Energy Conservation Development / Energy Use Rationalization Technology Actualization Development / Size-Reducing Development of A

March 2013

DENSO CORPORATION

・IEnergy Use Rationalization Technology Strategic Energy Conservation Development / Energy Use Rationalization Technology Actualization Development / Size-Reducing Development of a

CO2 Heat Pump Hot-Water Supply System using Ejector Technology (FY2005-FY2007) Residential Heat Pumps ‒ Contributing to Expanding the Market for EcoCute

Reduction of energy consumed domestically is one of the important issues in measures against global

warming including CO2 reduction. In the supply of hot-water, accounting for approximately 30% of the energy consumed domestically, it is believed that installing a heat-pump method EcoCute unit has a great eﬀect on energy conservation. EcoCute units, which have widely spread since 2005, have been aiming to reach a total number of 5.2 million units by 2010. However, an EcoCute equipped with a large volume hot-water storage tank requires a large space in which to be installed, and this had been an issue stalling popularization in urban areas. Fin of heat exchanger Towards promoting the popularization of heat pump hot-water supply systems, NEDO has implemented a project called“Energy Use Rationalization Technology Strategic Development”. Denso Corporation, who was

the ﬁrst to create a CO2 coolant heat pump powered EcoCute system, continued making eﬀorts in reducing

the size of CO2 heat pump hot-water supply systems by taking advantage of elemental technologies acquired through the development of such as heat exchangers for vehicles. After ﬁnishing the project, a space-saving EcoCute, integrating the hot-water storage tank into a single The installed heat exchanger, an important component that gathers heat within the air to create body with the heat pump unit developed as the hot-water. accumulated result of studies from the project, has been put on the market. Energy conservation and improvement of eﬃciency is realized by incorporating each of the elemental technologies onto existing models. Through OEM production for major hot-water supply system manufacturers, the system is being sold throughout Japan. EcoCute is also being sold by other household electronic appliance manufacturers, and as of August, 2011, total sales have exceeded 3 million units. DENSO CORPORATION

20 July 2013

Mazda Motor Corporation ・General Technological Development of Innovative Energy Conservation Next-generation Low-emission Vehicles (FY2004-2008)

Clean Diesel Engine with the World’s Highest Level Fuel Eﬃciency and Environmental Performance

Diesel engines are capable of eﬃciently converting burning energy into driving force and are superior to gasoline engines in the fuel eﬃciency performance. In Japan, hybrid vehicles are currently attracting attention for their high environmental performance including the performance

relating to the exhaust gas, energy saving and CO2 emissions reductions. In Europe, however, diesel engine vehicles are very popular because of their high fuel eﬃciency performance. It is said that one out of every two vehicles in Europe is a diesel engine vehicle. On the other hand, traditional diesel engines emit larger amounts of air pollutants such as NOx (nitrogen oxides) and

PM (particulate matters such as soot) than gasoline engines, The piston head part of“SKYACTIV-D” - the shape with the large dent and achieving environmental performance on par with that has made it possible to achieve high fuel eﬃciency and reduced pollutant emissions at the same time. of gasoline engines by purifying the exhaust gas has required the use of a catalyst that requires a large amount Conceptual diagram of the burning inside the engine of noble metal and large exhaust gas treatment equipment High compression ratio Low compression ratio such as urea SCR equipment.

Against this background, NEDO conducted the“General Oxygen Technological Development for Innovative Next-generation Fuel particle Soot Low-emission Vehicles” Project for five years from FY2004 Uneven burning The burning efficiency is with the aim of improving the environmental performance of - The burning efficiency high because the degree of in the thick part is low. unevenness is lower. diesel engines to alleviate global warming and reduce the Burning the fuel after it has been uniformly mixed with air at a low emissions of environmental pollutants. Mazda Motor compression ratio improves the burning efficiency and reduces NOx and Corporation, which is the automobile manufacturer that has soot. been especially conscious of the possibilities of diesel engines among the Japanese automobile manufactures, participated in the project and endeavored to develop a new burning technology that does not compromise the high heat efficiency of diesel engines and to develop innovative catalyst technologies. As a result, Mazda Motor Corporation commercialized in 2012 the“SKYACTIV-D” diesel engine whose fuel efficiency is at the world’s highest level and whose exhaust gas is so clean that no NOx post-treatment equipment is required. This engine is being used in Mazda vehicles such as “ATENZA” and “CX-5,” and the number of SKYACTIV-D-equipped MAZDA vehicles sold (in Japan) by The high fuel efficiency-SKYACTIV-D engine with cleaner exhaust gas. This June 2013 exceeded 50,000, thereby greatly contributing to engine has an RPM range that is as wide as that of a gasoline engine. (photos courtesy of Mazda Motor Corporation) the popularization of diesel engine vehicles, which helps Mazda Motor Corporation reduce greenhouse gas emissions.

21 March 2013

JATCO Ltd.

Energy Conservation ・Development of Material Surface Control Technology for Low Friction Loss High Eﬃciency Drive Machines (FY2002-FY2006)

Improving Fuel Eﬃciency of a Belt CVT by Increasing the Coeﬃcient of Friction

With regard to transmission systems of vehicles, CVT (continuously variable transmissions) having driving performance and fuel eﬃciency superior to conventional staged AT (automatic transmissions) are

gaining attention, and as the use of such leads to CO2 reduction, vehicle manufacturers throughout the world have been implementing them on various models. At JATCO LTD. boasting the world’s greatest share for CVT systems, increased fuel efficiency and improved environmental performance have been realized by numerous technological reforms since the 1990’s. However, with regard to“friction” which plays an important role in relaying torque, little was The pulley of a CVT. The coefficient of friction is improved by engraving detailed grooves. known about the mechanism of the phenomenon and it was difficult to be considered upon quantification. During such, NEDO implemented the project of “Development of Material Surface Control Technology for Low Friction Loss High Efficiency Drive Machines”, in which hydraulic equipment and turbine bearings were subject to the project as well as CVT systems. Cooperative studies were conducted by Jatco, Idemitsu Kosan, Kobe Steel, the Tokyo Institute of Technology, and Iwate University with regard to CVT systems, where a 20% improvement of the coefficient of friction between the element and the pulley was Pulley realized. This has been recognized as a remarkable academic result as well. Mechanism of a CVT (Image provided by JATCO Ltd) Subsequently, the elemental technology developed in this project was implemented in the newest “JatcoCVT8”, displaying further improved fuel efficiency and realizing high efficiency. This technology is used in two vehicle models being sold by a major vehicle manufacturer, and total shipments have exceeded 150,000 units. It is expected that models featuring this technology will continue to increase. JATCO Ltd.

22 December 2009

Mitsubishi Fuso Truck and

Bus Corporation Energy Conservation

・R&D of Advanced Clean Energy Vehicles (ACE Project) (FY1997‒FY2003)

Trucks and Buses Also Follow Hybrid Trends

Eco-friendly vehicles that emit fewer greenhouse on the market in 2006 and the Aero Star Eco Hybrid gases and air pollutants are becoming more popular. large route bus was released in 2007. Both exceed As with passenger vehicles, the demand is also Japan’s 2015 fuel eﬃciency standards for heavy-duty increasing for commercial vehicles such as trucks and vehicles. As of March 2011, more than 1,000 Canter buses which operate on hybrid systems that integrate Eco Hybrid trucks had been sold. With orders now internal combustion engines and electric motors. coming in from Ireland and Australia, these hybrid

About 20% of the CO2 emissions in Japan are vehicles are drawing worldwide attention. produced by the transporation sector. Of this percentage, freight vehicles are responsible for up to 35%. If commercial vehicles gradually switch to hybrid

models, this will not only reduce CO2 emissions but also help reduce the potential eﬀects of global warming. Hybrid vehicles store energy produced during deceleration̶energy that’s normally discarded in ordinary vehicles̶in storage batteries with the motor serving as the power generator. This energy is reused during acceleration. Not only does this reduce the burden on the engine, it also completely eliminates Engine room of Aero Star Eco Hybrid CO2 and air pollutants that are normally present in exhaust fumes. Through this project, Mitsubishi Fuso Truck and Bus Corporation has developed two hybrid systems: a parallel-type hybrid system for small trucks and a series-type hybrid system for large buses. The Canter Eco Hybrid light-duty truck was released

Total engine exhaust (in liters)

Conventional buses: Hybrid buses: Mitsubishi Fuso Truck and Bus Corporation Aero Star Eco Hybrid large route bus engine

23 December 2009, March 2010

Hitachi Vehicle Energy, Ltd.

・Development of Technology for the Dispersed Energy Conservation Storage of Battery Power (LIBES) (FY1992‒FY2001),etc.

Mass Production of Lithium-ion Secondary (Rechargeable) Batteries for Hybrid Vehicles

Reducing CO2 in the transportation sector as a countermeasure against global warming presents a significant challenge. For this reason, research and development of various eco-friendly vehicles, including hybrid vehicles, is being conducted. The hybrid vehicle runs on an integrated electric motor and internal combustion engine, and is the result of remarkable technological innovations in the battery field. Further technological progress in this area has also led to the development of large-capacity and high-power 48-cell module lithium-ion secondary batteries for use in large-sized vehicles such as trucks and buses. The performance and quality sought in lithium-ion secondary batteries for hybrid vehicles that are frequently recharged and discharged during a short period of time are considerably different from home appliance batteries, which only require minimal energy output. Innovative research and development and the establishment of comprehensive mass production technologies have been key in developing practical applications for the batteries. Hitachi Vehicle Energy participated in a

groundbreaking 10-year NEDO project in the early Hybrid electric vehicles phase of lithium-ion secondary battery development and after much trial and error, successfully came up with safe and low-cost lithium-ion materials. The company encountered numerous, unexpected problems in its eﬀorts to mass produce the materials, Hybrid-use 4th generation but through the collaboration of engineers from a Output density various ﬁelds, it eventually succeeded in the stable production of lithium-ion secondary batteries. 3rd generation Having succeeded in developing high-quality, 2nd generation

large-capacity and high-power lithium-ion secondary Lead 1st generation storage batteries, Hitachi Vehicle Energy has emerged as the batteries Nickel-hydrogen batteries global leader in production of the technology, supplying more than three million battery cells for use Energy density Hitachi Vehicle Energy, Ltd. in hybrid electric vehicles throughout the world. Evolution of lithium-ion secondary batteries

24 March 2012

Kobelco Construction Machinery Co., Ltd.

Kobe Steel, Ltd. Energy Conservation ・New Sunshine Project/Research and Development Project of Technologies for Creating New Environment Industry/ Research and Development of Hybrid Construction Machinery (FY1999‒FY2002),etc. Development of World’s First Hybrid Hydraulic Excavator

Contributes Greatly to Energy Saving and CO2 Reduction

Of the greenhouse gases produced in Japan, about 1% are said to be emitted by construction machinery, 60% of which are attributed to hydraulic (power) excavators. For this reason, the construction and civil engineering industries are becoming increasingly interested in energy-efficient hydraulic excavator equipment. One fuel-efficient option that is attracting attention is the hybrid hydraulic excavator. To develop this technology, NEDO carried out two projects: Research and Development of Hybrid Construction Machinery (FY1999 - FY2002) and Radiator Research and Development of a Hybrid Excavator (FY2003 - FY2004). As a result of these initiatives, Kobelco Construction Machinery and Kobe Steel succeeded in developing the world’s first hybrid Battery excavator in 2006. The two companies continued their efforts to Rotary motor develop practical applications for this technology, and in January 2010 they began marketing the 8-ton-class Control valve SK80H-2 hybrid excavator, which was 40% more fuel Engine Generator motor efficient than conventional excavators. That year, the Hydraulic pump SK80H-2 received a 2010 Minister of the Environment Motor of hybrid excavator currently on the market Award for the Prevention of Global Warming in the technical development and product categories. The SK80H-2 was also the first type of construction machinery to be certified as being low carbon by the Standard model: Selection of engines taking into account SK70SR-2 Engine output: 41kW maximum load Ministry of Land, Infrastructure, Transport and Tourism. (High) Load

In addition to contributing to the development of Load exceeding engine output → Assisted by battery the hybrid excavator, NEDO’s research achievements generator moor are now being applied to the development of more Load below engine output fuel-eﬃcient conventional machinery. As a result of → Recharges battery Image drawing

these eﬀorts, Kobelco Construction Machinery has (Low) Hybrid model: Selection of Time engine taking into account SK80H-2 Engine output: 27kW successfully enhanced the fuel eﬃciency of its average load Motor output: 20kW

conventional equipment by about 20%. Kobelco Construction Machinery Co., Ltd. / Kobe Steel, The output of standard equipment (red line) can be achieved even with a small engine (blue line) using a battery and motor.

25 December 2012

Mitsubishi Heavy Industries, Ltd.

・Moonlight Project / Development of High Eﬃciency Gas Energy Conservation Turbine(FY1978-FY1987 / Project of the Ministry of Economy, Trade and Industry),etc.

Contributing to Solve Global Environment and Energy Issues with a WorldWorld’’s Highest Level High Eﬃciency Large Sized Gas Turbine

Ever since the Great East Japan Earthquake that 32%. Not only do such gas turbines contribute to took place on March 11th, 2011, the dependence on Japan’s current electricity demand and measures to thermal powered generation has been increasing. prevent global warming, they in the future are Currently, almost 90% of Japan’s demand for anticipated to greatly contribute to developing electricity is being supplied by thermal powered countries where a great increase in the demand for generation. In midst of this, the“Gas Turbine electricity is expected to occur. Combined Cycle Generator System (GTCC)” is gathering attention due to having a high heat eﬃciency of over 60%, and having almost

approximately 50% less exhaust volumes of CO2 and NOx when compared against coal-ﬁred thermal power. Full-scale development in our country of the large sized gas turbine which is essential to this system dates back to the“Moonlight Project”, a national project implemented in 1978. Even after this, performance has been further improved through such as the“New Sunshine Project” implemented under the lead of NEDO. At Mitsubishi Heavy Industries

where we have been participating since the time of Cooling hole of blade the Moonlight Project, in the field of large sized gas turbines being led by American and European forces, we have continued to develop large sized gas turbines displaying the world’s best performance. For example, the“1,600 ° C Grade Type-J Gas Turbine” introduced in February, 2011 boasts a heat efficiency of over 61%, and is equipped with a high performance film cooling technology developed through the national project. In global shares of large sized gas turbines for generators during the period of January-September of 2012, while Siemens has 38%, Mitsubishi Heavy Industries having 26% is catching up

Mitsubishi Heavy Industries, Ltd. to compete for second place with GE now having

26 March 2011

Kobe Steel, Ltd. ・Project for Fundamental Energy Conservation Technology Energy Conservation Development Research and Development of Flexible Turbine Systems for Diverse Applications (FY2001 ‒FY2003),etc.

Micro Steam Energy Generator Eﬀectively and Thoroughly Utilizes Manufacturing Steam

The steam produced when heated water boils and (Installation setup for steam process) evaporates is used for a wide range of purposes at Steam manufacturing sites and various other kinds of reducing valve facilities. During manufacturing processes, this steam is reduced to the necessary pressure by the steam Steam process reducing valve, but the excess steam generated during this pressure reduction process is discharged into the atmosphere without being used. Steam power

generation has been drawing attention as a way to Boiler effectively use excess steam without wasting it. In Illustration of boiler and SteamStar combination 2001, Kobe Steel initiated research efforts aimed at the effective use of steam and started accumulating technical expertise and know-how in steam power generation through NEDO projects. In a user survey conducted at the time, it was revealed that steam demand for most users was less than 1 MPa, which is 2 to 20 tons of steam flow per hour. Steam used in small- to medium-sized factories, which account for a large percentage of Japan’s manufacturing sector, is low-volume, low-pressure steam. To use the steam for processing, there is a need for high-precision control of steam pressure high-precision machining screw reduction functions at factories. If energy is collected efficiently from the steam and high-efficiency power generation can be achieved while also reducing its pressure with a high degree of precision, it would be killing two birds with one stone. In light of these surveys, Kobe Steel has been developing practical, compact high-efficiency steam generators since 2004. The company elected to develop its micro steam energy generator SteamStar™ by incorporating a screw-type method rather than a turbine and applying technologies developed through

NEDO projects. Kobe Steel oﬀers 132 kW and 160 SteamStar installed at a steam manufacturing plant in Amagasaki, Hyogo Prefecture kW power-generating capacity units and has sold 80 Compact design saves space and reduces construction costs SteamStar generators to date. Units can be installed indoors or outdoors. Kobe Steel, Ltd.

27 December 2013

Mitsui Engineering & Shipbuilding Co., Ltd.

Energy Conservation ・Strategic Development of Energy Conservation Technology Project”(FY2001-2005)

Optimally Adjusting the Ratio between Heat and Electricity to Suit the Place of Utilization - Development of a Gas Engine System that Expands the Scope for the Popularization of Natural Gas Cogeneration

When operating a power generator using a heat engine, to the stand-alone gas engine power generation efficiency, the generation of waste heat is unavoidable. Because the Mitsui Engineering & Shipbuilding Co., Ltd. achieved an supply of electricity in Japan has been mainly based on efficiency value of 42.5%, which is a value on the world’s intensive large-scale power stations, it has not been possible highest level. At present, five cogeneration system units to utilize this waste heat. In recent years, however, and four stand-alone gas engine units (a total of nine units) “cogeneration” has been gaining popularity. Cogeneration is are in operation throughout Japan. In the area of a mode of power generation wherein both electricity and stand-alone engine products, Mitsui Engineering & heat are supplied. That is, power generation equipment is Shipbuilding Co., Ltd. developed a gas engine product that installed at facilities of customers and local areas and the is one class larger together with Daihatsu Diesel Mfg. Co., heat generated by the power generation is collected and Ltd. after completion of the project, and started selling the utilized for such purposes as air conditioning and the product in 2012 (three units are already in operation). production of steam for use in factories. In line with the efforts to alleviate global warming, the voice for promotion of the popularization of“distributed power generation systems” has been strengthening. Distributed power generation systems are systems wherein both electricity and heat are supplied on a locality-by-locality (or building-by-building or factory-by-factory) basis. Cogeneration is attracting attention as a mode of distributed power generation. However, because cogeneration uses power generation systems that are smaller than those used at conventional thermal power stations, it is difficult to achieve high efficiency (because it is difficult to take advantage of economies of scale). In addition, there are cases where seasonal variations (or variations caused by other factors) in Knocking detection sensor attached to the gas engine the utilization ratio between electricity and heat reduce the energy-saving performance. Against this background, Mitsui Engineering & Shipbuilding Co., Ltd., which is a company that has engaged itself in the development and production of diesel engines for ships for many years, participated in the NEDO project and developed a gas engine cogeneration system by combining 1 to 2MW class gas engines (for which the market demand is high) with the world’s first fully fired steam generator. This made it possible to achieve the optimal ratio between heat and electricity by making adjustment according to the demand (which had been difficult to achieve with conventional systems), thereby significantly expanding the range of facilities that can

Mitsui Engineering & Shipbuilding Co., Ltd. Pilot fuel injection valve for ignition - one of the key components that beneﬁt from the introduction of cogeneration. With regard have made it possible to achieve the high eﬃciency.

28 November 2013

MAYEKAWA MFG. CO., LTD.

・Strategic Development of Energy Conservation Technology Energy Conservation Project - Development of a Dehumidiﬁcation-type High-performance Air-based Freezing System that Uses Polymer Adsorbent (FY2003-2005) and other projects

Ultra-low-temperature Freezing System that Achieves -60℃ Using Air as the Refrigerant

Among“refrigerating warehouses” used to store foods in the In December 2008 (which was five and half years after the frozen state, those used to store large high-value fishes such as start of the development), MAYEKAWA MFG. CO., LTD. started tuna and skipjack at a temperature below -50℃ are called“ selling“PascalAir,” an air refrigerant-based freezing system for ultra-low-temperature refrigerating warehouses.” There are ultra-low-temperature refrigerating warehouses. A total of about about 400 such refrigerating warehouses throughout Japan (in 25 units of PascalAir were introduced at facilities in Japan in five fishery bases for tuna fishing boats, fish-consuming large cities years after the start of sale. It is expected that PascalAir will and other places), and they are supporting the physical become more popular in the future as the demand for PascalAir distribution of fish to restaurants, our homes, etc. However, it is will increase in conjunction with renovation of old not well known that the use of these ultra-low-temperature ultra-low-temperature refrigerating warehouses. refrigerating warehouses had been on the verge of being discontinued up until quite recently. That is, the use of chlorofluorocarbon type refrigerants, which had been traditional main refrigerants in the refrigerating warehouse industry, was going to be no longer possible after the year 2020, because international rules including the Montreal Protocol for stopping the depletion of the ozone layer and the Kyoto Protocol for stopping global warming had strongly demanded that those chlorofluorocarbon type refrigerants with high environmental impact be replaced with ones with lower environmental impact. Companies in the ultra-low-temperature refrigerating warehouse industry had feared that they would be forced to abolish ultra-low-temperature refrigerating warehouses because there would be no refrigerant to use for them. Against this background, MAYEKAWA MFG. CO., LTD., which is an industrial freezer manufacturer, tackled the task of The“heart” of PascalAir - the compressor with integral turboexpander developing an innovative system that uses the very familiar“air” as the refrigerant rather than traditional chlorofluorocarbon type refrigerants. What motivated MAYEKAWA MFG. CO., LTD. to pursue this technological development was the three years of development work the company conducted under the“Project for Strategic Development of Technologies for Achieving More Efficient Utilization of Energy” of NEDO. After completion of the project, MAYEKAWA MFG. CO., LTD. conducted a two-year field test using an ultra-low-temperature refrigerating warehouse for tuna in actual operation to ensure the viability of the introduction of the developed technology into the market, and established, in cooperation with refrigerating warehouse operators, who were target users, a system for practical operation of the new technology that utilizes air, which is a safe and novel refrigerant, and is capable of achieving a reduction in the annual power consumption of up to 50% (that is, dramatic energy saving). MAYEKAWA MFG. CO., LTD. The PascalAir unit installed in a facility of Fukazawa Reizo K.K.

29 September 2011

JFE Engineering Corporation

・New Sunshine Project, Network System for Extensive Energy Energy Conservation Application (Eco-Energy City Project) (FY1997‒FY2000),etc.

Air-conditioning System Uses Hydrate Slurry to Cool Large Facilities, Save Energy

Air-conditioning systems that offer both cooling and Bizen City, Okayama Prefecture. Outside of Japan, the heating are indispensable for maintaining a system has been installed in several facilities in North comfortable environment in highly populated facilities America as part of JFE Engineering’s efforts to market such as office buildings, shopping centers and Japanese energy-efficiency heat storage technology factories. Unlike residential air-conditioning units, abroad. which are installed in individual rooms, commercial air-conditioners are designed to provide climate control throughout an entire building. Because of this they consume a large amount of energy. Finding ways to save energy is thus an important concern for building owners and management. The energy consumption of private-sector commercial properties is increasing annually. To save energy and reduce the potential for global warming, enhancing the efficiency of air-conditioning systems is vital. Through several NEDO projects, JFE Engineering developed an innovative heat storage air-conditioning Hydrate Slurry (Kawasaki station, Kanagawa) system that uses hydrate slurry (NeoWhite) to store thermal energy instead of water or ice as in

conventional air-conditioning systems. This new Cooling of solvent Termination of overcooling Cooling of NeoWhite 1. Solvent overcooling system 2. Overcooling termination system 3. NeoWhite cooling system system, which has contributed greatly to Cooling tower air-conditioning energy savings in the commercial Freezing system NeoWhite heat storage tank property sector, is the result of JFE Engineering’s

NeoWhite continuous efforts to apply the expertise and water knowledge its research and development staff has NeoWhite Solution generated NeoWhite achieved through NEDO projects, from the initial system stages of development to the final demonstration and practical application stages. Hydrate slurry is generated using three systems: a solvent As of September 2011, the system was in operation overcooling system, an overcooling termination system, and a NeoWhite cooling system. at eight facilities, including the Azalea underground mall adjacent to Kawasaki Station in Kanagawa Prefecture,

JFE Engineering Corporation Yokohama City Shopping Center, and a bearing plant in

30 ・Strategic DevelopmentofEnergyConservationTechnology company’s original and otherprojectsendeavoredtodevelopthe Achieving MoreEfficientUtilizationofEnergy” NEDO’s on whatindustrythefactorybelongsto. temperature rangeoftheheatuseddiffersdepending belonging todifferentindustriesismade,becausethe can beachievedifheatinterchangebetweenfactories different industriesarelocatedclosetoeachother, industrial complexes,inwhichfactoriesbelongingto reached itslimit,furtherenergysavingonthelevelof although energysavingatindividualfactorieshad construction company,recognizedthefactthat, technologies alone. further energysavingispossiblewiththeexisting industrial complexeshavereachedthestagewhereno measures formanyyears.Forthisreason,Japan’s industrial complexeshavetakeninternalenergy-saving petroleum refineriesandchemicalfactoriesin domain areespeciallyadvanced.Inparticular, world. Energy-savingmeasuresintheindustrial for energysavingisalsoonthehighestlevelin and Japan’sdevelopmentofelementtechnologies through theSharingofHeatbetweenFactories through theSharingofHeatbetweenFactories Achieving EnergySavingontheLevelofIndustrialComplexes Chiyoda Corporation been adoptedbyfourindustrial complexesinJapan technology” efficiency improvement. The which thecompanyachieved dramaticenergy demonstration testinanactual industrialcomplex,in industrial complex,andsuccessfullyconducteda heat energybetweenfactorieslocatedinthesame be appliedtoanalysesofthesharingmaterialsand optimizing theflows,sothatpinchtechnologycan and heatflowsinasinglefactory,plant,etc. technology,” which isatechnologyforexpandingthe Project (FY2000-2006),etc. Accordingly, ChiyodaCorporationparticipatedin Chiyoda Corporation,aplantdesignand Japan isacountrythatadvancedinenergy-saving, January 2014 “Strategic DevelopmentofTechnologiesfor ananalysistoolforanalyzingthematerial developedbyChiyodaCorporation has “area-wide pinchtechnology,” “area-wide pinch “pinch project

Industry of Thailand Photo oftheJointAnnouncement byNEDOandtheMinistry ofthe Complexes inJapan(asofFY2000) The ChibaIndustrialComplex,whichIsOneoftheMainIndustri Technologies andSystems” Improving EnergyConsumptionEfficiencyandOther Demonstration ofTechnologiesandSystemsfor Thailand) aspartofthe places astheMapTaPhutIndustrialComplexin demonstration projectsconductedoverseas(insuch been usedsinceFY2011asatechnologyfor other countries,asexemplifiedbythefactthatithas industrial complexesnotonlyinJapanbutalso effective energy-savingsolutiontechnologyfor technology isattractingstrongattentionasan Complexes). Inaddition,thearea-widepinch (the Chiba,Kashima,MizushimaandOitaIndustrial The ChibaIndustrialComplexComprisedof23Factories JR UchiboLine 1 glassfactory 3 chemicalfactories 1 petroleumrefinery Anegasaki 4 chemicalfactories 2 petroleumrefineries “Project forInternational ofNEDO. Industrial road 11 chemicalfactories 1 petroleumrefinery Goi al

Chiyoda Corporation Conservation Energy July 2012

Japan Industrial Furnace Manufacturers Association ・Development of High Performance Industrial Furnace Energy Conservation (FY1993-FY1999),etc.

High Performance Industrial Furnace Greatly Contributing to Energy Conservation and Environmental Load Reduction in Industrial Fields

Of the energy consumption volume used in all of Development Project were shared within the Japan, 18% is consumed by industrial furnaces. consortium, and as a result of this, actualization of the However, up until now the effective utilization rate of high performance industrial furnace rapidly made heat from the furnaces was approximately 35%, while progress. As of 2011, this method is being used in the remaining 65% was being released into the approximately 1,300 furnaces domestically. atmosphere along with the combustion exhaust gas. As a method of improving efficiency, although there is the technology of what is called a“regenerative burner” (hereinafter referred to as a Regene-Burner) this system had a dilemma where the more the exhausted heat collection ratio (wherein exhausted heat is used to preheat air for combustion) is increased, generation of NOx (Nitrogen Oxide), an air pollutant, also increased. For this reason, managing both energy conservation and environmental load reduction of industrial furnaces was thought to be difficult. However, in the early 1990’s, an industrial furnace manufacturer in Japan discovered a combustion method in which the generated volume of Heated slag NOx does not increase along with the increase in the heat collection ratio. Approximately 70% of the Heat Energy Meanwhile, NEDO implemented the“Development in the Gas is collected of High Performance Industrial Furnace” project in Fuel 1993-1999 and the“High Performance Industrial Heat Reservoir

Furnace Installation Field Test” in 1998-2000, and Flames

Room centered on the Japan Industrial Furnace Temperature Air Preheated Air Exhaust Gas Manufacturers Association, eﬀorts were made in the Exhaust Gas research and development of a“high performance Switching Valve

industrial furnace” capable of saving energy while The heat reservoir is heated with having a small environmental load. As a result, a high Switches between certain the exhaust gas. cycles (Regenerative Combustion) performance industrial furnace with energy saving

effects and CO2 reduction effects of more than 30%, and reduction of NOx by more than 50%, both in comparison with furnaces using conventional methods, was successfully developed. In promoting the field test project, all of over 300 patents individually obtained by When switched, Japan Industrial Furnace Manufacturers Association the air blowing into corporations in the High Performance Industrial Furnace the furnace is heated Renege-Burner by the heat reservoir

32 March 2013

Kimura Chemical Plants Co., Ltd. ・New Sunshine Project (FY1993-FY2001),etc. Energy Conservation

Distillation Facilities Boasting Maximum Energy Conservation Eﬀects of 60%

The industrial ﬁeld is responsible for 34% of Japan’s

CO2 exhaust volume, while the field of chemical industry emits 5% of this. Of this, distillation processes seen in such as the fractional distillation of petroleum and concentration of alcohol plays an extremely important role. However, energy conservation technologies in the Japanese field of chemical industry are of the world’s highest standards, and currently units of energy sources seem to have reached its limits. Even still, as a ground-breaking new technology that enables further energy conservation,“HIDiC” (Heat Integrated Distillation Column) is gathering attention. By applying this technology where the heat that is exhausted when steam is cooled goes through a process of heat exchange and compression internally and is then used again when heating, a dramatic reduction of energy can be made possible. Although Kimura Chemical Plants has continued to nurture this technology from more than 20 years ago, while obtaining the knowledge of the National Institute of Advanced Industrial Science and Technology, this Entire view of a pilot plant technology has finally been realized through the NEDO project. In verification tests conducted on the same scale as actual plants, energy reduction by as much as 60% was achieved in the distillation process of fractional distillation of gasoline. In the future, this technology is expected to be put to use in not only petroleum chemistry related fields, but in various fields such as food products and biomass manufacturing while focusing on use in developing countries. Kimura Chemical Plants Co., Ltd.

33 Energy Conservation Test specimens for durability testing

ECM Cement Reduces Energy Consumption and CO2 Emissions by More Than 60%

Large amounts of energy are required to produce cement mercial production of Portland blast-furnace slag cement for use in buildings and civil engineering projects. In this with high volume GGBFS. project, cement that requires 60% less energy to produce than conventional cement was developed and put into Research for commercialization by a new team practical use by intermixing a greater quantity of Grand capable of market expansion Granulated Blast Furnace Slag (GGBFS), a byproduct of steel manufacturing. To facilitate the commercial application of research and development results, the team members participated in a Persistent and meticulous basic research to new NEDO project from FY2011. With a view toward determine optimum mix proportion promoting future use of a new type of cement, they formed a “dream team” by adding a construction compa- In the production of Portland cement, the most common ny and cement manufacturers as new members and cement type, the clinker production process requires a carried out research activities that assumed use of the new significant amount of energy. However, in the production cement at actual construction sites. The major focus of of Portland blast-furnace slag cement, a type of Portland such activities was on the quality and durability of the cement mixed with GGBFS, the clinker production process cement actually used for construction. Controlling the requires less net energy consumption because less particle size distribution of GGBFS was essential to main- Portland cement is needed. In a NEDO project that started taining stable strength, and high durability was achieved in FY2008, a team led by Takenaka Corporation and the by adjusting cement constituents to control heat genera- Tokyo Institute of Technology undertook research and tion, a cause of occurrence of cracking. In this way, Ener- development on Portland blast-furnace slag cement with gy-CO2-Minimum (ECM) cement, a new low-carbon type high volume GGBFS content. Since using high volume of cement that requires 60% less energy to produce than GGBFS content causes performance problems, such as Portland cement, was developed. The team has steadily delayed strength development, the team thoroughly accumulated a construction track record using ECM analyzed its data on mix proportions for Portland cement cement, which is categorized as Type C Portland blast-fur- and GGBFS. This analysis revealed that the Portland nace slag cement (60–70% GGBFS content). It is aiming cement proportion could be reduced to 30%. They also to further promote use of ECM cement to achieve greater conducted research and development on chemical energy savings. Bringing an Ecological admixtures (superplasticizers) that would provide sufficient fluidity when cement is used. As a result of these Revolution to Construction efforts, they arrived at an ideal mix proportion for com- Sites

Tokyo Institute of Technology • Takenaka Corporation

Kajima Corporation • Nippon Steel & Sumikin Blast Furnace Slag Cement Co., Ltd. GGBFS and small DC Co., Ltd. • Taiheiyo Cement Corporation amount of gypsum 60–70% Nippon Steel & Sumikin Cement Co., Ltd. • Takemoto Oil & Fat Co., Ltd. Grinding and mixing ECM cement Portland cement Fossil fuels Strategic Technology Development for Energy Use Rationalization Approximately 30%

Research and Development Program for Innovative Energy Efficiency Technology Investigation of cement reaction and Test Specimens produced on the ECM cement production process cure rates based on mix proportion basis of demonstration experiment (Data courtesy of ECM using film canister as test chamber results Joint Research and Development Team)

16 NEDO PROJECT SUCCESS STORIES 2017 SUCCESS STORIES 17 Energy Conservation All SiC(Silicon Carbide) inverter installed under train floor Practical Application of “SiC Power Semiconductor” That Contributes to a Next-Generation Electric Society, as Rolling Stock Inverters Used in Railways

Power semiconductor devices convert direct current (DC) Developing mass production technology into alternating current (AC), or vice versa, and adjust the through an enhanced focus on large-scale voltage to enable the use of various electronic machines project implementation in later project stages and appliances. Technology for improving the energy efficiency of power semiconductor devices is essential for One of the challenges in developing mass production the society where a large amount of energy is consumed. technology for the commercial application of SiC power In this project, silicon carbide (SiC) power semiconductor semiconductor devices was the need of a high-tempera- devices were developed for practical application, and ture manufacturing environment. Crystal growth of SiC rolling stock inverters using those devices demonstrated ingots from SiC raw material powder would require an approximately 40% less energy consumption than ultra-high temperature as high as 2,200°C, and the current mainstream inverters using silicon (Si) power implantation of ions into SiC wafers needs to be done at a semiconductor devices. much higher temperature than is the case for Si wafers. The establishment of thermal management technology Project launched two decades ago to develop was therefore the most important issue for both AIST and future power semiconductor devices Mitsubishi Electric Corporation. The high temperature problem was addressed during the It has been long anticipated that using SiC rather than Si continuous implementation of large-scale NEDO projects for power semiconductor devices would dramatically and a rolling stock inverter for railways was developed improve the device performance, but SiC had shortcom- which is expected to provide significant energy savings. In ings such as its high cost and the difficulty in manufactur- 2014, the inverter was introduced in refurbished ing wafers. In a NEDO project launched in FY1998, the 1000-series commuter trains operated by Odakyu National Institute of Advanced Industrial Science and Electric Railway Co., Ltd. Since that time, it has been used Technology (AIST) developed large-diameter, high-quali- in many other railway systems both within and outside ty SiC wafers and prototype SiC power devices. Mitsubishi Japan. Electric Corporation, which manufactures rolling stock Power semiconductor devices have a wide variety of uses inverters for railways, fabricated novel prototype inverters and their use is expected to further expand to automo- with SiC metal-oxide-semiconductor field-effect transis- biles and high-output electric power infrastructure. tors (MOSFETs) that was expected to consume less energy than conventional inverters using Si insulated gate bipolar transistors (IGBTs).

Motor current Introducing a New Era of Motor current

Voltage Voltage Power Electronics Ideal sinusoidal wave Ideal sinusoidal wave

Waveform of current for electric Current waveform for electric motor National Institute of Advanced Industrial Science and Technology (AIST) motor driven by conventional inverter in high-speed switching operation Mitsubishi Electric Corporation • Odakyu Electric Railway Co., Ltd. Reduction of harmonic loss due to improved sinusoidal waveform

Research and Development of Fundamental Technology for a Power Electronics Inverter Top: Mechanism of energy saving resulting from Top right: Sliced wafers high-speed switching operation Next-Generation Power Electronics Project Realizing Low Carbon-Emission Society (Data courtesy of Mitsubishi Electric Corporation) Bottom right: Prototype 11-kW SiC inverter fabricated in February 2009. The inverter was down- sized to one quarter the size of a conventional inverter, and power loss was reduced by 70%, a 18 NEDO PROJECT SUCCESS STORIES 2017 world record at the time. SUCCESS STORIES 19 Shikoku Instrumentation Co., Ltd. developed an LED Commercialization of unprecedented lamp with ultrahigh intensity and ultrahigh flux and LED lamps by overcoming multiple Energy Conservation commercialized it in the MIRACH-LED® series of high-ceiling lights and floodlights. By replacing technological challenges high-intensity discharge (HID) lamps, which contain Once the direction of development was decided, the mercury or other toxic substances, MIRACH-LED® company applied to participate in NEDO’s project and lamps are expected to contribute to energy was accepted, thereby setting a commercialization conservation and global environment protection. process in motion. Efforts to develop a powerful light source Regarding the COB module, the company found a way to fix white inorganic paint onto the surface of a FGHP. and a novel heat radiation system It also succeeded in developing a silver paste ideal for Shikoku Instrumentation launched its LED business in metallic wiring and addressed pending patent issues. 2009 and later set its sights on the commercialization Next, the company developed an optimal heat sink of ultrahigh intensity and flux LED lamps to replace HID design that would improve heat radiation efficiency Commercialization of lamps in gymnasiums and other high-ceiling areas. In and resolve molding issues at the same time. the background were increasing popular support for As a result, the company commercialized an energy conservation in Japan following the Great East unprecedented LED lamp with ultrahigh intensity and an Energy-Saving LED Lamp Japan Earthquake and growing global concern regarding flux in 2014. Since being introduced to the market, the environmental pollution caused by mercury. product has been used at various places, including large Since the commercialization of such lamps required the dam construction sites, golf driving ranges, and With Ultrahigh Intensity and development of an ultrahigh intensity and flux LED automobile crash test sites. The company is currently light source, the company decided to prepare a plan to exploring the possible application of the lamp to water develop a chip-on-board (COB) module using LED disinfection equipment, and further diversification of Ultrahigh Flux chips mounted on a substrate as a single light source. the product is expected. However, the output of COB modules at the time was (Interview: September 2018) High-speed mounting of LED chips on substrate approximately 100 W at best, and securing an output of 600 W as well as high luminous efficiency and long life required a heat radiation system that would be more powerful than ever before. Against this backdrop, Shikoku Instrumentation focused on technologies to facilitate heat transfer by

using a copper plate as the COB substrate because of its Developers at Shikoku Instrumentation, excellent thermal conductivity and to secure excellent from right, light reflecting performance by applying white paint to Mr. Shouji Murakami, Mr. Hiroshi Yajima, and the surface of the substrate. In addition to using a Mr. Kenji Fukuda

High-power COB module developed in this project Device to coat COB substrate with white More than 2,000 LED chips mounted on a 70 square radiation fin heat sink to release heat generated into the inorganic paint millimeter substrate and connected by gold wire air, the company adopted a heat spreader called the Fine Grid Heat Pipe (FGHP) to develop a high-efficiency Shikoku Instrumentation Co., Ltd. heat radiation system. In other words, by using a copper Strategic Energy Saving Technology Innovation Program FGHP as the COB substrate, the company decided to develop a heat radiation system with unprecedented Aims Challenges Achievements cooling performance that would simultaneously allow smooth heat transfer and efficient heat sinking. Yanba Dam construction site at night is as bright Establishing technology Installation of ultrahigh as day Heat to reduce heat intensity and flux LED Contributing to energy generation in LED chips, lamps at places such as Cross section example conservation through which can cause a dam construction sites and development of LED New heat sink model golf driving ranges. Efforts reduction in the lifetime New COB Reflector lamps with ultrahigh model of ultrahigh-flux LED will be made going forward Heat spreader intensity and Light-emitting lamps and degradation to enable such lamps to be side LED ultra-high flux chips of their luminous applied to water disinfection equipment. efficiency Light Vapor path Wick area Internal structure of FGHP heat spreader. Illumination of Marugame Castle in Schematic diagram of newly Heat is dissipated through vapor paths and Kagawa Prefecture with beautifully lit stone walls developed LED lamp capillary tubes called wicks.

08 NEDO Project Success Stories 09