Industrial Heat Pump Applications in Japan€¦ · ©CRIEPI 56% 26% 18% Industrial 6,600 PJ/year...

Industrial Heat Pump Applications in Japan

Takenobu KAIDACentral Research Institute of Electric Power Industry (CRIEPI)

Chillventa CONGRESS 2018Nuremberg, Germany

October 15, 2018

©CRIEPI

CO2 Emissions Reduction by Electrification

2

Key points for significant reduction of CO2 emissions

Low carbonization of electricity

Higher efficiency electricity usage

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

1970 1990 2010 2030 2050

CO

2em

issi

on

fac

tor

[kg-

CO

2/k

Wh

] 2011.3.11Great East Japan Earthquake & Tsunami

0.37

Under investigation

0.530 (2015)

0.352 (2010)

0

1

2

3

4

5

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CO

P

CO2 emission factor [kg-CO2/kWh]

City gas

Heavy oil A

Estimation conditions

- City gas: 0.0499 kg-CO2/MJ- Heavy oil A: 0.0693 kg-CO2/MJ- Conbustion efficiency: 0.9

Transition and target of CO2 emission factor for electricity in JapanHeat Pump (EHP) vs. Boiler regarding CO2 emissions

under the condition that the heat load is equal

©CRIEPI

56%26%

18%

Industrial6,600 PJ/year

13%

16%

13%

9%

49% Commercial2,800 PJ/year

27%

3%

27%8%

35%

Residential2,200 PJ/year

Final Energy Consumption in Japan

3

Approximately 40% of the final energy consumption is “heat.”

Industrial sector has the largest amount of energy consumption.

Residential14%

Commercial20%

Industrial43%

Transport23%

■ Space Heating■ Space Cooling■ Hot Water Heater■ Kitchen■ Lighting & Power

■ Space Heating■ Space Cooling■ Hot Water Heater■ Kitchen■ Lighting & Power

■ Heating■Material■ Lighting & Power

IndustrialHeating

Total Final Energy Consumption in Japan: 13,548 PJ (FY2015)

©CRIEPI

Commercialized IHPs in Japan

4

Sup

ply

Tem

per

atu

re [°C

]

Heating Capacity [kW]

Water-source Heat Pumps

Source: JEHC (Japan Electro-Heat Center), “Guideline for using industrial heat pump,” 2017 [in Japanese]

©CRIEPI

Commercialized IHPs in Japan

5

Heating Capacity [kW]

Sup

ply

Tem

per

atu

re [°C

]Air-source Heat Pumps

Source: JEHC (Japan Electro-Heat Center), “Guideline for using industrial heat pump,” 2017 [in Japanese]

©CRIEPI

Installation Target of IHPs by the Government

6

“The Plan for Global Warming Countermeasures”

Decided by the Cabinet on May 13, 2016

26% reduction of GHG emissions by FY2030 compared to FY2013(= 367 million ton-CO2 reduction)

The role of industrial heat pumps (IHPs)

Over 150 times spread(11 MW in FY2013 to 1,673 MW in FY2030)

1.35 million ton-CO2 reduction(= about 0.4% of total GHG emissions reduction )

0

200

400

600

800

1,000

1,200

1,400

1,600

1,800

FY2

01

3'1

4'1

5'1

6'1

7'1

8'1

9'2

0'2

1'2

2'2

3'2

4'2

5'2

6'2

7'2

8'2

9'3

0

Expected

Actual

Expected

Cu

mu

lati

ve In

stal

lati

on

Hea

tin

g C

apac

ity

[MW

]

Source: METI (Ministry of Economy, Trade and Industry) & MOE (Ministry of the Environment) Joint Meeting, Feb. 28, 2018 [in Japanese]

©CRIEPI 7

Installation Situation

©CRIEPI

Collection of Installation Cases

8

Collection from published information

Japan Electro-Heat Center (JEHC)

Heat Pump & Thermal Storage Technology Center of Japan (HPTCJ)

The Energy Conservation Center, Japan (ECCJ)

Japan Society of Refrigerating Air Conditioning Engineers (JSRAE)

Collected examples

84 examples

Installation cases of industrial heat pumps, published by Japan Electro-Heat Center (JEHC)

Voice of customer

Effects of energy, CO2

and cost reductions

System flow

Installed results (~FY2016)

84 examples: 4.9 MW(6% of government statistics)

88.1 MW

©CRIEPI

Installation Situation | Installation Year

9

After the mid-2000’s

2005- Steam-less air-conditioning system (by HP chiller & Evaporative Humidifier) [up to 50°C]

2008- High temperature hot water supply HP [up to 90°C]

2009- Hot air supply HP [up to 120°C]

2012- Steam supply HP [up to 165°C]

0

10

20

30

40

50

60

70

2001 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12 '13 '14 '15 '16 '17

Nu

mb

er

of

Inst

alla

tio

n C

ase

Cumulative Installation Case

Installation Case per Year

* 66 example cases which installation years have been published among the total number 84 of installation cases collected

©CRIEPI

0

5

10

15

20

25

30

35

Food (33) Machinery (18) Electronics (10) Chemistry (10) Agriculture& Fisheries (7)

Paper (3) Unknown (3)

Nu

mb

er o

f In

stal

lati

on

Cas

e

Heating

Heating& Cooling

Hot Water Supply

Drying

Distillation or Concentration

Air Conditioning

Installation Situation | Industry and Process

10

Food industry: the most, various process, simultaneous heating & cooling

Machinery, Electronics and Chemistry: steam-less AC for clean room

Agriculture: AC for greenhouse

Paper industry: large potential but small application

©CRIEPI

Installation Situation | Type of Heat Pump

11

Hot water supply type is used most often.

Circulation heating > Once-through heating

22

17

5

1

4

7

7

12

2

5

2

0 5 10 15 20 25 30

Air Source | Hot Water Supply HP

Water Source | Hot Water Supply HP

Air & Water Source | Hot Water Supply HP

Water Source | Hot Air Supply HP

Water Source | Steam Supply HP

Mechanical Vapor Recompression

Others (PAC, OAC, Unknown)

Number of Installation Case

Circulation Heating

Once-thorough Heating

©CRIEPI

Installation Situation | Heating Capacity & Supply Temperature

12

The required heating capacity and temperature depend on the process.

Many installations in the hundreds of kW class (700kW ≃ 1 ton/h steam boiler)

Many installations of 65°C or 90°C hot water supply

4

12

7

19

12

5

25

0 5 10 15 20 25

Q≤10 [kW]

10<Q≤50 [kW]

50<Q≤100 [kW]

100<Q≤500 [kW]

500<Q≤1,000 [kW]

1,000<Q≤3,000 [kW]

Unknown


Heating Capacity

18

8

18

7

15

0

4

1

13

0 5 10 15 20 25

T≤50 [°C]

50<T≤60 [°C]

60<T≤70 [°C]

70<T≤80 [°C]

80<T≤90 [°C]

90<T≤110 [°C]

110<T≤120 [°C]

120<T≤130 [°C]

Unknown


Supply Temperature

©CRIEPI

Installation Situation | Energy-saving Effects

13

Reduction of heat load by installation near process

Reduction of cooling load by simultaneous heating & cooling

Self heat recovery and high COP operation by MVR (Mechanical Vapor Recompression)

*

* *

* *

* * *

* * ** *

*

0

10

20

30

40

50

60

70

80

90

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51

Pri

mar

y En

erg

y Sa

vin

g Ef

fect

[%

]

■Simultaneous Heating & Cooling

■Mechanical Vapor Recompression (MVR)

■Waste Heat Recovery

■Others (Air Source, etc.)

* Reduction of heat load by installing near process

* 51 example cases which primary energy consumption reduction effects have been published among the total number 84 of installation cases collected

©CRIEPI 14

Case Study 1-Simultaneous Heating & Cooling-

©CRIEPI

Case 1 | Washing Process in Automobile Parts Production

15

Industry Machinery

Production Automobile parts (Differential case)

User company AISIN AW Co., Ltd.

Installed year 2010

Process Cutting (Cooling), Washing (Heating)

Application Hot Water (65°C) & Cold Water (15°C)

HP manufacturer Zeneral Heat Pump Industry Co., Ltd.

HP System AWW Heat PumpsRefrigerant: R134aHeating capacity: 476 kW(22 kW/unit × 6 units)(43 kW/unit × 8 units)

Effects CO2 reduction: 80%Primary energy reduction: 84%Energy cost reduction: 79%Payback period: 3.5 years

Outline of Installation Process and Application

Feed Material

Cutting Process

Washing Process

Assembly Process

• Coolingcutting liquid

• Heatingwashing liquid

Product (Differential Case)AWW Heat Pump(Air to Water & Water to Water)

©CRIEPI

AfterBefore


16

Boiler

Washing ProcessCutting Process

Cutting Liquid Washing Liquid

Chiller

Work

20°C 60°C

15°C

Steam

300m

Heat Pump

Washing ProcessCutting Process

Cutting Liquid

Work

20°C 60°C

15°C

65°C

Hot Water

Washing Liquid

Applicationof Heat Pump

Issue 1 | Low effective use of steamSteam was supplied from boiler to 300 m away washing machines. This caused large heat loss from piping. Total thermal efficiency of steam supply system was 0.2.

Issue 2 | Individual equipment installed in heating and cooling processChiller was used for cooling process. This caused hot waste heat dissipation to ambient air. Cooling COP of the chiller was 2.

Resolution | Installation of simultaneous heating & cooling heat pump near processBy installing heat pump near process, heat loss was reduced and supply temperature was decreased.And by simultaneous heating and cooling use, this heat pump could achieve total COP of 5.

©CRIEPI


17

Evaporator Condenser15°C

10°C

65°C

60°C

Compressor

Simultaneous Heating & Cooling Operation Mode

Evaporator15°C

10°C

Compressor

Condenser

Cooling Operation Mode

Evaporator

Condenser65°C

60°C

Compressor

Heating Operation Mode

0

5

10

15

20

25

30

35

40

0 10 20 30 40 50 60 70 80 90

Ther

mal

dem

and

[kW

]

Time [min]

Cooling demand

Heating demand

Simultaneous Heating & Cooling operation

Cooling operation Heating operation

Operation

3 operation modes

Switching operation modes and unit control can cope with unbalance between heating and cooling demand

No back-up boiler and chiller

©CRIEPI


18

Effects

CO2 emissions

‒ 80% reduction

‒ 1,094 ton-CO2/year reduction

Water consumption (Steam line)

‒ 100% reduction

‒ 6,953 kL-Water/year reduction

Primary energy consumption

‒ 84% reduction

‒ 437 kL-Oil/year reduction

Running cost

‒ 79% reduction

‒ 26 million JPY/year reduction

Payback period

‒ 3.5 years

One of Top 10 BATsto Improve Energy Efficiency

©CRIEPI

Other Simultaneous Heating & Cooling Application

19

Noodle production

Application of brine source heat pump hot water heater

Primary energy consumption: 35% reduction

Boiler Boiling bath Cooling bath

98°C 1°C

Boiler Boiling bath Cooling bath

98°C 1°C

Fuel Fuel

Feed Water 17°C Feed Water 17°C

Chiller

1°C

Feed Water 17°C

-5°C

1°C90°C Heat Pump

Hot Water TankIce thermal storage tank

Before


After

©CRIEPI

Summary | Simultaneous Heating & Cooling

20

Application Examples

16 examples in food industry

2 examples in machinery

Key points

Close distance of heating process and cooling process

Coping with unbalance between heating and cooling demand

‒ Resolution 1: Switching operation mode with AWW heat pump

‒ Resolution 2: Thermal storage

©CRIEPI 21

Case Study 2-MVR-

©CRIEPI

Case 2 | Concentration Process in Salt Production

22

Industry Food

Production Salt (from deep ocean water)

User company Muroto Kaiyoshinsosui Co., Ltd.

Installed year 2015

Process Concentration

Application Steam (70°C)

HP manufacturer Sasakura Engineering Co., Ltd.

HP System Mechanical Vapor Recompression (MVR)Steam temperature: 70°C (-0.07MPaG)Steam flow: 400 kg/h

Effects Primary energy reduction: 79%Energy cost reduction: 78%Payback period: 2 years (with subsidy)

Outline of Installation

3% 10% 24%

Concentration of salt

Process and Application

Feed MaterialConcentration

(RO Membrane)Concentration(Evaporation)

Crystallization Separation Shipping

• Deep Ocean Water • Reverse Osmosis Membrane

• MVR

• Steam Kettle • Centrifugal Separation

Mechanical Vapor Recompression Product (Salt)

©CRIEPI

AfterBefore


23

Boiler

Steam

RO Membrane

Steam Kettlefor Concentration

Steam Kettlefor Crystallization

3%

10%

24%

Centrifugal Separator

Concentrated Water Tank


Deep Ocean Water Tank

Salt+Bittern

Boiler

Steam

RO Membrane

3%

10%

24%

Centrifugal Separator



Deep Ocean Water Tank

Salt+Bittern

MVRApplicationof Heat Pump

Waste heat Heat recovery

©CRIEPI

After


24

Salt Water100°C

Salt Water65°C

Steam 60°C

70°CSteam

Waste Heat (Steam)

Steam K

ettle

Heat Loss

Steam K

ettle

Heat Loss

Waste Heat (Steam)

Heat Recovery

110°CSteam

Electric Power

Heavy Oil

Input Energy

Input Energy

Before

Atmospheric pressure

Vacuum pressure

©CRIEPI


25

Effects

Primary energy consumption

‒ 79% reduction(Evaporative concentration process)

‒ 49% reduction(Total salt production processes)

Energy cost

‒ 10 million JPY/year reduction

Payback period

‒ 2.0 years (with subsidy)

‒ 3.5 years (without subsidy)

0

0.2

0.4

0.6

0.8

1

1.2

Before After

Ene

rgy

Co

nsu

mp

tio

n [

L/kg

]

Concentration (Evaporation)CrystallizationConcentration (RO Membrane)Centrifugal Separation

▲49%

©CRIEPI

Summary | MVR

26

Application Examples

2 examples in concentration process (Salt production, Drainage treatment)

1 example in distillation process (Alcohol production)

2 examples in drying process (Tissue production, Sewage treatment)

Key points

Long time continuous process

Low BPR (Boiling Point Rising) for distillation process

Attention to corrosion or scale deposition because of direct compression

Described later(Case studies 3 & 4)

©CRIEPI

Case 3 | Distillation Process in Dextran Production

28

Industry Chemistry

Production Dextran (Polysaccharides)

User company Meito Sangyo Co., Ltd.

Installed year 2017

Process Distillation of methanol

Application Hot water (90°C)

Contractor Kimura Chemical Plants Co., Ltd.

HP manufacturer Kobe Steel, Ltd. (KOBELCO)

HP System HEM-HR90 (× 2 units)Refrigerant: R134a+R245faHeating capacity: 800 kW

Effects CO2 reduction: 60%Primary energy reduction: 60%Energy cost reduction: 63%


Feed Material FermentationCollection of Precipitation

Acid Hydrolysis

Collection of Precipitation

Vacuum Concentration

Spray DryingDextran

(Powder)

• Sugars • Distillation of methanol

• Distillation of methanol

Heat Pump Distillation Column Product (Dextran)

©CRIEPI


29

Boiler

City Gas

Methanol drainage 50%

Cooling Tower

Methanol 99% over

Distillate Cooler

Steam 120°C

65°C

100°C

Reboiler

Water

Distillation column

(Atmospheric pressure)

Before

Waste heat

30°C

35°C


Methanol drainage 50%

Distillate Cooler

44°C

80°C

Reboiler

Water

Distillation column

(Vacuum pressure)

After

Heat recovery

30°C 35°C

Methanol 99% over

86°C 80°C

Heat pump

Electric Power

Hot water supply HP can be used when distillation column is decompressed.

©CRIEPI


30

Why MVR was not selected?

44°C

80°C

M

M

M

M

M

M

Compressor× 6 stages

MVR

Require a special specification compressorbecause of methanol vapor compression

Require 6 stage compressors because of high BPR→ high cost and complicated operation

86°C

Heat Pump

Lower risk of methanol flammability Use a general-purpose heat pump→ lower cost and better operability

44°C

80°C

30°C 35°C

Methanol 99% over

80°C 86°C

Heat pumpHigh BPR

(ΔT=42°C)

©CRIEPI

Case 4 | Distillation Process in Bio-ethanol Production

31

Industry Chemistry

Production Bio-ethanol

User company Hokkaido Bioethanol Co., Ltd.

Installed year 2012

Process Distillation of ethanol

Application Steam (120°C)

Contractor Japan Chemical Engineering & Machinery Co., Ltd.

HP manufacturer Kobe Steel, Ltd. (KOBELCO)

HP System SGH120 (× 5 units)Refrigerant: R245faSteam flow: 2 ton/h

Effects CO2 reduction: 43%Energy cost reduction: 54%Payback period: 3.5 years


Feed Material Liquefaction Fermentation

Distillation Dehydration Shipping

• Sugar beet• Non-standard wheat

• Steam supply • Zeolite membrane

10% 95% 99.5%

Concentration of Ethanol

Heat Pump Distillation Column

©CRIEPI

Case 4 | Distillation Process in Bio-ethanol Production

32

Boiler

Heavy Oil

Fermentation liquid 10%

Cooling Tower

Ethanol 95%

Distillate Cooler

Steam 110°C

80°C

100°C

Residual remnant

Distillation column


Before

Waste heat


Fermentation liquid 10%

Distillate Cooler

80°C

100°C

Distillation column


After

Heat recovery

60°C 65°C

Ethanol 95%

Residual remnantElectric Power

Flash TankHeat Pump

115°C

110°C

Steam 110°C

Steam supply HP is used when distillation column is not decompressed.

©CRIEPI

Conclusions

34

Installation Situation of Industrial Heat Pumps in Japan

Installation target by the government is heating capacity of 1,673 MW by FY2030.

Heating capacity of 88.1 MW was installed before FY2016.

The most have been installed in “Food industry.”

The HP type used most often is “Circulation heating hot water supply HP.”

Effective Applications

Reduction of heat load by installation near process

‒ Leads to high COP operation by low temperature lift and self heat recovery

Simultaneous heating and cooling

‒ Applied industry: Food industry, Machinery

Mechanical vapor recompression (MVR)

‒ Applied process: Concentration, Distillation, Drying

‒ In the case of high BPR for distillation, indirect self heat recovery is selected.

Industrial Heat Pump Applications in Japan€¦ · ©CRIEPI 56% 26% 18% Industrial 6,600 PJ/year...

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Transcript of Industrial Heat Pump Applications in Japan€¦ · ©CRIEPI 56% 26% 18% Industrial 6,600 PJ/year...