DENSO CORPORATION

　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.　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 body with the heat pump unit developed as the 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.

March 2013

DENSO CORPORATION

・IEnergy Use Rat iona l i zat ion Technology St rateg ic 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 EcoCuteResidential Heat Pumps ‒ Contributing to Expanding the Market for EcoCute

The installed heat exchanger,an important component that gathers heat within the air to create hot-water.

Fin of heat exchanger

Energy Conservation

20

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 o f the i r h igh fue l effic iency 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, and achieving environmental performance on par with that of gasoline engines by purifying the exhaust gas has required the use of a catalyst that requires a large amount of noble metal and large exhaust gas treatment equipment such as urea SCR equipment. Against this background, NEDO conducted the “General

Technological Development for Innovative Next-generation Low-emission Vehicles” Project for five years from FY2004 with the aim of improving the environmental performance of diesel engines to alleviate global warming and reduce the emissions of environmental pollutants. Mazda Motor Corporation, which is the automobile manufacturer that has 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

“ A T E N Z A” a n d “ C X - 5 , ” a n d t h e n u m b e r o f SKYACTIV-D-equipped MAZDA vehicles sold (in Japan) by June 2013 exceeded 50,000, thereby greatly contributing to the popularization of diesel engine vehicles, which helps reduce greenhouse gas emissions.

Mazda Motor Corporation

July 2013

Energy Conservation

Mazda Motor Corporation

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

・General Technological Development of Innovat ive Next-generation Low-emission Vehicles (FY2004-2008)

The piston head part of “SKYACTIV-D” - the shape with the large dent has made it possible to achieve high fuel efficiency and reduced pollutant emissions at the same time.

The high fuel efficiency-SKYACTIV-D engine with cleaner exhaust gas. This engine has an RPM range that is as wide as that of a gasoline engine. (photos courtesy of Mazda Motor Corporation)

Burning the fuel after it has been uniformly mixed with air at a low compression ratio improves the burning efficiency and reduces NOx and soot.

Conceptual diagram of the burning inside the engine

Oxygen

Fuel particle

Soot

High compression ratio Low compression ratio

Uneven burning - The burning efficiency in the thick part is low.

The burning efficiency is high because the degree of unevenness is lower.

21

JATCO Ltd.

　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 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 realized. This has been recognized as a remarkable academic result as well.　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.　

March 2013

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

JATCO Ltd.

・Development of Material Surface Control Technology for Low F r i c t i o n L o s s H i g h E ffi c i e n c y D r i v e M a c h i n e s (FY2002-FY2006)

The pulley of a CVT.The coefficient of friction is improved by engraving detailed grooves.

Mechanism of a CVT (Image provided by JATCO Ltd)

Pulley

Energy Conservation

22

Mitsubishi Fuso Truck and Bus Corporation

　Eco-friendly vehicles that emit fewer greenhouse gases and air pollutants are becoming more popular. As with passenger vehicles, the demand is also increasing for commercial vehicles such as trucks and buses which operate on hybrid systems that integrate internal combustion engines and electric motors.　About 20% of the CO2 emissions in Japan are 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 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

December 2009

on the market in 2006 and the Aero Star Eco Hybrid large route bus was released in 2007. Both exceed Japan’s 2015 fuel efficiency standards for heavy-duty vehicles. As of March 2011, more than 1,000 Canter Eco Hybrid trucks had been sold. With orders now coming in from Ireland and Australia, these hybrid vehicles are drawing worldwide attention.

Mitsubishi Fuso Truck and Bus Corporation

Trucks and Buses Also Follow Hybrid TrendsTrucks and Buses Also Follow Hybrid Trends

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

Total engine exhaust (in liters)

Conventional buses: Hybrid buses:

Aero Star Eco Hybrid large route bus engine

Engine room of Aero Star Eco Hybrid

Energy Conservation

23

Hitachi Vehicle Energy, Ltd.

　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 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.　H i t a ch i Veh i c l e Ene r g y pa r t i c i pa t ed i n a groundbreaking 10-year NEDO project in the early 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, but through the collaboration of engineers from a various fields, it eventually succeeded in the stable production of lithium-ion secondary batteries.　Having succeeded in developing high-quality, large-capacity and high-power lithium-ion secondary batteries, Hitachi Vehicle Energy has emerged as the global leader in production of the technology, supplying more than three million battery cells for use in hybrid electric vehicles throughout the world.

December 2009, March 2010

Hitachi Vehicle Energy, Ltd.

・Development of Technology for the Dispersed S t o r a g e o f B a t t e r y P o w e r ( L I B E S ) (FY1992‒FY2001),etc.

Output density

Energy density

Hybrid-use

Leadstoragebatteries

Nickel-hydrogen batteries

4th generation

3rd generation

2nd generation

1st generation

Evolution of lithium-ion secondary batteries

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

Hybrid electric vehicles

48-cell module

Energy Conservation

24

　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

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

excavator in 2006.

　The two companies continued their efforts to

develop practical applications for this technology, and

in January 2010 they began marketing the 8-ton-class

SK80H-2 hybrid excavator, which was 40% more fuel

efficient than conventional excavators. That year, the

SK80H-2 received a 2010 Minister of the Environment

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

Ministry of Land, Infrastructure, Transport and Tourism.

　In addition to contributing to the development of

the hybrid excavator, NEDO’s research achievements

are now being applied to the development of more

fuel-efficient conventional machinery. As a result of

these efforts, Kobelco Construction Machinery has

successfully enhanced the fuel efficiency of its

conventional equipment by about 20%.

Kobelco Construction Machinery Co., Ltd.Kobe Steel, Ltd.

March 2012

Development of World’s First Hybrid Hydraulic Excavator Contributes Greatly to Energy Saving and CO2 ReductionDevelopment of World’s First Hybrid Hydraulic Excavator Contributes Greatly to Energy Saving and CO2 Reduction

Kobelco Construction Machinery Co., Ltd. / Kobe Steel, Ltd.

・New Sunshine Project/Research and Development Project of Technologies for Creating New Environment Industry/ Research and Development of Hybr id Construct ion Machinery (FY1999‒FY2002),etc.

The output of standard equipment (red line) can be achieved even with a small engine (blue line) using a battery and motor.

Engine

Battery

Rotary motor

Control valve

Generator motor

Hydraulic pump

Motor of hybrid excavator currently on the market

Standard model: Selection of engines taking into account maximum load

SK70SR-2 Engine output: 41kW

Load exceeding engine output→ Assisted by battery 　 generator moor

Load below engine output→ Recharges battery

Hybrid model: Selection of engine taking into account average load

SK80H-2 Engine output: 27kWMotor output: 20kW

(High)

Load

(Low)

Image drawing

Time

Radiator

Energy Conservation

25

Mitsubishi Heavy Industries, Ltd.

　Ever since the Great East Japan Earthquake that

took place on March 11th, 2011, the dependence on

thermal powered generation has been increasing.

Currently, almost 90% of Japan’s demand for

electricity is being supplied by thermal powered

generation. In midst of this, the “Gas Turbine

Combined Cycle Generator System (GTCC)” is

gathering attention due to having a high heat

effic i e n c y o f o v e r 60% , a nd h a v i n g a lmo s t

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

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

turb ines for generators dur ing the per iod of

January-September of 2012, while Siemens has 38%,

Mitsubishi Heavy Industries having 26% is catching up

to compete for second place with GE now having

December 2012

32%. Not only do such gas turbines contribute to

Japan’s current electricity demand and measures to

prevent global warming, they in the future are

anticipated to greatly contribute to developing

countries where a great increase in the demand for

electricity is expected to occur.

Mitsubishi Heavy Industries, Ltd.

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

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

Cooling hole of blade

Energy Conservation

26

　The steam produced when heated water boils and evaporates is used for a wide range of purposes at manufacturing sites and various other kinds of facilities. During manufacturing processes, this steam is reduced to the necessary pressure by the steam 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 effectively use excess steam without wasting it. In 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 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 kW power-generating capacity units and has sold 80 SteamStar generators to date.

Kobe Steel, Ltd.

March 2011

Micro Steam Energy Generator Effectively and Thoroughly Utilizes Manufacturing SteamMicro Steam Energy Generator Effectively and Thoroughly Utilizes Manufacturing Steam

Kobe Steel, Ltd.

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

SteamStar installed at a steam manufacturing plant in Amagasaki, Hyogo PrefectureCompact design saves space and reduces construction costsUnits can be installed indoors or outdoors.

Illustration of boiler and SteamStar combination

high-precision machining screw

Steamprocess

(Installation setup for steam process)

Boiler

Steam reducing valve

Energy Conservation

27

Mitsui Engineering & Shipbuilding Co., Ltd.

　When operating a power generator using a heat engine, the generation of waste heat is unavoidable. Because the supply of electricity in Japan has been mainly based on intensive large-scale power stations, it has not been possible to uti l ize this waste heat. In recent years, however, “cogeneration” has been gaining popularity. Cogeneration is a mode of power generation wherein both electricity and heat are supplied. That is, power generation equipment is installed at facilities of customers and local areas and the heat generated by the power generation is collected and utilized for such purposes as air conditioning and the 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 b o t h e l e c t r i c i t y a n d h e a t a r e s u p p l i e d o n a l o c a l i t y - b y - l o c a l i t y ( o r b u i l d i n g - b y - bu i l d i n g o r 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 the utilization ratio between electricity and heat reduce the energy-saving performance. 　Aga ins t th i s background , M i t su i Eng ineer ing & 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 benefit from the introduction of cogeneration. With regard

December 2013

to the stand-alone gas engine power generation efficiency, Mitsui Engineering & Shipbuilding Co., Ltd. achieved an efficiency value of 42.5%, which is a value on the world’s highest level. At present, five cogeneration system units and four stand-alone gas engine units (a total of nine units) are in operat ion throughout Japan. In the area of stand-alone engine products, Mitsui Engineering & Shipbuilding Co., Ltd. developed a gas engine product that is one class larger together with Daihatsu Diesel Mfg. Co., Ltd. after completion of the project, and started selling the product in 2012 (three units are already in operation).

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

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

Mitsui Engineering & Shipbuilding Co., Ltd.

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

Knocking detection sensor attached to the gas engine

Pilot fuel injection valve for ignition - one of the key components that have made it possible to achieve the high efficiency.

Energy Conservation

28

Among “refrigerating warehouses” used to store foods in the frozen state, those used to store large high-value fishes such as tuna and skipjack at a temperature below -50℃ are called “ultra-low-temperature refrigerating warehouses.” There are about 400 such refrigerating warehouses throughout Japan (in fishery bases for tuna fishing boats, fish-consuming large cities and other places), and they are supporting the physical distribution of fish to restaurants, our homes, etc. However, it is not well known that the use of these ultra-low-temperature 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 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.

November 2013

In December 2008 (which was five and half years after the start of the development), MAYEKAWA MFG. CO., LTD. started selling “PascalAir,” an air refrigerant-based freezing system for ultra-low-temperature refrigerating warehouses. A total of about 25 units of PascalAir were introduced at facilities in Japan in five years after the start of sale. It is expected that PascalAir will become more popular in the future as the demand for PascalAir w i l l i nc rease i n con junc t ion w i th renova t ion o f o ld ultra-low-temperature refrigerating warehouses.

MAYEKAWA MFG. CO., LTD.

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

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

The “heart” of PascalAir - the compressor with integral turboexpander

The PascalAir unit installed in a facility of Fukazawa Reizo K.K.

Energy Conservation

29

JFE Engineering Corporation

　Air-conditioning systems that offer both cooling and

heat ing a re ind i spensab le fo r ma in ta in ing a

comfortable environment in highly populated facilities

such as office buildings, shopping centers and

factories. Unlike residential air-conditioning units,

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 consumpt ion o f pr i vate -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

system that uses hydrate slurry (NeoWhite) to store

thermal energy instead of water or ice as in

conventional air-conditioning systems. This new

s y s t em , wh i c h h a s c on t r i b u t ed g r e a t l y t o

air-conditioning energy savings in the commercial

property sector, is the result of JFE Engineering’s

cont inuous efforts to apply the expert ise and

knowledge its research and development staff has

achieved through NEDO projects, from the initial

stages of development to the final demonstration and

practical application stages.

　As of September 2011, the system was in operation

at eight facilities, including the Azalea underground mall

adjacent to Kawasaki Station in Kanagawa Prefecture,

Yokohama City Shopping Center, and a bearing plant in

September 2011

Bizen City, Okayama Prefecture. Outside of Japan, the

system has been installed in several facilities in North

America as part of JFE Engineering’s efforts to market

Japanese energy-efficiency heat storage technology

abroad.

JFE Engineering Corporation

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

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

Hydrate slurry is generated using three systems: a solvent overcooling system, an overcooling termination system, and a NeoWhite cooling system.

Cooling of solvent

1. Solvent overcooling system

Termination of overcooling

2. Overcooling termination system

Cooling of NeoWhite

3. NeoWhite cooling system

Coolingtower

Freezingsystem

NeoWhitegeneratedsystem

NeoWhite

NeoWhite

NeoWhite heat storage tank

Solution

water

Hydrate Slurry (Kawasaki station, Kanagawa)

Energy Conservation

30

Chiyoda Corporation

Chiyoda Corporation

Japan is a country that is advanced in energy-saving, and Japan’s development of element technologies for energy saving is also on the highest level in the world. Energy-saving measures in the industrial domain are especially advanced. In particular, petroleum refineries and chemical factories in industrial complexes have taken internal energy-saving measures for many years. For this reason, Japan’s industrial complexes have reached the stage where no further energy saving is possible with the existing technologies alone. Ch i yoda Co rpo ra t i on , a p l an t des i gn and construction company, recognized the fact that, although energy saving at individual factories had reached its limit, further energy saving on the level of industrial complexes, in which factories belonging to different industries are located close to each other, can be achieved if heat interchange between factories belonging to different industries is made, because the temperature range of the heat used differs depending on what industry the factory belongs to. Accordingly, Chiyoda Corporation participated in NEDO’s “Strategic Development of Technologies for Achieving More Efficient Utilization of Energy” project and other projects and endeavored to develop the company’s original “area-wide pinch technology,” which is a technology for expanding the “pinch technology,” an analysis tool for analyzing the material and heat flows in a single factory, plant, etc. and optimizing the flows, so that the pinch technology can be applied to analyses of the sharing of materials and heat energy between factories located in the same industrial complex, and successfully conducted a demonstration test in an actual industrial complex, in which the company achieved dramatic energy efficiency improvement. The “area-wide pinch technology” developed by Chiyoda Corporation has been adopted by four industrial complexes in Japan

January 2014

(the Chiba, Kashima, Mizushima and Oita Industrial Complexes) . In addit ion, the area-wide pinch technology is attracting strong attention as an effective energy-saving solution technology for industrial complexes not only in Japan but also in other countries, as exemplified by the fact that it has been used s ince FY2011 as a technology for demonstration projects conducted overseas (in such places as the Map Ta Phut Industrial Complex in Thailand) as part of the “Project for International Demonstration of Technologies and Systems for Improving Energy Consumption Efficiency and Other Technologies and Systems” of NEDO.

Achieving Energy Saving on the Level of Industrial Complexes through the Sharing of Heat between FactoriesAchieving Energy Saving on the Level of Industrial Complexes through the Sharing of Heat between Factories

・Strategic Development of Energy Conservation Technology Project (FY2000-2006),etc.

Photo of the Joint Announcement by NEDO and the Ministry of the Industry of Thailand

The Chiba Industrial Complex, which Is One of the Main Industrial Complexes in Japan (as of FY2000)

Energy Conservation

31

1 petroleum refinery 3 chemical factories 1 glass factory

2 petroleum refineries4 chemical factories

1 petroleum refinery 11 chemical factories

The Chiba Industrial Complex Comprised of 23 Factories

JR Uchibo LineAnegasaki

Industrial road

Goi

　Of the energy consumption volume used in all of Japan, 18% is consumed by industrial furnaces. However, up until now the effective utilization rate of heat from the furnaces was approximately 35%, while the remaining 65% was being released into the 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 fu rnace manufacturer in Japan d iscovered a combustion method in which the generated volume of NOx does not increase along with the increase in the heat collection ratio.　Meanwhile, NEDO implemented the “Development of High Performance Industrial Furnace” project in 1993-1999 and the “High Performance Industrial Furnace Installation Field Test” in 1998-2000, and c en t e r ed on t he J apan I ndu s t r i a l F u r na ce Manufacturers Association, efforts were made in the research and development of a “high performance industrial furnace” capable of saving energy while having a small environmental load. As a result, a high 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 corporations in the High Performance Industrial Furnace

July 2012

Development Project were shared within the consortium, and as a result of this, actualization of the high performance industrial furnace rapidly made progress. As of 2011, this method is being used in approximately 1,300 furnaces domestically.

Japan Industrial Furnace Manufacturers Association

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

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

Flames

Approximately 70% of the Heat Energyin the Gas is collected

ExhaustGas

Fuel

Preheated Air

Heat Reservoir

RoomTemperature AirExhaust

Gas

Switching Valve

The heat reservoir is heated with the exhaust gas.Switches between certain

cycles (Regenerative Combustion)

When switched, the air blowing into the furnace is heated by the heat reservoir

Heated slag

Renege-Burner

Energy Conservation

32

Japan Industrial Furnace Manufacturers AssociationJapan Industrial Furnace Manufacturers Association

Kimura Chemical Plants Co., Ltd.

　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 , dist i l lat ion

processes seen in such as the fractional distillation of

petroleum and concentration of alcohol plays an

ext remely impor tant ro le . 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 i t s l im i t s . E ven s t i l l , a s a

ground-breaking new technology that enables further

energy conservation, “HIDiC” (Heat Integrated

Disti l lation 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

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.

March 2013

Kimura Chemical Plants Co., Ltd.

Distillation Facilities Boasting Maximum Energy Conservation Effects of 60%Distillation Facilities Boasting Maximum Energy Conservation Effects of 60%

Entire view of a pilot plant

・New Sunshine Project (FY1993-FY2001),etc. Energy Conservation

33

16 17

Large amounts of energy are required to produce cement for use in buildings and civil engineering projects. In this project, cement that requires 60% less energy to produce than conventional cement was developed and put into practical use by intermixing a greater quantity of Grand Granulated Blast Furnace Slag (GGBFS), a byproduct of steel manufacturing.

Persistent and meticulous basic research to determine optimum mix proportion

In the production of Portland cement, the most common cement type, the clinker production process requires a significant amount of energy. However, in the production of Portland blast-furnace slag cement, a type of Portland cement mixed with GGBFS, the clinker production process requires less net energy consumption because less Portland cement is needed. In a NEDO project that started in FY2008, a team led by Takenaka Corporation and the Tokyo Institute of Technology undertook research and development on Portland blast-furnace slag cement with high volume GGBFS content. Since using high volume GGBFS content causes performance problems, such as delayed strength development, the team thoroughly analyzed its data on mix proportions for Portland cement and GGBFS. This analysis revealed that the Portland cement proportion could be reduced to 30%. They also conducted research and development on chemical admixtures (superplasticizers) that would provide sufficient fluidity when cement is used. As a result of these efforts, they arrived at an ideal mix proportion for com-

Energy Conservation

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

NEDO PROJECT SUCCESS STORIES 2017

Investigation of cement reaction and cure rates based on mix proportion using film canister as test chamber

ECM cement production process(Data courtesy of ECM Joint Research and Development Team)

Test Specimens produced on the basis of demonstration experiment results

Strategic Technology Development for Energy Use RationalizationResearch and Development Program for Innovative Energy Efficiency Technology

Tokyo Institute of Technology • Takenaka CorporationKajima Corporation • Nippon Steel & Sumikin Blast Furnace Slag Cement Co., Ltd.DC Co., Ltd. • Taiheiyo Cement CorporationNippon Steel & Sumikin Cement Co., Ltd. • Takemoto Oil & Fat Co., Ltd.

Bringing an Ecological Revolution to Construction Sites

mercial production of Portland blast-furnace slag cement with high volume GGBFS.

Research for commercialization by a new team capable of market expansion

To facilitate the commercial application of research and development results, the team members participated in a new NEDO project from FY2011. With a view toward promoting future use of a new type of cement, they formed a “dream team” by adding a construction compa-ny and cement manufacturers as new members and carried out research activities that assumed use of the new cement at actual construction sites. The major focus of such activities was on the quality and durability of the cement actually used for construction. Controlling the particle size distribution of GGBFS was essential to main-taining stable strength, and high durability was achieved by adjusting cement constituents to control heat genera-tion, a cause of occurrence of cracking. In this way, Ener-gy-CO2-Minimum (ECM) cement, a new low-carbon type of cement that requires 60% less energy to produce than Portland cement, was developed. The team has steadily accumulated a construction track record using ECM cement, which is categorized as Type C Portland blast-fur-nace slag cement (60–70% GGBFS content). It is aiming to further promote use of ECM cement to achieve greater energy savings.

Grinding and mixing

Fossil fuels

ECMcement

GGBFS and smallamount of gypsum

60–70%

Portland cementApproximately 30%

SUCCESS STORIES

Test specimens for durability testing

18 19

Power semiconductor devices convert direct current (DC) into alternating current (AC), or vice versa, and adjust the voltage to enable the use of various electronic machines and appliances. Technology for improving the energy efficiency of power semiconductor devices is essential for the society where a large amount of energy is consumed. In this project, silicon carbide (SiC) power semiconductor devices were developed for practical application, and rolling stock inverters using those devices demonstrated approximately 40% less energy consumption than current mainstream inverters using silicon (Si) power semiconductor devices.

Project launched two decades ago to develop future power semiconductor devices

It has been long anticipated that using SiC rather than Si for power semiconductor devices would dramatically improve the device performance, but SiC had shortcom-ings such as its high cost and the difficulty in manufactur-ing wafers. In a NEDO project launched in FY1998, the National Institute of Advanced Industrial Science and Technology (AIST) developed large-diameter, high-quali-ty SiC wafers and prototype SiC power devices. Mitsubishi Electric Corporation, which manufactures rolling stock inverters for railways, fabricated novel prototype inverters with SiC metal-oxide-semiconductor field-effect transis-tors (MOSFETs) that was expected to consume less energy than conventional inverters using Si insulated gate bipolar transistors (IGBTs).

Developing mass production technology through an enhanced focus on large-scale project implementation in later project stages

One of the challenges in developing mass production technology for the commercial application of SiC power semiconductor devices was the need of a high-tempera-ture manufacturing environment. Crystal growth of SiC ingots from SiC raw material powder would require an ultra-high temperature as high as 2,200°C, and the implantation of ions into SiC wafers needs to be done at a much higher temperature than is the case for Si wafers. The establishment of thermal management technology was therefore the most important issue for both AIST and Mitsubishi Electric Corporation.The high temperature problem was addressed during the continuous implementation of large-scale NEDO projects and a rolling stock inverter for railways was developed which is expected to provide significant energy savings. In 2014, the inverter was introduced in refurbished 1000-series commuter trains operated by Odakyu Electric Railway Co., Ltd. Since that time, it has been used in many other railway systems both within and outside Japan.Power semiconductor devices have a wide variety of uses and their use is expected to further expand to automo-biles and high-output electric power infrastructure.

Energy Conservation

Practical Application of “SiC Power Semiconductor” That Contributes to a Next-Generation Electric Society, as Rolling Stock Inverters Used in Railways

SUCCESS STORIESNEDO PROJECT SUCCESS STORIES 2017

Top right: Sliced wafersTop: Mechanism of energy saving resulting from high-speed switching operation (Data courtesy of Mitsubishi Electric Corporation) Bottom right: Prototype 11-kW SiC inverter fabri-

cated 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 world record at the time.

Research and Development of Fundamental Technology for a Power Electronics Inverter Next-Generation Power Electronics Project Realizing Low Carbon-Emission Society

National Institute of Advanced Industrial Science and Technology (AIST)Mitsubishi Electric Corporation • Odakyu Electric Railway Co., Ltd.

Introducing a New Era of Power Electronics

Waveform of current for electric motor driven by conventional inverter

Current waveform for electric motor in high-speed switching operation

Reduction of harmonic loss due to improved sinusoidal waveform

Motor current

Voltage Ideal sinusoidal wave Voltage Ideal sinusoidal wave

Motor current

All SiC(Silicon Carbide) inverter installed under train floor