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Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 1
3rd Conference of AHPNW “Research and Development of
Heat Pump and Thermal Storage Technologies
in Industrial and Residential Sectors”
Pioneering
Industrial Heat Pump Technology
in Japan
Dr. Choyu Watanabe
Chubu Electric Power Co., Inc.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 2
1 Introduction
2 Apparatus technology 1) Definition and types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application 1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
Contents
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Heat pump technology important for boosting
Reducing CO2 emissions
Reducing primary energy consumption
Increasing the amount of renewable energy used
Scope of industrial applications Expected to expand,
further enhancing these effects
Introduction
3
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Pioneering
Industrial Heat Pump Technology
in Japan
for hot water supply
for hot air supply
for re-heating of circulating water
for steam generation
4
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 5
IEA (International Energy Agency)
HPP (Heat Pump Program)
HPP operates under the IEA and was founded in 1978 as one
of the international technology collaborations on the basis of
implementing agreements.
HPP is a non-profit organization under which participants in
different countries cooperate in projects in the field of heat
pumps and related heat pumping technologies such as air
conditioning, refrigeration and working fluids (refrigerants).
The current member countries are Austria, Canada, Denmark,
Finland, France, Italy, Germany, Japan, the Netherlands,
Norway, South Korea, Sweden, Switzerland, United Kingdom
and the United States.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 6
The objective of the annex is to reduce the use
of energy and emissions of greenhouse gas
emissions by the increased application of heat
pumps in industry.
Start date: May 2010, End date: April 2014
IEA HPP Annex 35
(Application of industrial heat pumps)
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 7
IEA HPP Annex 35 National expert meeting of Japan
Objectives
・Mutual exchange of information on industrial heat pumps
・Providing a country report for Annex activities
Members
・Organized by stakeholders of industrial heat pumps
・21 people from universities, research institutes, electric power
utility, engineering and manufacturing companies
Representative organizations for the IEA HPP
・NEDO (New Energy and Industrial Technology Development
Organization )
・HPTCJ (Heat Pump & Thermal Storage Technology Center
of Japan)
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 8
1 Introduction
2 Apparatus technology 1) Definition and types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application 1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
Contents
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 9
Definition of Industrial Heat Pumps
Heat pumps used for
recovery and heat upgrading
in industrial processes
and for
heating, cooling and air-conditioning
in industrial buildings
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 10
closed-cycle mechanical heat pump open-cycle mechanical vapor
recompression heat pumps
open-cycle thermal vapor
recompression heat pumps closed-cycle absorption heat pumps
Four General Types of Industrial Heat Pumps [1]
[1] US Department of
Energy: "Industrial Heat
Pumps for Steam and Fuel
Savings", DOE/GO-
102003-1735, 2003.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 11
1 Introduction
2 Apparatus technology 1) Definition and types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application 1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
Contents
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 12
High Temperature Heat Pumps
Closed-cycle mechanical heat pump
• CO2 transcritical cycle
• Single-stage compression reverse Rankine cycle
• Two-stage compression reverse Rankine cycle
• Cascade reverse Rankine cycle
Open-cycle mechanical vapor recompression heat pumps
Open-cycle thermal vapor recompression heat pumps
• Hybrid vapor recompression system
Closed-cycle absorption heat pumps
• Type-2 absorption heat pump
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
1.0 1.2 1.4 1.6 1.8 2.0
0
50
100
150
Entropy: S(kJ/(kg*K)
Tem
per
atu
re:t(℃
)
Liquid & GasGas
Critical Point
Super Critical
Hot Water (Air) Supply
3.5MPa
12MPa
Cool Water (Air)
CO2 Transcritical Cycle
13
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Water-Source CO2 Transcritical Heat Pump
Mayekawa Mfg. Co., Ltd.
delivering hot air, with screw type compressor
14
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 15
PE02
H01
PE03
Valve
TE02
Evaporator
TE01
Ball valve
Compressor
PE01
Evaporator
Charge port
Gas cooler
Internal heat exchange
TE03
TE04
TE05
PS01
strainer
FS01
TE
07
TE
06
Heat
sou
rce
wate
r ou
tlet
Heat
sou
rce
wate
r in
let
strainer
Ball valve
Air
Hot air
Eco-Sirocco Piping diagram
Type:ES-HAW12 Ver.1.1
Valv
e
High pressure refrigerant
Heat source water
Low pressure refrigerant
Symbol Equipment name
EXV01,EXV02 Electronic expansion valve
H01 Oil heater
PS01 Pressure switches
PE01 ~ PE03 Pressure transmitter
TE01 ~ TE07 Resistance Temperature Detector ( RTD )
FS01 Fluid sensor
EXV01
EXV02
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 16
High Temperature Heat Pumps
Closed-cycle mechanical heat pump
• CO2 transcritical cycle
• Single-stage compression reverse Rankine cycle
• Two-stage compression reverse Rankine cycle
• Cascade reverse Rankine cycle
Open-cycle mechanical vapor recompression heat pumps
Open-cycle thermal vapor recompression heat pumps
• Hybrid vapor recompression system
Closed-cycle absorption heat pumps
• Type-2 absorption heat pump
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Single-stage Reverse Rankine Cycle (R134a)
17
1.2 1.4 1.6 1.8 2.0 0
50
100
Entropy: S(kJ/(kg*K)
Tem
per
atu
re:t(℃
)
Liquid + Gas Gas
Critical Point
Liquid
Hot Water
0.5MPa
1.5MPa
Cool Water (Air)
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Heat Pump for Washing Process
18
Zeneral Heat Pump Industry Co., Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 19
High Temperature Heat Pumps
Closed-cycle mechanical heat pump
• CO2 transcritical cycle
• Single-stage compression reverse Rankine cycle
• Two-stage compression reverse Rankine cycle
• Cascade reverse Rankine cycle
Open-cycle mechanical vapor recompression heat pumps
Open-cycle thermal vapor recompression heat pumps
• Hybrid vapor recompression system
Closed-cycle absorption heat pumps
• Type-2 absorption heat pump
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Two-Stage Compression
Reverse Rankine Cycle (R134a)
20
1.2 1.4 1.6 1.8 2.0 0
50
100
Entropy: S(kJ/(kg*K)
Tem
per
atu
re:t(℃
)
Liquid + Gas Gas
Liquid
Hot Water
Cool Water
Critical Point
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 21
System flow
Heat source water
Outlet temperature
Heat source water
Inlet temperature
10 ~ 50 ℃
Heat source
the quantity of heat
Q1
The maximum hot water
Inlet temperature
90 ℃
Hot water
Hot water
the quantity of heat
Q2 = Q1 + W
Electric power W
Economizer
Turbo compressor
Hot water heat pump
ETW - L
The main
expansion valve
Vice-expansion valve
The first step impeller The second step impeller
Evaporator Condenser
Waste Heat Recovery Heat Pump Water Heater
Two-Stage Turbo-Compressor System with Economizer
Mitsubishi Heavy Industries, Ltd.
Refrigerant: R-134a
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 22
Waste Heat Recovery Heat Pump Water Heater
Two-Stage Turbo-Compressor System with Economizer
Mitsubishi Heavy Industries, Ltd.
Heating capacity(kW) 376 545 547
Cooling capacity (kW) 266 400 405
Electrical output of Compressor motor (kW)
104 136 133
Condenser
Entering water temperature (oC)
50 65 80
Leaving water temperature (oC)
60 75 90
Evaporator
Entering water temperature (oC)
15 35 50
Leaving water temperature (oC)
10 30 45
Specifications
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Two-Stage Compression Reverse Rankine Cycle
(R245fa)
23
1.2 1.4 1.6 1.8 2.0
50
100
150
Entropy: S(kJ/(kg*K)
Tem
per
atu
re:t(℃
)
Liquid + Gas Gas
Critical Point
Liquid
Hot Water (Steam)
0.4MPa
2.3MPa
Cool Water
1.0MPa
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Refrigerant Compressor
Expansion
Valve
Condenser Evaporator
Flash
Tank
Waste Hot
Water (65oC)
Water
Supply
(20oC)
Steam, 120oC,
0.1MPa Gauge,
0.51t/h Heat Pump Unit
Steam-Generating Heat Pump SGH 120 Model
24
370kW, COP3.5 Industrial Process
Kobe Steel, Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 25
Steam-Generating Heat Pump SGH 120 Model Supply 0.0 to 0.1 MPa Gauge steam, lifting up waste heat at 35 to 65oC
Flash Tank
Kobe Steel, Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Refrigerant Compressor
Expansion
Valve
Condenser Evaporator
Steam Compressor
Flash
Tank
Waste
Hot Water
(70oC)
Water
Supply
(20oC)
Steam
100-110 oC
Steam, 165oC,
0.6MPa Gauge
0.89t/h
Heat Pump Unit
26
660kW, COP2.5
Steam-Generating Heat Pump SGH 165 Model
Industrial Process Kobe Steel, Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 27
Steam-Generating Heat Pump SGH 165 Model Supply 0.2 to 0.8 MPa Gauge steam, lifting up waste heat at 35 to 70oC
Flash Tank
Kobe Steel, Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 28
Steam-Generating Heat Pump SGH 165 Model
Installed at Electric Power Engineering Research Laboratory
of Central Research Institute of Electric Power Industry (CRIEPI),
Yokosuka City, Japan
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 29
High Temperature Heat Pumps
Closed-cycle mechanical heat pump
• CO2 transcritical cycle
• Single-stage compression reverse Rankine cycle
• Two-stage compression reverse Rankine cycle
• Cascade reverse Rankine cycle
Open-cycle mechanical vapor recompression heat pumps
Open-cycle thermal vapor recompression heat pumps
• Hybrid vapor recompression system
Closed-cycle absorption heat pumps
• Type-2 absorption heat pump
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 30
Cascade Reverse Rankine Cycle For Reheating Circulating Hot Water
R134a
cycle
R410A
cycle
45oC
7oC
88oC
40oC
100
60
0
-20
120
40
20
80
Tem
pera
ture
(oC
)
100 200 300 400 500
Enthalpy (kJ/kg)
Cool
Water
or Air
Hot
Water
or Air
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 31
Supply unit
1st stageHeating in the compressor
2nd stageFurthermore, heating in the compressor
( Image )
Heat source unit
Circulation pump
Washing machine ・Heating system etc.
Circulation
heating
Heat of
the air
Heat of
the air
Heat of
the air
The reuse of the cold air
is possible, too
Cascade Heat Pump System for Reheating Circulating Hot Water
Toshiba Carrier Corporation
Heating capacity 14.0kW
COP 3.5*
Leaving water temperature 50- 90 oC
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 32
Heat source unit (R410A, Twin Rotary Compressor)
Cascade Heat Pump System for Reheating
Circulating Hot Water
Supply source unit (R134a, Twin Rotary Compressor)
Toshiba Carrier Corporation
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 33
High Temperature Heat Pumps
Closed-cycle mechanical heat pump
• CO2 transcritical cycle
• Single-stage compression reverse Rankine cycle
• Two-stage compression reverse Rankine cycle
• Cascade reverse Rankine cycle
Open-cycle mechanical vapor recompression heat pumps
Open-cycle thermal vapor recompression heat pumps
• Hybrid vapor recompression system
Closed-cycle absorption heat pumps
• Type-2 absorption heat pump
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 34
Hybrid Vapor Recompression System Mayekawa Mfg. Co., Ltd.
Thermal vapor recompression
Mechanical vapor recompression
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 35
High Temperature Heat Pumps
Closed-cycle mechanical heat pump
• CO2 transcritical cycle
• Single-stage compression reverse Rankine cycle
• Two-stage compression reverse Rankine cycle
• Cascade reverse Rankine cycle
Open-cycle mechanical vapor recompression heat pumps
Open-cycle thermal vapor recompression heat pumps
• Hybrid vapor recompression system
Closed-cycle absorption heat pumps
• Type-2 absorption heat pump
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 36
Solution temperature
Sat
ura
ted t
emper
ature
Hot waterCooling water Steam
Q
Q
Abs.
Gen.
Eva.
Con.
(ABSORPTION HEAT TRANSFORMER)
Type-2 Absorption Heat Pump
Duhring diagram
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 37
Absorber
GeneratorEvaporator
Condenser
Steam
Hot
Water
80-90oC
Cooling
Tower
40oC
Tem
pera
ture
Refrigerant
vapor
Refrigerant
lift
temperature
Refrigerant
vapor
Strong
Solution
Solution Heat
Exchanger
Weak
Solution
Feed
Water
temperature
difference
120oC
WASTE HEAT RECOVERY STEAM GENERATOR
(ABSORPTION HEAT TRANSFORMER)
Type-2 Absorption Heat Pump
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 38
Type 003 006
Steam
Production 385 kg/h 770 kg/h
Temperature 120 °C
Pressure 0.2 MPa (Absolute)
Feed water temperature 80 °C
Hot water 88 → 79.3 °C
895 L/min 1790 L/min
Cooling Water 25 → 30 °C
775 L/min 1550 L/min
Power source 3φ200 V × 50/60 Hz
Operating weight 6 ton 9 ton
Size (mm) L2100 × W1800
× H2550
L3600 × W1800 ×
H2550
EBARA Refrigeration Equipment &Systems Co., Ltd.
Specifications of waste heat recovery steam generators
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 39
Waste Heat Recovery Steam Generator (Type 006) EBARA Refrigeration Equipment &Systems Co., Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 40
Waste hot water
Steam Header
Equipment
A
Equipment
B
Absorption
heat transformer
Boiler A Boiler BCooling
Tower
Ejector
2.0MPa 92
0.5MPa 134Process
89100Fuels
47
0.1MPa 42
number : energy ratio
Block Diagram of the System Installed
Heat Recovery Steam Generator (Type 006) EBARA Refrigeration Equipment &Systems Co., Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 41
1 Introduction
2 Apparatus technology 1) Types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application 1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
Contents
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 42
Basic Characteristics of Refrigerants
for High Temperature Heat Pump Applications
Refrigerant Chemical formula GWP Flammability Tc oC
Pc MPa
NBP oC
R744 CO2 Carbon dioxide 1 none
30.98 7.3773 -78.40
R1234yf CF3CF=CH2 2,3,3,3-
tetrafluoropropene 4 weak 94.7 3.382 -29.48
R134a CF3CH2F 1,1,1,2-
tetrafluoroethane 1430 weak 101.06 4.0593 -26.07
R1234ze(E) CFH=CHCF3 trans-1,3,3,3-
tetrafluoropropene 6 weak 109.37 3.636 -18.96
R1234ze(Z) CHF=CHCF3 cis-1,3,3,3-
tetrafluoropropene <10 none 153.7 3.97 9.76
R245fa CF3CH2CHF2 1,1,1,3,3-
pentafluoropropane
1030 none 154.01 3.651 15.14
R365mfc CF3CH2CF2C
H3 1,1,1,3,3-
pentafluorobutane 794 weak 186.85 3.266 40.19
for low GWP
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 43
Saturated Vapor Pressure Curve
R134a R1234ze(E)
R245fa R1234ze(Z)
R365mfc
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 44
1 Introduction
2 Apparatus technology 1) Definition and types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application 1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
Contents
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 45
If
Heat generated with heat pumps
Waste heat exhausted in plants
Stored in a thermal storage material,
We can expect
Improvement of disparities between day(peak) and
night(off-peak) power loads
Further utilization of waste heat
Normally
Water or ice are used as thermal storage materials.
But
Thermal storage materials
Over a wide temperature range from -3 to 250 oC
Thermal Storage Materials
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 46
Thermal
storage material
Melting point
(oC)
Latent Heat
(kJ/kg)
Application method and
field
Trehalose
C12H22O11
0 to -3 Nearly 210 Ice slurry (0 to 30 wt. %),
Cold storage of food
Tetra-n-butyl ammonium
bromide Type 1
5 to 8 193 Hydrate slurry
(13 to 20 wt. %),
Air conditioning of
machine parts factories
Parafin
(tetradecane)
5.9 229.1 Ice slurry (10 wt. %),
Air conditioning of
machine parts factories
Sodium acetate trihydrate
CH3COONa•3H2O
58.8 247 - 255 Thermal storage for solar
water heater or waste
heat of 60°C
Erythritol
HOCH2 (CHOH)2CH2OH
118 320 Thermal storage for waste
heat of a temperature
below 200°C Mannitol
HOCH2(CHOH) 4 CH2OH
165.5 303.7
Characteristics and Application of Thermal Storage Materials
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 47
1 Introduction
2 Apparatus technology 1) Definition and types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application 1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
Contents
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Steam Supply Service in a Manufacturing Plant
Producing cars, auto parts, electrical equipment, food, etc.
Steam is produced in the energy center
Supplied to some factories and all areas of each factory
Used in the manufacturing process
48
Energy Center
Factory Factory Factory
Factory Factory Factory
Manufacturing Plant
Steam Supply Service
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Total Energy Efficiency of Steam Supply Service
generally low (e.g. 20%-40%) due to
Boiler loss
Heat loss from piping
Steam leakage loss in traps
Drain recovery loss
49
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Steam Supply Service in a Factory
The most commonly used steam temperature
zone is in the range e.g. 55-80℃
Many electric heaters are used for these
processes for which temperature control is
required
50
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Distributed Heat Pumps Significant energy savings are expected by
Replacing some steam supply service and electric heaters
With distributed high-temperature heat pumps
51
Heat Pumps Heat Pumps,
Preheating
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Heat Recovery Simultaneous utilization of cooling and heating
Utilization of waste heat
52
Heat Pump Heat Pump,
Preheating
Steam
Generating
Heat Pump
Waste Heat Refrigeration Cooling
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 53
Type of industry Process
Temperature (oC)
40 60 80 100 120
Non-electrical machine
Drying
Washing
Degreasing
Electrical machine
Drying
Washing
Degreasing
Transport equipment Washing
Drying
Food
Boiling
Sterilization
Washing
Beverage Washing
Sterilization
Air
Water
Steam
Temperature of Heat Demand in Industrial Processes
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 54
1 Introduction
2 Apparatus technology 1) Definition and types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application 1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
Contents
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 55
nearly 20oC nearly 60oC
Cutting Process and Washing Process
Cutting and washing process of machinery parts
Cooling water-soluble cutting oil with chillers
Heating washing liquid by boiler steam
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Heat Pump for Washing Process
56
Zeneral Heat Pump Industry Co., Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 57
Ground Plan of Machine Parts Factories
with Heat Pump Installed
East Factory West Factory
8 heat pumps with heating power of 44kW
Heating power of 22kW
6 heat pumps with heating power of 22kW
AISIN AW Co., Ltd., Gamagori plant
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 58
Operation Results of Heat Pumps for Washing Process
in the Machine Parts Factories
Energy Consumption [GJ/year]
CO2 Emission [ton-CO2/year]
Conventional System
20,238 1,340
Developed System
5,515 194
Rate of Reduction
73% 86%
Reduction of 89 % in running cost
Payback time of Investment is 3 or 5 years
Gamagori plant, AISIN AW Co., Ltd.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 59
Temperature of the Heat Demand in General Painting
Process in Car Production Factory
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 60
Hot water tank
Booth(Recycled air)Booth(Fresh air)
SA
EA EA
Fresh air
conditioner
SA
EA EA
Fresh air
conditioner
RA
RA
Conventional system
Steam boiler
Absorption refrigerator
Steam coil Hot water coil
INV
Booth(Fresh air) Booth(Recycled air)
Steam drain
Heat recovery
heat pump
Modified system
Steam boiler
Absorption refrigerator
Heat Pump Introduction to Painting Process in Car Production
Hamura No4 plant, Hino Motors, Ltd. <Engineering>
Taikisha Ltd.
Tokyo Electric Power Co., Inc.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 61
Type HEM-150Ⅱ
Cooling capacity 456 kW
Heating capacity 566 kW
Refrigerant HFC407E
Compressor Starting system
Inverter
Type Semi-hermetic twin-screw
Input 110.1 kW
Rated COP Cooling 4.14
Heating 5.14
Quantity 1
Heat Recovery Heat Pump
Annual operating time
4,880 hr.
Hamura No4 plant,
Hino Motors, Ltd.
<Engineering>
Taikisha Ltd.
Tokyo Electric Power Co., Inc.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 62
Effects of Introduction of the Heat Pumps
Compared with the Conventional System
A reduction of 63% in running cost
A reduction of 47% in CO2 emission
A reduction of 49% in primary energy
Payback time of Investment is 3 or 4 years
Hamura No4 plant,
Hino Motors, Ltd.
<Engineering>
Taikisha Ltd.
Tokyo Electric Power Co., Inc.
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 63
1 Introduction
2 Apparatus technology 1) Definition and types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application 1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
Contents
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
Pioneering high-temperature heat pumps in Japan
• CO2 transcritical cycle
• Single-stage compression reverse Rankine cycle
• Two-stage compression reverse Rankine cycle
• Cascade Rankine cycle
• Hybrid vapor recompression system
• Type-2 absorption heat pump
The energy efficiencies of steam supply service and
electric heaters in manufacturing plants are often
low.
Significant energy savings are practicable by
distributed heat pumps and heat recovery.
64
Conclusions
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
In order to apply heat pumps for industrial applications,
• Investigate the required heat condition at end
demand, waste heat, operation time, installation
space, etc. for each manufacturing process
carefully
• Identify and quantify energy savings, economic
benefits, etc.
In order to disseminate industrial heat pumps,
• Provide many examples of application which show
the benefits of the heat pumps clearly
65
Prospects
Heat Pump & Thermal Storage Technology Center of Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 66
Thank you for your attention !