddevelop substitutes for fossil fuels. He had decided todevelop and popularize a recycle fuel that meets bothchallenges at the same time, and had been strivingtowards that goal.Then, the Crushing and Grinding Equipment Division of

Kawasaki Heavy Industries, Ltd. recognized the importanceof his undertaking, and had started working with himtoward putting RPF into practical use.During the period from FY1998 to 2001, the Division

participated in the “Research and Development toDevelop Revolutionary Environmentally-friendly EnergyTechnologies with Immediate Effects - Development of

January 2014

Technologies to Recycle Flammable Wastes intoFuels” project of NEDO. Under the project, the Divisionconstructed a demonstration plant on the premises of theYachiyo Factory of Kawasaki Heavy Industries, Ltd.,conducted tests using the demonstration plant toaccumulate technical data and knowledge and improvedthe equipment based on the obta ined data andknowledge, thereby laying the foundation for thepopularization of RPF. By 2012, RPF grew and becamepopular to the extent where an energy market with annualproduction of 1.1 million tons and annual sales of 23billion yen had been formed.

RPF, the new recycle solid fuel

Development of “RPF,” an Inexpensive New Fuel thatEmits a Smaller Amount of CO2 than Fossil FuelsDevelopment of “RPF,” an Inexpensive New Fuel thatEmits a Smaller Amount of CO2 than Fossil Fuels

・Research and Development to Develop RevolutionaryEnvironmentally-friendly Energy Technologies with ImmediateEffects - Development of Technologies to Recycle FlammableWastes into Fuels (FY1998-2001)

CO2 Emission Reduction Effect of RPF

CO2 emission reductions

The case where coal is burned as the fuel using boilers and waste plastics are disposed of by incineration

Total

Disposal of waste plastics by incineration

Procurement of coal Use of coal (burning)

The case where RPF is used as the substitute fuel for coal

Total

Production of RPF Use of RPF (burning)Reduction per 1 ton of RPF: 2.062+-CO2

Reduction for waste plastics (The reduction for waste paper is zero.)

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January 2015 February 2015

Recycling Rate of Four Major Home Appliance Items:Approximately 84% of More Than 170 Million Disposedof Home Appliances

Japan has become an affluent country due to h igheconomic growth af ter the Second Wor ld War. In the1990s , however , i t began to face problems such as ashortage of landfills , result ing in an increase of i l legaldumping. In particular, the disposal of used large homeapp l i ances ( i . e . , TVs , a i r cond i t ioner s , r e f r ige ra to r s ,washing machines) using landfills became a major socialproblem.NEDO therefore implemented the Development andDemonstrat ion of a Home Appl iance Recycl ing P lant/Development of Cryogenic Crushing Technology for WasteIndustrial Products Utilizing Unused Energy (Cold Energy)project (FY1992‒FY1997) as part of its effort to construct ahome appliance recycling system. Hitachi, Ltd., which hadbeen engaged in the development of recycling technologyfor waste industrial products, participated in the projectand worked to develop technologies that form the basisfo r home app l i ance recyc l ing p l an t s . These inc ludetechnologies for d isassembl ing, crushing, separat ing,and reus ing used home appl iances as wel l as systemdemonstration and hazardous waste prevention.The resu l t s o f research and deve lopment f rom th isproject contributed to the establishment of a new homeappliance recycling system under the Act on Recycling ofSpecified Kinds of Home Appliances enacted in 2001. Arecycling system unique to Japan (in which consumers bearrecycling costs, retailers accept used home appliances, andmanufacturers recycle them) was put into practice. Today,49 home appliance recycling facilities operate nationwide.The recyc l ing ra te o f used l a rge home app l iances i sapproximately 84%, and the cumulative number of disposedof home appliances has reached 170 million since 2001. Asa result, the final disposal volume, which was 10,000 metrictons when the Act on Recycling of Specified Kinds of HomeAppliances was enacted in 2001, decreased to 5,000 tonsin FY2012, thereby contributing to a sustainable recycling-oriented society.

Recycling 15,000 Tons Per Year of Waste Plastic Into a Blast Furnace Reducing Agent Reduces CO2 Emissions by 42,000 Tons

In Japan, the Waste Management and Public Cleansing Act was enacted in 1970, andsince then waste has been disposed of in accordance with the act. In the middle of the 1980s, however, a landfill shortage, hazardous substances contained in waste, and other waste problems grew to become serious issues. Since it was difficult to combat the situation by waste disposal regulations alone, the Act on the Promotion of Effective Utilization of Resources was enacted in 1991 to promote recycling. This act stipulates the types of businesses in which recycling should be promoted and the items to be recycled. It also prescribes that recycling be promoted by the autonomous efforts of each industry assisted by administrative guidance. The Waste Management and Public Cleansing Act was significantly revised in the same year, and the Basic Environment Act was enacted in 1993 as a basic law to deal with all environmental issues, including waste and recycling problems. Subsequently, the Act on the Promotion of Sorted Collection and Recycling of Containers and Packaging was enacted in 1995 and was fully enforced in April 2000. Also, the Act on Recycling of Specified Kinds of Home Appliances was enacted in 1996 and fully enforced in April 2001.In addition to its activities in the energy field, NEDO established a framework for research and development of industrial technologies in 1988. Since then, it has worked to develop technologies to reduce environmentally harmful substances and dispose of and recycle waste, and has helped companies to develop technologies and introduce equipment for improving energy efficiency and reducing CO2 emissions. In particular, the effective use of waste plastic is a major issue. Domestic plastic production has exceeded 12 million tons per year since 1990, while domestic plastic consumption has been more than 10 million tons per year over the same period. As a result, the amount of waste plastic has been nearly 10 million tons per year since 1988. It is also important to improve energy efficiency in manufacturing, where a large amount of energy is consumed, in order to improve competitiveness and reduce CO2 emissions.NKK Corporation, the predecessor of JFE Steel, developed technology to inject waste plastic as a reducing agent into a blast furnace as a way to effectively use the growing amount of waste. The technology was put into practical use in 1996. In 2000, it started to use plastic containers and packaging instead of industrial waste plastic made of mixed materials as a blast furnace reducing agent. After this, technology using a blast furnace reducing agent was further developed into technology for manufacturing pulverized plastic, which is highly reactive in a blast furnace, by heating and melting waste plastic before dechlorinating, cooling, and solidifying it. An advanced plastic recycling (APR) plant was constructed in 2007 with financial support from NEDO and it has been in operation since then. This contributes to reducing both the consumption of coal as a reductant and CO2emissions, per unit weight, in pig iron manufacturing.

Development and Demonstration of a Home Appliance Recycling Plant/Development ofCryogenic Crushing Technology for WasteIndustrial Products Utilizing Unused Energy (Cold Energy)

Hitachi, Ltd.Tokyo Eco Recycle Co.,Ltd.

JFE Steel Corporation

Magnetic separator that sorts out iron using magnetic force(Photo courtesy of Tokyo Eco Recycle Co., Ltd.)

Melted and mixed waste plastic is rapidly cooled and sent to a coarse crusher

Inside the APR plant, pulverized waste plastic is pushed out of a pipe

Pulverized waste plastic

Eddy current sorter that collects nonferrous metals(Photo courtesy of Tokyo Eco Recycle Co., Ltd.)

Nonferrous metals and plastics collected after variousprocesses (Photo courtesy of Tokyo Eco Recycle Co., Ltd.)

Recycling of Waste Plastic Reduces CO2 Emissions in a Blast Furnace. Pulverization Further Improves Efficiency

Construction of a New White Goods Recycling System inCollaboration with Local Governments and Manufacturers

Development of Technology to Recycle Waste P last ic Into a B last Furnace Reducing Agent

January 2015 February 2015

Recycling Rate of Four Major Home Appliance Items: Approximately 84% of More Than 170 Million Disposedof Home Appliances

Japan has become an affluent country due to h igh economic growth af ter the Second Wor ld War. In the 1990s , however , i t began to face problems such as a shortage of landfills , result ing in an increase of i l legal dumping. In particular, the disposal of used large home app l i ances ( i . e . , TVs , a i r cond i t ioner s , r e f r ige ra to r s ,washing machines) using landfills became a major socialproblem.NEDO therefore implemented the Development and Demonstrat ion of a Home Appl iance Recycl ing P lant/Development of Cryogenic Crushing Technology for Waste Industrial Products Utilizing Unused Energy (Cold Energy)project (FY1992‒FY1997) as part of its effort to construct a home appliance recycling system. Hitachi, Ltd., which had been engaged in the development of recycling technology for waste industrial products, participated in the project and worked to develop technologies that form the basis fo r home app l i ance recyc l ing p l an t s . These inc lude technologies for d isassembl ing, crushing, separat ing, and reus ing used home appl iances as wel l as system demonstration and hazardous waste prevention. The resu l t s o f research and deve lopment f rom th is project contributed to the establishment of a new home appliance recycling system under the Act on Recycling of Specified Kinds of Home Appliances enacted in 2001. A recycling system unique to Japan (in which consumers bear recycling costs, retailers accept used home appliances, and manufacturers recycle them) was put into practice. Today, 49 home appliance recycling facilities operate nationwide. The recyc l ing ra te o f used l a rge home app l iances i s approximately 84%, and the cumulative number of disposed of home appliances has reached 170 million since 2001. As a result, the final disposal volume, which was 10,000 metric tons when the Act on Recycling of Specified Kinds of Home Appliances was enacted in 2001, decreased to 5,000 tons in FY2012, thereby contributing to a sustainable recycling-oriented society.

Recycling 15,000 Tons Per Year of Waste Plastic Into a BlastFurnace Reducing Agent Reduces CO2 Emissions by 42,000 Tons

In Japan, the Waste Management and Public Cleansing Act was enacted in 1970, and since then waste has been disposed of in accordance with the act. In the middle of the 1980s, however, a landfill shortage, hazardous substances contained in waste, and other waste problems grew to become serious issues. Since it was difficult to combat the situation by waste disposal regulations alone, the Act on the Promotion of Effective Utilization of Resources was enacted in 1991 to promote recycling. This act stipulates the types of businesses in which recycling should be promoted and the items to be recycled. It also prescribes that recycling be promoted by the autonomous efforts of each industry assisted by administrative guidance. The Waste Management and Public Cleansing Act was significantly revised in the same year, and the Basic Environment Act was enacted in 1993 as a basic law to deal with all environmental issues, including waste and recycling problems. Subsequently, the Act on the Promotion of Sorted Collection and Recycling of Containers and Packaging was enacted in 1995 and was fully enforced in April 2000. Also, the Act on Recycling of Specified Kinds of Home Appliances was enacted in 1996 and fully enforced in April 2001.In addition to its activities in the energy field, NEDO established a framework for research and development of industrial technologies in 1988. Since then, it has worked to develop technologies to reduce environmentally harmful substances and dispose of and recycle waste, and has helped companies to develop technologies and introduce equipment for improving energy efficiency and reducing CO2 emissions. In particular, the effective use of waste plastic is a major issue. Domestic plastic production has exceeded 12 million tons per year since 1990, while domestic plastic consumption has been more than 10 million tons per year over the same period. As a result, the amount of waste plastic has been nearly 10 million tons per year since 1988. It is also important to improve energy efficiency in manufacturing, where a large amount of energy is consumed, in order to improve competitiveness and reduce CO2 emissions.NKK Corporation, the predecessor of JFE Steel, developed technology to inject waste plastic as a reducing agent into a blast furnace as a way to effectively use the growing amount of waste. The technology was put into practical use in 1996. In 2000, it started to use plastic containers and packaging instead of industrial waste plastic made of mixed materials as a blast furnace reducing agent. After this, technology using a blast furnace reducing agent was further developed into technology for manufacturing pulverized plastic, which is highly reactive in a blast furnace, by heating and melting waste plastic before dechlorinating, cooling, and solidifying it. An advanced plastic recycling (APR) plant was constructed in 2007 with financial support from NEDO and it has been in operation since then. This contributes to reducing both the consumption of coal as a reductant and CO2 emissions, per unit weight, in pig iron manufacturing.

Development and Demonstration of a Home Appliance Recycling Plant/Development of Cryogenic Crushing Technology for Waste Industrial Products Utilizing Unused Energy (Cold Energy)

Hitachi, Ltd.Tokyo Eco Recycle Co.,Ltd.

JFE Steel Corporation

Magnetic separator that sorts out iron using magnetic force (Photo courtesy of Tokyo Eco Recycle Co., Ltd.)

Melted and mixed waste plastic is rapidly cooled and sent to a coarse crusher

Inside the APR plant, pulverized waste plastic ispushed out of a pipe

Pulverized waste plastic

Eddy current sorter that collects nonferrous metals (Photo courtesy of Tokyo Eco Recycle Co., Ltd.)

Nonferrous metals and plastics collected after various processes (Photo courtesy of Tokyo Eco Recycle Co., Ltd.)

Recycling of Waste Plastic Reduces CO2 Emissions in a BlastFurnace. Pulverization Further Improves Efficiency

Construction of a New White Goods Recycling System in Collaboration with Local Governments and Manufacturers

Development of Technology to RecycleWaste P last ic Into a B last FurnaceReducing Agent

With finite freshwater resources available, competition is intensifying in the water treatment business worldwide. Although Japan has led the global seawater desalination market with its membrane technolo-gies, it has lagged behind other coun-tries in the water treatment systems market. In this project, an environ-mentally friendly, energy-saving water treatment system was devel-oped and put into practical applica-tion based on the novel idea of integrating seawater desalination with sewage treatment. A demon-stration project in South Africa has already started.

Striving to reduce costs and salinity control of RO brine

In the Middle East, Africa, and other arid regions, seawater desalination systems are nothing new, but they face two major problems. The first problem is high operating costs, because reverse osmosis (RO) mem-brane filtration, which is used to separate permeate water into fresh-water and brine to be discharged into the ocean, involves high power costs to pump seawater through the RO membrane at high pressure. The second problem is the high salinity of

brine that is discharged into the ocean after RO membrane filtration, which eventually damages ecosys-tems in the surrounding waters. To solve these problems, NEDO promoted the development of an integrated seawater desalination and sewage reuse system. Combining seawater desalination with sewage membrane treatment, this system utilizes concentrated water from a sewage RO system in a seawater RO system, which in turn halves the pressure of water that is fed to the seawater RO membrane and there-fore reduces power costs. Further-more, the dilution of seawater that is pumped through the RO membrane reduces the salinity of brine that is discharged into the ocean to the same level as seawater. Aiming to utilize this system to jump-start Japan’s lagging water treatment business, Japanese companies estab-lished the Global Water Recycling and Reuse Solution Technology Research Association (GWSTA) and launched a system demonstration project.

Addressing membrane fouling and entering the global market

A demonstration plant was estab-lished near a seaside sewage treat-ment plant in Kitakyushu City, Fukuo-ka Prefecture. One of the main challenges faced during the project was membrane fouling. In the first year, quick fouling hampered stable operation of the plant, forcing the project participants to determine whether it was caused by inorganic matter derived from seawater or organic matter derived from sewage. They found that bacteria derived from the seawater thrived on nutri-ents in treated sewage water, and solved the problem by using a disin-fectant. As a result, a continuous supply of reclaimed water, which was stable in quality and quantity, was supplied to Kyushu Electric Power Company’s Shin Kokura plant for two and a half years beginning from April 2011. This achievement drew the attention of overseas parties involved in water treatment, leading to the launch of an international demon-stration project. The value-added Japanese water treatment system that developed from novel ideas—ideas that only latecomers to the market can come up with—is expect-ed to be introduced and expand into markets outside Japan.(Interview: September 2017)

Overall process of the integrated seawater desalination and sewage reuse system (data courtesy of GWSTA)

Sewage before treatment (left), water after membrane

bioreactor treatment (right), and final product water in the

integrated membrane system (middle)

Reverse osmosis membrane for sewage treatment

Seawater intake on Kanmon Straits

Water treatment system for cost reduction and salinity control of RO brine

Ongoing utilization of seawater and sewage: the underlying concept of the system

Achieving international recognition of demonstration project results

10 11SUCCESS STORIESNEDO PROJECT SUCCESS STORIES 2018

Seawater dilutionPower reduction

Reduction in quantity of pre-treatment water Concentrated water

Reduction of salt concentration to seawater level

Low-pressure pump

Medium pressure pump

Sewage1500 m3/d

1400 m3/d

400 m3/d

MBR Sewage RO

Kyushu Electric Power Company

boiler water

Seawater

Reclaimed water

400 m3/dSewage RO-concentrated water

ChloramineUF Seawater RO

Low cost, energy savings

Reduction in load on the ecosystem

Water Saving and Environmentally-Friendly Water Recycling ProjectGlobal Water Recycling and Reuse Solution Technology Research Association (GWSTA)

Resolution of Global Environmental ProblemsSeawater reverse osmosis membrane

at Water Plaza Kitakyushu

Novel Ideas: Producing a Game-Changer Amid Intensifying Competition for Water Resources