Award-Winning Energy Technologies
In Japan, several energy-related foundations have established energy grand prize and awarding
programs to recognize outstanding innovative energy-related technologies in their respective ﬁelds.
With the supervision of METI (Ministry of Economy, Trade and Industry) and the courtesy of
relevant foundations and award-winning companies, this chapter introduces the technologies by the
recent winners of these awards.
The awards of the energy technologies and the awarding organizations are as follows:
Energy Conservation Grand Prize Award:
Demand Side Management Award:
Cogeneration Grand Prise Award:
Energy Utilization Center JAPAN)
New Energy Grand Prise:

ECCJ(Energy Conservation Center, Japan)
HPTCJ(Heat Pump and Thermal Storage Technology
Center of Japan)
ACEJ(Advanced Cogeneration and
New Energy Foundation (NEF)Award-Winning Technology Contents
File No.

Title of Technology

Company Name

Page No.
182

BP01

Challenge to save energy in the cast iron melting process

Nissan Motor Co., Ltd.
Tochigi Plant

BP02

Energy saving in printing factories withnew ink materials and drying technology

ADBANK Co., Ltd.

184

BP03

Energy-saving innovation in the concentration process using“heat recycling”

Sasakura Engineering
Co., Ltd.

186

BP04

Energy conservation and labor saving by introducing infrared
heater type mold heater in casting

Chubu Electric Power
Miraiz Co., Inc. and others

188

BP05

Helium leakage inspection process based on a new idea,
challenge to cut energy by 1/2

DENSO CORPORATION

190

BP06

~ZEB By Your Side~
Thorough Economic Efficiency, Zero Energy Office

TAKENAKACORPORATION

192

BP07

Highly efficient heat utilization process at
new lithium-ion battery factories

Primearth EV Energy Co.,
Ltd. and others

194

BP08

Reduced power consumption for air conditioning and lightingwith wireless communications at shopping center

JLL Mall Management Co.,
Ltd. and others

196

BP09

Nice and comfortable energy-saving stores controlled by PMV(Predicted Mean Vote) methodology utilizing AI technology

FUKUSHIMA GALILEI
CO. LTD.

198

BP10

Tackling energy-saving through predictive management ofsymptoms

DENSO CORPORATION

200

BP11

Efforts for higher-efficiency heat supply plant utilizing the“Energy Balance Flow”

TOKYO TOSHI SERVICECOMPANY

202

BP12

Energy saving activities at mother factory combining BCP measures~Implementation of advanced air control, etc. andguidance to other factories~

Panasonic Corporation
Tsu Factory

204

BP13

Multi-site integrated energy network services for energy saving(JFE-METS)

JFE Engineering
Corporation

206

BP14

Achievement of district energy conservation and load levelingthrough the best mix of electricity and gas usage and utilizationof reclaimed sewage water

Nagoya City Energy Co., Ltd.
Nikken Sekkei Ltd.
Nikken Sekkei Research InstituteShinryo Corporation

208

BP15

Initiative to achieve super high-rise smart wellness offices
in Akasaka Intercity AIR, and energy conservation thattranscends the boundaries of development areas

Akasaka Intercity
Management Co., Ltd.
and others

210

BP16

“The Oki Hybrid Project”: Expanding the introduction ofrenewable energy, cooperating with the community,and utilizing Japan's latest technology

Chugoku Electric Power
Transmission & Distribution
Co., Inc. and others

212Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html

BP01

Keywords

Y3

equipment or facility

Z4electricity

E31

manufacturer of transportation equipment
Nissan Motor Co., Ltd. Tochigi Plant

Challenge for energy saving in the melting production process of cast ironFeaturesThis is the electricity reduction activity of holding furnace in the melting production process of cast iron.
u By adjusting the composition ratio of iron melted in a cupola, we made two kinds of molten metals.
The molten metals were stored by two holding furnaces, and were supplied to each factory.
u We adjust the composition ratio when molten metals are supplied, and we make two kinds of molten metals.
As result, we were able to stop usage of one holding furnace.
u Electricity reduction effect:3,564MWh/year (crude oil:897kℓ CO2: 1,693t)
It is equivalent to 45% of electricity usage of the holding furnace on the fourth cast iron factory in Nissan
Motor Co., Ltd. Tochigi Plant.
Basic Concept or Summary
Nissan Motor Co., Ltd. established the mid-term environment plan “Nissan·Green·Program 2022” and is
coping with four environment problems: Climate change, Resources dependence, Atmosphere quality andaquatic resources. In Tochigi Plant, we are reducing CO2 emissions caused by manufacture, and this case is
one of our CO2 emissions reduction activities.
Summary
Different molten metal materials are used depending on the production parts. The Gray cast iron is
generated by melting by cupola. And the ductile cast iron is generated by removing sulfur and adding carbon
from the gray cast iron. These materials were stored by each holding furnace. When there is a decrease inproduction, energy loss increases when two holding furnaces are operating. So we made two changes andstopped usage of one holding furnace.

Point1 Manufacture method of molten metal of intermediate composition
We make molten metal of the intermediate composition by desulfurizing iron melted with cupola, and it is stored
by a holding furnace. To adjust the composition ratio by adding additive agents, the intermediate composition
should first be adjusted with the lower ingredient standard of the gray cast iron and ductile cast iron.

Point2 Composition adjustment of two metals
We add carburizer for making ductile cast iron, and add iron sulfide (compound of sulfur and iron) formaking gray cast iron from molten metal of the intermediate composition. By changing the additive agent
depending on the kind of molten metal, we can make two kinds of molten metals from one holding furnace.

Effects or Remarksu Electricity reduction effect: 297kWh/month 3,564MWh/year (crude oil:897kℓ CO2: 1,693t)
u Awards
Director General Prize of Agency of Natural Resources and Energy (small group activity)
at the 2019 Energy Conservation Grand Prize (supported by Ministry of Economy, Trade and Industry)

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Notes for Introduction

By changing the additive agent and addition method, it can decrease theunmelted residue of the additive agent

Records of Domestic and Domestic The fourth cast iron factory in Nissan Motor Co., Ltd. Tochigi Plant.
Overseas Introduction
Contact:

Nissan Motor Co., Ltd. Tochigi Plant, Production Engineering department,
Environment and Energy group Tel:+81-285-56-1246
Nissan Motor Co., Ltd. Tochigi Plant, Engineering section No.2, Casting section No.2
Tel:+81-28-556-1351

BP01

Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html

BP02

Keywords

Y3

equipment or facility

Z3/Z4

natural gas/electricity

S4

Factory Energy Management System (FEMS)

E15

printing & allied industry
ADBANK Co., Ltd.

Energy Conservation at Printing Factory by New Ink Materials and Drying Technologies
Featuresu Addressing development of web offset LED-UV printing
since 2016, we domestically succeeded in its practical use
for the first time in October 2017. Allowing printing on thinner
paper, this method has reduced “paper cost”. It has alsoachieved zero consumption of gas energy because there isno need to use a large dryer which had been required in thedrying process, and furthermore, VOC control measures
have allowed environmental friendliness.
u Introduced main technologies
1. High-output LED lamp
New company building (Completed in Feb. 2018)
Since domestically manufactured LED lamps had beenlacking power, we pioneered use of an overseas LED-UV lamp manufacturer, realizing 600 rpm byhigh-power lamps capable of instantaneous curing.
2. Development of LED-UV inks
Using pigments cured in response to ultraviolet rays, we have jointly developed with a manufacturer
LED-UV inks which do not blur under high-speed rotation, reducing gas energy required in the drying
process by 100%.
3. Lower paper cost by printing on thinner paper
Development of LED-UV curing technology has realized printing on thinner paper and reduced paper
cost by 12%.
Basic Concept or Summary
Introduced technologies
1. Development of a web press provided with high-output LEDlamps• Since conventional UV lamps have a high environmentalload because of their mercury-based method and highenergy cost, we have chosen long life, power-saving andhigh-power LED-UV lamps free from producing heat andozone.
• Overseas high-power LEDs have been introduced in orderto print without lowering the maximum web offset speed
from 600 rpm.
• A hybrid web press with oil-based inks has beendeveloped and designed to endure actual operation.
2. Development of UV curing inks capable of enduringhigh-speed rotation• Since pigments cured in response to ultraviolet rays arevery expensive, original blending which allows sufficient
curing with a small amount has been jointly developed withan ink manufacturer.
• The first LED-UV inks have been developed domestically,
and they do not blur in high-speed printing at 600 rpm or
more.
• Since the inks are dried by the ultraviolet curing method, alarge dryer is not required, achieving zero consumption ofgas.
• Emissions of VOC (Volatile Organic Compounds) gases
generated from the oil-based inks are reduced to protect
the environment.

Large dryer unnecessary for LED printing

Web press with oil-based/UV curing inks

Effects or Remarks

BP02

AD BANK

Energy Conservation Resultsn Effects of the web offset LED-UV printing
1. Energy conservation
MeasureBefore activity

After activity

Total energy
conservation result

Power-saving

150 kW x 7 hours (per web
press) x 72 rotations/year =75,600 kWh Ô 19 kL

65 kW x 7 hours (per web
press) x 72 rotations/year =32,760 kWh Ô 8 kL

–11 kL
(57.9% reduction)

Gas energy
reduction

76,046 m3 (annual
consumption) x 23.8% (LEDprint operating rate)= 18,090 m3 Ô 21 kL

0 kL–21 kL(100% reduction)

40 kL

8 kL

–32 kL(80% reduction)

Total

Conventional ratio: Annually 80% reduction in terms of crude oil equivalent
2. Cost reduction
B2 equivalent of 40-kg paper has been reduced to 37-kg thinner paper, reducing paper cost by 12%.
Conventional ratio: Annually 12% reductionu Subsidy projects
2014 Adopted the FY2013 supplementary budget, manufacturing subsidy.
2015 Adopted the FY2014 supplementary budget, manufacturing subsidy.
2017 Adopted the FY2016 supplementary budget, manufacturing subsidy.
2018 Adopted the FY2017 supplementary budget, manufacturing subsidy.
2019 Adopted the FY2018 supplementary budget, manufacturing subsidy.
u Major awards received
Oct. 2017 Press conference “Web Offset LED-UV Printing for Cost Reduction”
Feb. 2018 Approved management innovation plan “Practical Use of LED-UV Printing”.
Nov. 2018 Acquired the CLIONE mark “GOLD+”.
Dec. 2019 Awarded the “SME Agency Director General’s Prize” of the Successful Case of Energy
Conservation in Factory & Building.

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Domestic

Contact:

Major introduction record
The company name cannot be mentioned, but a leading printing company is considering
introduction.

ADBANK Co., Ltd.
52 Kisshoin Shimanomazumecho, Minami-ku, Kyoto
Tel: +81-75-694-1312
URL: http://adbank.co.jp/

Source:JASE-W Japanese Smart Energy Products & Technologies

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BP03

Keywords

Y3

equipment or facility

Z2/Z3

oil/natural gas

S4

Factory Energy Management System (FEMS)

E26

manufacturer of production machinery
Sasakura Engineering Co., Ltd.

MVR Type Evaporating Concentrator contributing to sustainable production activities
Featuresu Contribution to 3R (Reuse, Reduce, Recycle) by energy saving
u Reuse of waste steam for heat source by collecting waste steam and increasing temperature at vapor
compressor (Mechanical Vapor Recompression [MVR])u In-house design of a vapor compressor dedicated to our evaporating concentrator

Application of Evaporating Concentrator

MVR Type Evaporating Concentrator

Basic Concept or Summary
Operation principle of MVR type evaporating concentrator
À Reduce the pressure inside the evaporator by vacuum pump
Á Raw water is sprayed and distributed as a thin film over the outside of the tubes by circulation pump.

Â Heated steam is forwarded into the heat transfer tube inside, and the thin film boils at the outside of the
tube surface.
Ã Newly created vapor from the thin film is compressed passing through the vapor compressor and its
temperature is thus raised before being passed to the inside of the tubes, where it condenses to form thecondensate inside the heat transfer tubes. Condensate is discharged to outside of the system.
Ä Concentration of the raw water progresses, and the liquid concentrated to a predetermined concentration
is discharged by the circulation pump to outside of the circulation line

Flow of MVR Type Evaporating Concentrator

Image of MVR

Effects or Remarks

BP03

u Energy saving effectAlthough steam is used as a heat source at startup, if the evaporation operation reaches a steadycondition, evaporating concentration is possible with only the power of the vapor compressor and a small
amount of steam for backup.
Therefore, high Coefficient of Performance (COP) with super energy saving is possible.

u Example (Example by change from typical disc dryer to our MVR type evaporating concentrator)
Reduction of 95% energy consumption in the concentration process (Crude oil equivalent of -1,184kL/Year)
Simple investment payback year is 0.72 year
u Awards
1) 2019 Energy Conservation Grand Prize, Agency for Natural Resources and Energy Award2) 2019 L2-Tech certified products

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Notes for Introduction

Lab test using actual sample liquid may be required in order to realize theoptimum design.

Records of Domestic and Japan: More than 830 units
Overseas Introduction
Other countries: More than 120 units
Vietnam:2010, 2011, 2014
Chile:
2013
Thailand: 2012, 2015, 2018
Indonesia: 2014, 2015, 2017, 2019
Philippines: 2008

Contact:

Sasakura Engineering Co., Ltd.
Tokyo Water Treatment Marketing Section
TEL: +81-3-5566-1212 FAX: +81-3-5566-1233
URL: http://www.sasakura.co.jp/e/products/water/112.html

Source:JASE-W Japanese Smart Energy Products & Technologies

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BP04

Keywords

Y3

equipment or facility

Z3

natural gas

E31

manufacturer of transportation equipment

SUZUKI MOTOR CORPORATION METRO DENKI KOGYO Co., Ltd./Chubu Electric Power Miraiz Co., Inc.

Energy conservation and labor saving
by introducing infrared heater type mold heater in casting
FeaturesThis is an initiative to significantly reduce energy consumption and heatingtime in low-pressure casting processes focusing on the mold heating phase*,
which consumes much energy.
Gas burner using LP gas, etc. has been mainly used for mold heating of
casting equipment that produces engine casting parts. We’ve replaced it withan “infrared heater type mold heater” with a high power infrared heater,which was designed, developed, tested and improved by three companies.
As a result, we’ve achieved energy conservation and labor saving in field
work, and also improved safety and productivity, by reducing energy
consumption by 58%, CO2 emissions by 62%, and the required time for mold heating by 32% incomparison with conventional gas burners.
* It is necessary to preheat the mold before casting for the purpose of stabilizing product quality and protecting the mold.

Comparison of energy consumption

Comparison of CO2 emission

Four-wheeler engine plant
at Sagara plant

Basic Concept or SummaryAirpressure

Low-pressure casting machine<The development of infrared heater type mold heater with high power and short heating time>
1. Use mid-infrared heater that can shorten the heating time since its wavelength matches the infraredabsorption wavelength and the coating agent on the mold surface.
2. Lower the heater position to the limit in the device in order to shorten the distance between the heater andthe mold.
3. Reduce the number of protective grids by installing them between heater lamps.
4. Install reflector on the side to prevent infrared leakage.
5. Install leveling bolts for height adjustment so that the heater is able to be installed in various molds.

Effects or Remarks

BP04

n Energy saving effectLP gas consumption [t/month]Power consumption [MWh/month]
Crude oil equivalent [kL/month]CO2 emissions [t-CO2/month]Gas burner type
17
52
35.7
77.5

Infrared heater type
0
58
14.9
29.5

Amount of reduction-17+6- 20.8- 48.0

Reduction rate
-100%
+12%
- 58%
- 62%

n Incidental effects- Labor saving by abolishing flame monitoring when using gas burner and extending the repair cycle of moldcoating agent.
- Labor saving by reducing mold trouble caused by convection heat whenusing gas burner.
Infrared heater typemold heater- Improvement of non-defective rate by equalizing
mold temperature distribution.
n Payback period(per 20 units)
Initial cost: approximately 30 million yen(including electric work)
Annual running cost savings: approximately 10 million yen
Calculated investment payback period:3 years
n Sagara plant energy conservation system and joint development execution system

Sagara plant energy conservation system

Joint development execution systemn Awards received- Energy Conservation Center energy conservation grand prize Agency for Natural Resources and Energy
Directors award 2015
- Patent: “Mold heating device” Application No. 2014-215570- Patent: “Mold heating device” App. No. 2018-222680- Patent: “low-pressure casting equipment and heater unit for low-pressure casting equipment” App. No. 2019-125433
Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Notes for Introduction

It is necessary to examine specifications such as heater power according tomold size and heating temperature.
Pre-delivery
inspection center

Four-wheel bodyassembly plant

Four-wheel engine plant

Records of Domestic andOverseas Introduction

Sagara plant 37 units in 2014

Osuka plant 14 units in 2016

SIM plant(Indonesia) 4 units in 2019

SMG plant(India) 10 units in 2019

Our product has been already introduced to SUZUKI MOTORCORPORATION and other automobile-related manufacturers. We will keep
expanding its introduction in the future.
Contact:

Chubu Electric Power Miraiz Co., Inc.
URL/inquiry information: https://miraiz.chuden.co.jp/

Source:JASE-W Japanese Smart Energy Products & Technologies

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Keywords

Y3

equipment or facility

Z4electricity

E31

manufacturer of transportation equipment

Thermal Management Unit (TMU) Manufacturing Department, DENSO CORPORATION

Helium Leak Test Process Based on New Idea – Approaches to Half Energy Usage –Features

FY2010 FY2011FY

FY2012FY2013

FY2014FY2015FY2016

Approaches
across company
In-housecommendation

DENSO Eco Vision 2015
2025
Setting the environmental policy “DENSO Eco Vision 2025”, we have
2nd place Award for Excellent Energy Conservation 2nd place
1st place
been making efforts to halve energy usage (compared with 2012) by
3 core activities
Matchless energy
2025 across the company. In order to achieve this goal, the TMU
conservation activities
Advanced energy JIT
Manufacturing Department has set three core activities (1) “Advanced
Facility/Air
EnergyHeating furnace“Reduce net energy”
conservationHeat
Air conditioning/Vapor
patrolmanagement
energy JIT”, (2) “Advanced visualization” and (3) “1/N and N times by
Case 2
Waste elimination
technological innovation” to address “matchless energy conservation
Advanced visualization
Consume zero energy
activities” (Fig. 1). As a result, we reduced electric energy
Approaches
at non-operating time
“Visualize operating status
Introduction of
No idling of facility
byVisualization of air
simultaneously”
energyInverter-based control, no use
Manufacturingconsumption by 25,460 MWh (crude oil equivalent of 6,358 kL) andconditioner
measurementof pressure booster valve
Dept.
Case 3
Collectionof
onlyenergyusage
CO2 emissions by 15.1% from FY2015 to FY2016. This time, of those
Prior rollout
activities, the following mainly introduces a “helium leak tester
Technological innovation
Double-speed“1/N and N times”
dispensing with a vacuum pump under atmospheric pressure”, a
Rollout of existing technology
furnace
Case 1technological innovation case we addressed, taking the opportunity of- Process-free - Lower load
- Power-free- Material change
installing a new line along with switching to a new radiator product.
- Higher speed
This technological development has dispensed with the need for a
Fig. 1. Matchless Energy Conservation Activities
vacuum pump which had been naturally and conventionally requiredin the test process, helping greatly reduce energy usage. The
developed technology has been not only globally rolled out, but also applied to other products requiring a leak test,
having a large effect on global CO2 reduction.

Basic Concept or Summary

Vacuum method

Case 1. “1/N and N times by technological innovation”: Atmospheric helium
leak testeru Difference between the vacuum and atmospheric methods

Vacuum method

Vacuum pump
Highrigidity test
chamber
Detector

FeatureFew gases other

Vacuum pump
Testchamber
Detector

Many gases otherA conventional leak test method vacuumizes a test chamber, encapsulates
than helium
than helium
Heliumhelium into a product and measures leaked helium with a detector. To
diffusion rate
conduct high-accuracy measurement, it is essential to vacuumize the test
Instantaneous diffusion Time-required diffusion
chamber. Conflicting with this, however, since vacuumization cost is very highUniform
Non-uniform
Heliumin both energy and facility expenses, it was decided to attempt anconcentration“atmospheric helium leak test” this time, which basically dispenses with
distribution in
test chamber
vacuumization.
Low
High
Low
High
Helium concentration
Helium concentration Risk ofIn the vacuum method, there are hardly any gases other than helium which
wrong
have leaked from the product, resulting in a high helium diffusion rate as
Uniform
Non-uniform evaluation
shown in Fig. 2. Accordingly, helium diffuses instantaneously to uniformize“Vacuum method” is natural for high-accuracy measurement.
concentration distribution. In the atmospheric method on the other hand, a
Conflicting
collision with gases other than helium slows down the diffusion rate very
much, requiring a longer time for diffusion and resulting in non-uniform
High vacuumization cost (Facility and energy expenses)
concentration distribution in a short time. In such a state, defective products
Fig. 2. Difference between Vacuum
may be incorrectly evaluated as being defectless.
and Atmospheric Methods

u Consideration of a stirring means

Test procedure Survey the impact of the leaku Embodiment of the idea

Fig. 4 shows the very device. Helium leaking from the product isuniformized by collecting and stirring in one direction by a blower. And
by detecting helium “daringly far” from the leak position, it can be
uniformized wherever it leaks.
When it was cross-checked with a testing machine whether the leakamount is equivalent in both the vacuum and atmospheric methods,
there was linear correlation as shown in Fig. 5, realizing the“atmospheric helium leak test” as equivalent to the vacuum method.

Work

He in atmospheric method(cc/min)

Ne

ar

Fa

r

First, a test was conducted by internally stirring with multiple fans. When a leakposition at constant leak amount.
master position for a constant leak amount was changed to make measurement as Test chambershown in Fig. 3, the leak amount varied greatly, failing to satisfy a target value in theFancase where a detector is located near the leak position. On the other hand, the leakamount varied less in the case where the detector is located far from the leakposition. The reason for this was considered to be because the helium concentration
Leak master
varies due to the impact of the air direction around the detector in the case where it is (Constant leak amount)located near the leak position, and because helium is stirred in the path to thedetector, this resulted in uniformizing the concentration in the case where it is locatedDetector
far from the leak position.
Fig. 3. Consideration of Stirring Means
Accordingly, the following three variation reduction factors were
estimated.
<Development point: Uniformize and detect He concentration quickly>(1) Detection far from the leak position
Collect chamber internal air in one direction
Cross-check(2) Uniformization by stirring in the path to the detector
Air flow(3) Detection after uniformization
Stir
Based on these, a new method was designed, different from theconventional detector position and stirring method.
Uniformize by stirring in blower

BP05

Linearcorrelation
He in vacuum method (cc/min)

Uniformize

Pallet position(Detector)
Detect after uniformization wherever it leaks

Fig. 4. Atmospheric
Test Method

Test equivalent tovacuum method
has been
realized.

Fig. 5 Comparison of Leak
Amount with Vacuum Method

Concept of overhead lighting JIT
Electric
power

Place
Place

Desiredgoal
Place

Constant anduniform
regardless oftime

Conventionally

Optimize lighting bydimming for eachblock.

Passage
Over facility

Respond to status change over time.
(Tools: Luminosity sensor, calendar timer, motion detector)

Control in chronological order (status change).

Time

Time

Luminosity

Energyfluctuation in
response tostatus changeover time

Electric power

Reducedelectric power

Luminosity

Electric
power

Morning

Daytime

Night

Time

(1) Visualization so far
E.g. (In increments of 1 hour)
Direct/Indirect

Break

Break

Day shift

Only energy usage has been visualized
and not linked to production results.

Direct/IndirectNon-operating

OperatingWaste energy has beenleft unknown at operating andnon-operating time.

Night shift(2) Desired goal
Visualization of energy efficiency trend
Processing time
= Production volume x C.T

Power consumption

Hourly power
consumption

Waste energy

Scatter diagram

Higher operating rate

Waste

Ideal energy
consumption

No idling
operation
Jun. 17 (Wed.)

Effects or Remarks

Intermediate
location
Materials yard

* Compliant with the Overhead Lighting Design Standard (DFS424100).

Electric
power

Necessaryluminosity
atnecessarytime

Flexible blocks(freely changeable)
inside the plant(production line)
according to theapplication.

Work area

Energy variationaccording toplace(application)

Place

Averageluminosity

Parts location
Plant

Electric
power

Desiredgoal

Case 3. “Advanced visualization”: Visualization of wasteenergyThe goal is “zero waste energy”. Conventionally, only
energy usage had been visualized and not linked to
production results, leaving waste energy unknown atoperating time. Accordingly, the relations between energy
usage and production results have been graphed and theirscatter diagram has been prepared in order to further
visualize an energy efficiency trend, thereby making thewaste visible (Fig. 7). This system has been utilized to
improve stoppage of the vacuum pump when the existingvacuum helium leak tester is not operating and to reduce
waste energy, promoting rollout of this improvement.

Place: Application

Electric power

Necessaryluminosity
innecessary
place

BP05

Approach to improvement

Constant anduniform
regardless ofplace(application)

Power consumption

Case 2. “Advanced energy JIT”: Lighting energy JIT
The goal is to reduce energy usage in overhead lighting to25%. As shown in Fig. 6, overhead lighting has been
designed based on the JIT idea of varying overhead
lighting energy which is constant and uniform regardless ofplace and time.
As an approach to improvement for the “place”, aproduction line has been divided to blocks according to an
application to optimize luminosity by dimming. For the“time”, luminosity has been automatically controlled byresponding to a change in sunlight, thereby reducing
energy usage to 25% in overhead lighting of a model
production line.

Net

Processing time (min.)* Waste energy: Energy other than net energy required for production (ideal energy consumption)(1) Atmospheric helium leak tester
1) Leak test electric energy reduced to 1/10 (per production line)2) Already rolled out domestically and overseas, resulting in 220 kL/year less usage in crude oil equivalent (up to FY2017).
3) Useful knowledge for minimizing the work area, higher maintainability, contribution to helium depletion problem and future
alternative gas for helium owing to lower facility expenses and simplified facilities(2) Lighting energy JIT
1) Overhead lighting electric energy reduced to 1/4 (model production line), resulting in 25 kL/year less usage in crude oil
equivalent.
2) When fully rolled out within this department, the expected effect is approx. 1,200 kL/year less usage.
(3) Visualization of waste energy1) Improvement of stoppage of the vacuum pump when the vacuum helium leak tester is not operating: 42 kL/year lessusage in crude oil equivalent (rolled out production lines)
2) Production lines where the waste energy visualization system has been introduced: 8 lines

u Awards received(1) FY2015 METI/ARNE Director General’s Prize of the Successful Case of Energy Conservation in Factory & Building(Industrial sector)(2) FY2017 METI/ARNE Director General’s Prize of the Successful Case of Energy Conservation in Factory & Building(Industrial sector)
Introduction to Other Companies- Notes for Introduction- Installation in Practice or Scheduleu Atmospheric helium leak testerBase

As shown in Fig. 8, the tester has been already rolled out to two
Expansion
This time
OperatingDoneunder planningdomestic bases in Kyushu and Fukushima, and one overseas basein China, globally having good results. (Up to FY2017)
OperatingDone
Domestic Kyushu
Conventionally, vacuumization (vacuum pump) was essential toOperating Done
Fukushima
strike a balance between high-accuracy measurement andChina
Operating Done
productivity. However, it is now possible to dispense with theOverseas
vacuum pump by drastically reviewing the measurement principle.
U.S.A., Mexico, Czech,
OthersUnder planning
Thailand, Indonesia, etc.
We will continue to roll out the tester to new domestic and overseas
production lines, replace the existing production lines and globallypromote further energy conservation activities, thereby contributing to realization of a carbon-neutral society.

Contact:

Manufacturing Planning Office, Thermal Management Unit Manufacturing Department,
DENSO CORPORATION
Tel: +81-563-55-1603 Fax: +81-563-55-1960
e-mail: akihiko.yamamoto.j2w@jp.denso.com

Source:JASE-W Japanese Smart Energy Products & Technologies

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BP06

Keywords

system or software

Y4

Z4

electricity

S3

ZEB/BEMSD

Design & Construction
TAKENAKA CORPORATION~ZEB BY YOUR SIDE~ APPROACHABLE ZEB
Featuresu This new office building has been completed with a more
economical cost than regular buildings and achieved“Nearly ZEB” (88% energy saving) as the actual
operation.
u In partnership with clients, “PDCA” of energy design andmanagement has been proceeding through both designand operation phases.
u Mainly focusing on the issue of ZEB’s cost, the 4 conceptsof ”Comfort, Economical, General Technologies, Easy
Operation” have been created for the realization ofApproachable ZEB which can contribute to the spread of
ZEB socially.
u Regarding S rank CASBEE-Saitama and S rank
CASBEE- Wellness Office, these buildings have bothcomprehensive environment efficiency and excellent
health quality.

Building name
Building use
Location
Total floor area
Story, Structure
Operation start

TS TECH Head Office
OfficeAsaka City, Saitama Pref. JP
3,727m2
3 Stories, SteelMarch 2018

Basic Concept or Summary
DesignMain technologies for Approachable ZEB

Four Concepts for Approachable ZEB

View, daylight, open-feeling and excellent insulation

ComfortFaçade with a comfortable view, daylighting andhigh-performance heat insulation.
Atrium with high-side-lighting between open offices.

Comfort

Comfortable temperatureand illuminance are
created with 'Outside
Environment'

Capacity of building
facilities is optimized forenergy saving
operation.

ZEB
BY YOUR
SIDE

Existing generaltechnologies for energy
saving can be easily
adopted for any building.

GeneralTechnologies

OfficeAtriumMeeting

Visualization makes
workers conscious of
the relationshipbetween working styleand energy use.

Easy Operation

FacadeEnergy Management Meeting with Client one
year after starting building use.
Tuning each building
system.
KAIZEN of building use
and operation

OfficeOffice floor area

Minimizing air conditioning load and equipment capacity
FaçadeStandard-32%

Outdoor Air
Lighting
Equipment

TS TECH

Human

Operation

RefreshTerrace

FacadeStandard
Façade load
Internal loadOutdoor air load-

-34%

Office floor area

Air conditioning and illumination control by presence/
absence detection by the thermopile sensor.

Targeting building energy
use yearly and monthly
Planning how to
operate building

Real time monitoring of energy saving achievement
degree and Outside comfort display
Measuring andcollecting energy
consumption.
Analyzing the difference
between target and result.

Building operation
based on setting
temperature andoperation schedule of air
conditioning and lighting.

Effects or Remarks

BP06

u BELS Certificate
Nearly ZEB (BEI=0.22) (Certified in Jan 2018)

1200
MJ/m2 yearu Achieved “Nearly ZEB” as the actual operation
Yearly primary energy consumption
2018: 145MJ/m2, -86.9% from standard
2019: 133MJ/m2, -87.9% from standard

1,106

1000
800
600
400
200

u CASBEE
CASBEE-Saitama S rank
CASBEE Wellness Office S rank
(self-confirmation)–87.9% –86.9% –78.9%

133

145

Result2019

Result
2018

234

0

DesignStandard

Yearly primary energy consumption resultu For Zero water building
City water use reduced by 64%
Almost all graywater used was supplied by
rainwater.
u Awards
Energy Conservation Grand Prize 2019:
Minister of Economy, Trade and Industry
Award 8th Carbon Neutral Awards:
Grand prize

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule

BELS Certificate(Nearly ZEB･BEI=0.22) Energy Conservation Grand Prize
Minister of Economy, Trade andIndustry Award

Major ZEB Achievement

TAKENAKA Higashi-kanto
Branch Office

TAKENAKA Tokyo Head Office

OPTAGE Building

Noda-Kamada Gakuen YokohamaSpecialized Training College

Tokyo University of Agriculture
Atsugi Campus

Dai-ichi-Life Shin-Ohi Office

Contact:

TAKENAKA CORPORATION
URL: https://www.takenaka.co.jp/takenaka_e/

and others

Source:JASE-W Japanese Smart Energy Products & Technologies

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BP07

Keywords

equipment or facility

Y3

Z3

natural gas

maufacturer of electrial machinary,equipment and supplies

E29

Primearth EV Energy Co., Ltd.

Approaches to high-efficiency Heat Utilization at New Lithium Ion Storage Battery Plant
FeaturesApproaches to the climate change issue by Primearth EV Energy
1. Automobile manufacturers have been increasing the electrification
ratio of running vehicles toward lower CO2 emissions. We address
the climate change issue by meeting the demand for storage
batteries, or key parts for electrification.
2. Considering a product’s life cycle, we make efforts to reduce CO2
Fig. 1. Lithium Ion Storage
emissions during production. When constructing a new plant, we
Battery Pack for Hybrid Vehicles
jointly develop an energy conservation system with our in-house
construction project team with the purpose of realizing
high-efficiency thermal energy which accounts for the majority of energy usage during production, a chiller
manufacturer and a facility management company as a means for lower CO2 emissions, reducing thecrude oil equivalent of 1,762 kL/year (27% lower) in comparison with a conventional plant (entire building).
Basic Concept or Summary
In order to enhance production of lithium ion storage batteries, a new plant building construction plan was
launched in the precincts of the Miyagi plant in 2014. When analyzing the energy consumption ratio of theexisting plant, the heat for air conditioning (heating, cooling, dehumidification) and drying and heating ofproducts accounted for 70% of energy utilization. Accordingly, we launched approaches to high-efficiency
heat utilization.
3. Recovered waste heat
64,787 GJ/year

Electric
power
165,324 GJ/year(16,939,000 Nm3/year)77%(6,638,000 kWh/year)
42,983 GJ/year
4,404,000 kWh/year

26,811 GJ/year(2,747,000 kWh/year)

Chiller(Auxiliary machine
included)

1,093 GJ/year

City gas(13A)
49,995 GJ/year(1,111,000 Nm3/year)
23%(112,000 kWh/year)

Boiler* Partly towastewater
treatment

29,650 GJ/year(3,038,000 kWh3/year)

Air conditioners- General air
conditioning- High-temperature aging- Dehumidifier

Production facilities
Ancillary facilities- Dust collector- Compressor, etc.
Lighting
Others

Production
facilities- Drying furnace

The heat quantity conversion factors are as follows:
Electric power = 9.76 GJ/1,000 kWh
City gas 13A = 45 GJ/1,000 Nm3

Production
dryingfurnace29,650Air
conditioning/
Heating
51,088Heat
utilization:
70%

Other thanheat: 30%

Production
facilities
28,704

Ancillaryfacilities
26,908215,319
GJ/yearAir
conditioning/
Cooling
26,811

Lighting/Plug socket
9,174

Air conditioner(Blower)
42,983

1. Reduced air
conditioning volume
2. Improved heatgeneration method

1. Reduced air
conditioning volume

Fig. 2. Energy Flow and Ratio by Application at Existing Plant (on Heat Quantity Basis)

Approaches to high-efficiency heat utilization
1. Reduced air conditioning volume
At the existing plant, the air conditioning facilities had beenutilizing 56% (36% + 20%) of the energy usage (Fig. 2).
Accordingly, it was decided to reduce air conditioning energy
by reducing the volume of the production area.
2. Improved heat generation method
At the existing plant, heating and cooling by air conditioning
had accounted for 36% of the energy usage. Particularly forthe heating source, steam had been supplied by a gas-fired
boiler to be utilized at each place of the plant, but there had
been lots of heat losses, resulting in low efficiency (Fig. 3).
Accordingly, in a new plant, it was decided to utilize a heatpump capable of heightening an output heat quantity withrespect to input electric power. Compared with a boiler of thesame capability, however, the heat pump requires a higher
investment amount, and its efficiency falls as the working
temperature increases (Fig. 4). Because of high return on
investment by improvement of running costs at less than
100°C where efficiency is high, it was decided to utilize theheat pump.
3. Recovered and utilized waste heat
For regeneration as to the drying furnace and humidifier
which heat at 100°C or higher, it was decided to employ anelectric heater, which is less efficient, but inexpensive andhas higher controllability, and increase efficiency byrecovering high-temperature waste heat.

Heat source

Transport/heating
Steam

City gas(13A)
Steam boiler

Steam

Gas
Boiler Mechanicalloss
 Blow

Electricity
Heat pumpHeat
recovery Recondensation, leak fromtrap
 Heat loss from pipeline

Hot water

Hot water

 Transport power (pump) Heat loss from pipeline
25%

Fig. 3. Heat Losses of Gas Boiler vs. Heat Pump
Calculation formula
COP = Efficiency of heat engine ŋ x {Operating temperature /(Operating temperature – Outside temperature)}
Conditions: Efficiency ŋ = 0.5
Outside temperature = Annual average temperature,
approx. 11ºC, around the Miyagi plant

Low temperaturezone (airconditioning)High temperature zone
(drying furnace,dehumidifier)Fig. 4. Efficiency of Heat Pump depending on
Temperature Zone

Effects or Remarks

2. Improved heat generation method(1) Development of high-capacity heat pump for air conditioning

Process

Facility

SourceKneading,
coating,
drying,pressing,
slitting

Assembly

Winding
Casing
Welding

Activation

1. Reduced air conditioning volume
As a source control measure, efforts were made to reducethe volume of the production area which requires air
conditioning.
• Improvement of processing capability of the facilities(Double speed, higher speed)• Downsizing of the process
These efforts resulted in:
27% less area of the production process
20% lower rated power of the production facilities (Fig. 5)[Energy conservation effect: -299 kL/year]

BP07

Hightemperature
aging

Comparison of production area
Miyagi plant
Existing plant
2 positiveelectrodes

2 negativeelectrodes

1 positiveelectrode

Comparison of processarea (volume)

1 negativeelectrode-27%

Higher speed
4 pcs.
 2 pcs.
Existing Miyagi
plant
plant
Power comparison of
production facilities

Downsizing-20%
Higher speed

Existing Miyagi
plant
plant

Fig. 5. Comparison of Production AreaHigh-

Air conditioner
Outdoor unit
Dehumidifier

temperature
Heating for air conditioning has been changed from steam supply
Lower vaporization heatcirculating HP(discharge into atmosphere)by a boiler to hot water supply by a heat pump (Fig. 6). In
Highsummer, cooling water of a chiller for air conditioning has been
Cooling
temperature
Chilleraging (●°C)
tower
used as a heat source water, contributing waste cold water to
Production
improved efficiency of the chiller. In winter, an air heat source is
Hot waterarea
heat pump(Heat obtained from
(Electricity)(20 to 25°C)
utilized in fear of heat source water freezing. For this reason, the coolingwater in summer)
Waste heat recovery (Winter)heat pump HEM-3WAY made by Kobe Steel (heating capability:
Less heat loss
84.4 kW x 5 units) has been utilized, capable of switching
Fig. 6. Heat Source Flow at New Plant
between water- and air-based heat sources. When the outside
temperature falls in winter, defrosting operation is required,
lowering the capability. As a measure, the waste heat (production exhaust, compressor’s waste heat, etc.)
generated in the plant has been consolidated into the heat pump through ducts in order to secure the ambient air
temperature of 10°C or higher at which defrosting operation is not required. As a result, an overall systemefficiency (COP) of 3.1 has been expected.

(2) Development of high-temperature circulating heat pump

The aging process requires the room temperature of 50°C or
higher, and the temperature of hot water supplied by the heatpump utilized in (1) cannot meet the requirements. Accordingly,
an air conditioner has been jointly developed with a chiller
manufacturer, which circulates the air at 60°C or higher toachieve the efficiency (COP) of 3 or above (first in the industry).
What is ingenious about the system is utilization of air
conditioning cold water (return) which has a low temperature ofless than 14°C as a hot water source, but can be stably
supplied even in winter, in order to stably supply the heatthroughout the year.
Efficiency at rated operation: COP 3.7 (Heating: 2.3, Cooling: 1.4)
Efficiency at maximum load: COP 5.7 (Heating: 3.3, Cooling: 2.4)
[Energy conservation effect in (1) and (2): -1,762 kL/year]

Capable of supply
up to 85°C hot air

Capable of hot-air
circulation heating

Employing green
refrigerantHigh energy
efficiency(Overall COP = 6.1*)* In case simultaneously utilizing
60°C supply and cold temperature

Examples of drying applications

Examples of heating applications

Coating, print, resins, rubber,pharmaceuticals, foodstuff, etc.

Aging, laminators and coaters,
various heating tests

Fig. 7. Commercially Available Hot Air Supply Heat Pump,
Eco-Circuit™ Made by Mayekawa Mfg. Co., Ltd.

The electrode drying process requires a high temperature of 100°C
or higher. A solvent contained in the exhaust gas from the drying
furnace is recovered after cooling and condensation by the solvent
recovery device. Then, it is heat-exchanged with high-temperature
exhaust to circulate the air to the drying furnace (Fig. 8). Since thisprocess had consumed approx. 17% of electric power usage, 2required furnaces have been reduced to 1 unit by increasing theinner temperature of the drying furnace to shorten a drying time,
thereby saving energy. Also, efforts have been made to review theplate thickness and heat transfer area of the heat exchanger toincrease the supply temperature to the furnace. As a result, a
required heat quantity is now expected to be reduced from 270.8
kWh to 111.6 kWh (59% lower).
[Expected energy conservation effect: ▲251 kL/year]

Heat
exchanger

3. Recovered and utilized waste heat

Solvent recovery
device (Cooling,condensation)

Approx.
1●●°C

Positive electrode coating
drying furnace (Electricheating in furnace)

6-Nm3/min. air
supply fromwithin process

Fig. 8. Overview of Exhaust System of Drying Furnace

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Primearth EV Energy
Miyagi 4th plant (2019), Miyagi 5th plant (2020), Miyagi 6th plant (Scheduled in 2021)
Contact:

Exhaust out ofprocess

Primearth EV Energy Co., Ltd.
Environmental Affairs & Engineering Group, Plant Engineering Department
Corporate information: https://www.peve.jp/ Inquire at: https://www.peve.jp/contact/

Source:JASE-W Japanese Smart Energy Products & Technologies

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BP08

Keywords

system or software

Y4electricity

Z4

I

Wholesale and Retail Trade
UNIMO Chiharadai Shopping Center

Reduced Power Consumption for Air Conditioning and Lightingwith Wireless Communications at Shopping CenterFeaturesu Case of reduced power consumption at a large shopping center “UNIMO Chiharadai” located in Ichihara city,
Chiba prefecture and annually attracting 5.5 million visitors.
u These facilities are managed by utilizing a real estate securitization scheme. Three companies, LaSalle Investment
Management (asset manager), Jones Lang LaSalle IP, Inc. (property manager) and AEON Delight Co., Ltd.
(building management company) have been closely collaborating to showcase their respective advantages.
u Taking the replacement of the asset manager in February 2015 as an opportunity, approaches to energy
conservation associated with investments have been promoted to aim at realization of highest-level sustainability.
u Compared with 4 years prior to replacement of the asset manager, annual electric usage has been reduced by
29.6%, or 488 kL in terms of the crude oil equivalent.
u In autumn, 2015, lighting in common-use spaces was changed to LEDs. Furthermore in July 2017, an air
conditioning control system was also introduced to reduce electric usage for air conditioning in the common-use
spaces. Both the LEDs and air conditioning control system have employed advanced systems based on
wireless communication technology.

Basic Concept or Summary
u In LED installation work, not only lighting of the entire building has been replaced with LEDs, but also wirelessdimming LEDs have been employed. The wireless dimming LEDs automatically sense building internal
luminosity with luminosity sensors, including impact of outside light, to save waste power and enhance energy
conservation effects.
n Setting controller
n Settings to maintain luminosity with daylight
Area

Standard
setting rate

Standard
luminosity

Standard area

Min. setting rate

1st-floor passage (Circuit)80%

270 lxFloor surface luminosity

60%

1st-floor restaurant passage

70%

210 lxFloor surface luminosity

No daylight setting

2nd-floor passage (Circuit)100%

287 lxFloor surface luminosity

60%

2nd-floor food court

60%

570 lxDesk surface luminosity50%

u Air conditioning (cooling only) in the common-use spaces of this shopping center uses nighttime power, and theheat source stored in the ice heat storage device is used for cold water pumps and air handling units to feed thecold air into the building. Inefficiency has been improved by the air conditioning control system.
Area
AHU
Damper (OA, RA)
Secondary cold water
pump (Cooling of AHU
circulation water)

Old system (Before introduction)
No temperature sensor, only scheduled
operation allowed.
Manual dampers with fixed opening.
Opened/closed according to the season, but
not timely opened/closed.
Scheduled operation. No inverter-based
control employed. Required amount controlled
by turning on/off three pumps, causing a loss.

New system (After introduction)
On/Off control by wireless temperature/humidity (outdoor/indoor air)sensors. Turned on/off automatically according to the set temperature.
Automatic opening control by electric dampers. Effective outdoor air
cooling based on measurement data by wirelessthermometers/hygrometers.
Variable flow rate control by newly installed inverters. Required flowrate considered based on measurement data of discharge pressure
and cold water out-going/in-coming temperature to automaticallycontrol inverter frequency.

[Before introduction]
Flow rate adjustment of the secondary cold water pump, operation/stop of the air conditioner and effective use ofoutdoor air cooling had been mainly operated manually, making it difficult to respond to a load change.

[After introduction]
Power consumption has been reduced and the indoor temperature has been uniformized by automatic control
responding to a load change.
Temperature/humidity sensors with built-in batteries are installed in 13 places in the building and 1 placeoutside, and their data are taken into the system by wireless communication technology to automatically control
the air conditioners.

Effects or Remarks
u LED installation work has reduced annual electric usage in the common-use spaces by 549,000 kWh (crude oil
equivalent of 141 kL). With respect to an investment amount of ¥46,220,000, the improvement effect was¥13,650,000/year and the payout period was 3.4 years.
u The air conditioning control system has reduced electric usage in the common-use spaces by 1,055,000 kWh(crude oil equivalent of 265 kL) in one year after introduction, greatly exceeding 544,000 kWh/year, thereduction goal at introduction time. With respect to an investment amount of ¥28,750,000 in this installation
work, the improvement effect was ¥29,800,000 in two years, recovering the investment in two years after
introduction.
u There had been no introduction case of the air conditioning control system into other facilities. It took time to
explain its introduction to the investors, but we have obtained more reduction effects than expected.
u Awarded the FY2019 ECCJ Chairman’s Prize of the Successful Case of Energy Conservation in Factory &Building.

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Notes for Introduction

u With promotion of sustainability by LaSalle Investment Management, investors’
understanding was obtained to launch LED installation work and introduce theair conditioning control system. Since both of them had few past successful
results at other facilities, however, repeated discussions and explanations wererequired before introduction.
u At a shopping center opened for business 365 days a year, a chief administrator
cannot be stationed every day, resulting in issues of uniformization at the
management level. However, efficient operation is allowed any time because
both the wireless dimming LEDs and air conditioning control system have been
automated.
u Particularly, the air conditioning control system is a sensuously operable
visualized system, allowing speedy operation.

Records of Domestic and u Introduction results of air conditioning control system into other facilities: 4 cases
Energy amount reduction, electricity: total 1,591,000 kWh, heavy oil: 15.4 kL,
Overseas Introduction
gas: 18,000 m3 (437 kL/6 months)

Contact:

UNIMO Chiharadai Operation Center, Jones Lang LaSalle IP, Inc.
Tel: +81-436-76-0003
E-mail: unimo.sp@ap.jll.com

BP08

Source:JASE-W Japanese Smart Energy Products & Technologies

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BP09

Keywords

Y4

system or software

Z4

electricity

S3

ZEB/BEMS

I

Wholesale and Retail Trade
FUKUSHIMA GALILEI CO. LTD.

Realization of Comfortable & Energy-Saving Environment by PMV Control with AI Technology
Featuresu In June 2018, we introduced our technology into 2 supermarkets in Japan andactualized the creation of further comfortability and energy-saving result in the
supermarkets.
u Contents of Technology introduced.
À Ventilation System
Shifting from previous ventilation system with exhaust fan to outside airprocessing ventilation system (Desiccant Air Conditioning Unit). Reducing
70% of air conditioning load, and 20% of chiller & freezer showcase load
Major application Food supermarket
have been achieved.
Place atKanoya, Kagoshima /Omihachiman, ShigaÁ Air Conditioning System
Total floor area 3,829 m2 / 3, 866 m2
Adopted “High Sensible Heat” air conditioning units and optimized theFloor
on story building
positioning of the air conditioners in the shops. At Sales floor, adopted
Completion year May 2018 / June 2018indirect vaporization cooling system. Combining with the effect of desiccant
air conditioning unit, it achieved about 67% reduction of air-cooling energy consumption.
Â Inter-integrated control system among equipment & facilities
Realization of comfortable shop environment following PMV through inter-integrated control of desiccant
air conditioning unit, air conditioner, and chiller/freezer showcase system. While keeping the comfortableenvironment in the supermarkets, AI technology automatizes the calculation of control parameters tominimize the energy consumption in the supermarkets.
Basic Concept or Summary
The system’s scheme is to realize more energy-efficiency by replacing previous air conditioning units withdesiccant air conditioning units as a method of removing humidity, which takes the most of energy during
the summer season.

Visual summary of the system as below: adopted desiccant air conditioning units to have positive-pressure
ventilation inside the supermarkets. By supplying the dehumidified air made by the desiccant system fromthe bottom of showcases, it creates a stratified air conditioning environment. The arrangement andlocations of air conditioning units were revised, “high sensible heat” air conditioning units as main
specification were used and indirect vaporization cooling system was adopted. To automatize the cooling
operation inside of the supermarkets, PMV is adopted, and through auto-controlling by EMS, a comfortableand energy efficient shop environment has been realized.

Effects or Remarks

BP09

u Energy Saving EffectAchieved the result of higher energy saving from the actual tests compared to the estimated energy saving
effect calculated during the planning stage. Achieved higher energy saving result than the targeted 20%
energy saving rate during the summer time.
As further effects, the below results were achieved:
À Contribute to above 16% energy saving per year on the electric
consumption of whole shops.
Á Contribute to above 140t reduction of CO2.
Â Contribute to sales increase by improving the comfortability in shop
environment (enhancement of migratory time).
Ã Make air conditioning temperature check by staff unnecessary.
Enable staff to focus on the running of shop operations.
Ä The creation of positive-pressure environment in the shops enhancescleaner hygiene environment (leading to the prevention of mold,insect and dust).
Å Prevention of condensation around showcases through dehumidifying.
Æ Prevention of cold isle in front of showcases by desiccant system.
u Energy Saving Effectu Remarks
Investment on ventilation systems at supermarkets
tends to be minimized only to meet the minimum
requirements of regulations. Especially these days,
from the perspective of energy saving, that investment
has tended to be restrained as much as possible.
Being forced to reconsider about the significance ofthe role of the ventilation system with the widespread
COVID-19 virus, it is expected that shop environments will be deteriorated by increasing ventilation more than
before. Taking “with Corona” concept in mind for shop planning, implementation of our system will play asignificant role not only for low carbonization but also as one of preventive actions against the infection.
u Awards･Patent･Subsidy- 2014, January, received the Minister of Economy, Trade and Industry Award at the Energy Conservation
Grand Prize. 2019, January, received the Minister of Economy, Trade and Industry Award at the Energy
Conservation Grand Prize.
- Open Patent, patent publication number: 2020-071010 “店舗設備制御システム”- Subsidy “L2-tech” in 2017(Ministry of Environment)
Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Domestic

Trial Company ,Inc: Super Center Trail x 2shops (Shiga prefecture, Kagoshima prefecture) 2020,
start to sell Galilei Air Tech System. Planning to introduce to supermarkets throughout Japan.

Overseas

2020, start to sell through our local subsidiaries in the South-East Asia region

Contact:

FUKUSHIMA GALILEI CO. LTD. Sales Strategy Departmen
TEL: +81-6-6477-2011(main) FAX: +81-6-6477-0755
URL: https://www.galilei.co.jp/
e-mail: ts@galilei.co.jp

movie→

Source:JASE-W Japanese Smart Energy Products & Technologies

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Keywords

Y3

equipment or facility

electricity

Z4

manufacturer of transportation equipment

E31

Thermal Management Unit (TMU) Manufacturing Department, DENSO CORPORATION

Approaches to Energy Conservation by Predictor Management
FeaturesFY

FY2010FY2011

Approaches
across company
In-housecommendation

FY2012FY2013

FY2015 FY2016 FY2017 FY2018

FY20142025

DENSO Eco Vision 2015

Setting the environmental policy “DENSO Eco Vision 2025”, we
2nd place Award for Excellent Energy Conservation 2nd place 1st place 4th place 2nd place
3 core activities
have been making efforts to halve energy usage (compared with
Matchless energy
conservation activities
2012) by 2025 across the company. In order to achieve thisAdvanced energy JIT
Facility/Air
Heating furnace“Reduce net energy”
EnergyHeat
Air conditioning/Vapor
goal, the TMU Manufacturing Department has set three coreconservation
Lighting energy JIT
management
patrolVaporlessWaste elimination
activities (1) “Advanced energy JIT”, (2) “Advanced visualization”
Advancedvisualization
This
case
and (3) “1/N and N times by technological innovation” to address
Approaches“Visualize operating status
Consume zero energy
No idling of facility
byIntroduction ofsimultaneously”
at non-operating timeInverter-based control, no use“matchless energy conservation activities” (Fig. 1). As a result,
Manufacturing
energyof pressure booster valve
Reduce waste energy by utilizing IoT
Visualization of air
Dept.
measurement
we reduced electric energy consumption by 47,200 MWh (crude
Collection of only energy usage conditioner
Prior rollout
oil equivalent of 11,760 kL) and CO2 emissions by 28% fromTechnological innovation“1/N and N times”
FY2015 to FY2018. This time, of these activities, the following
Double-speed
Atmospheric He leak test
Rollout of existing technology
furnace
Reduced nitrogen input into brazing furnace
introduces a case of advanced visualization “Approaches to- Process-free- Lower load
- Power-free- Material change
Energy Conservation by Predictor Management”.
- Higher speed
Targeting general processing facilities, this case is to create
Fig. 1. Matchless Energy Conservation Activities
energy conservation effects by preventing facility failures, or major
factors of waste energy. A mechanism has been built inexpensively, which timely outputs an alarm to prevent a failure
when maintenance is required, by always sensing many cylinder operating speeds at which error predictors had notbeen grasped so far. It has been already rolled out to in-house production lines. As it is easy to roll out to similar
processes, it is expected to greatly contribute to reduced waste energy and lower CO2 emissions.

Basic Concept or Summary

Concept: Prevention by predictor management before failure

1. Concept of reduced waste energy by predictor
management
Fig. 2 shows the concept of reduced waste energy across the
production lines by predictor management. Targeted this time
are radiator production lines, which are consistent productionlines consisting of multiple processes such as assembly ofaluminum parts, their brazing and leak test. Consequently,
stoppage of one process affects all processes, wasting a great
deal of energy. Accordingly, in order to prevent failures andincrease the operating rate of all production lines to obtainlarge energy conservation effects, we have made efforts formonitoring the cylinder operating speed of various facilities,
heater leak current value of the furnace, oscillation range ofRC (stirring) fans, light quantity of workpiece check sensors,and so on. This time, we describe predictor management ofcylinder failures which account for a particularly higher ratio
among these failure factors.

<Manufacturing process>9 categories of parts

Failure mode Failure predictor

Actuators, etc.
Leak, wear,
seizure,Air cylinders, rotary actuators,
high-speed linear actuators, etc. contamination

Tube manufacturing

Operating time,sound

Heaters, encoder cables, power snapping, contact
wiring, control wiring,
failureconnectors, etc.

Improper check,short-circuit

Electric leakage,
snapping

Bearings, etc.

More oscillations,higher load,
abnormal sound,heat generation

Oscillations, load,sound,
temperature

Electric wiring, etc. Insulation failure,
Fin molding, core assembly

Backlash,breakage,missing, wear

Bearings, LM guides, ballscrews, etc.

Flux application<Approaches this time>
Operating speed
Cylinder operating speed

Defect detection
methodOperation delay,leak soundThis caseSnapping, electric leakage
Heater leak current of
furnace
Oscillations, feed amount• RC fan oscillations of
furnace• Transfer belt feed amountThe brazing furnace operates at 600ºC with aheater if the product is not fed.

Brazing in furnace* High energy consumption

Sensors

Contamination,snapping

Resin molding

Photoelectric sensors, fiber
sensors, proximity sensors,omega switches, etc.

Tank assembly, caulking

Rollers, cutting tools, etc.

Lower light quantity

Light quantity

Light quantity
Light quantity of
workpiece check sensor

Stoppage of one process affects all processes, resulting in waste energy.
The vacuum pump of the vacuum leaktester operates continuously if the
production line stops.

Leak test* Model line
Appearance test, packaging

Robots, servo motors,
amplifiers, inverters, visual
devices, etc.

Alarm indication,
abnormal soundMechanical parts

Change inWear, deformation dimension, change
in shape

Stoppers, guides, rails, screws,
pawls, etc.

Abnormal sound,heat generation

Abnormal sound,heat generation

Current, voltage, temperature• Motor current value• Servo amplifier
temperature

Displacement,
profileLarge energy conservation effects by increasing an overall operating rate

2. Predictor management by monitoring the cylinder operating
speed
Fig. 3 shows a mechanism of cylinder malfunction. An air
cylinder is delayed in operation because of a pressure drop byinternal/external air leak and a sliding resistance due tocontamination/insufficient lubrication. Even when there is anoperational delay, it is difficult to notice an error if an operation
check sensor is turned on. After this, repeating the operational
delay, the facility finally fails and stops. The error is only
noticed at that time. Conceiving based on this that monitoring
the cylinders operating with different connected parts leads tomonitoring of the operating condition of the entire facility, we
have developed and introduced a system which always
monitors the forward- and backward-moving speeds of all 350
cylinders of the target production lines.

Fig. 2. Predictor Management Parts and Detection Method
Malfunction mechanism
Valve B

Valve A

Internal air leak
Worn and cut rod packing Lower

pressure

External air leakRod

PistonThe defect is
not noticed if
the operation
check sensor isturned on.

Worn and cut piston packing

Solenoid
valve

External load and resistanceSliding
Contamination and resistanceinsufficient lubrication

Sensor D
Sensor C
Auto switch

Operation delay

BP10

Noticed only
when the facility
stops.

Noticed only when the facility stops.
Viewpoints on cylinder monitoring
The cylinder consists of various parts to operate.
[Cylinder]
Chucking cylinder

Chucking part

Pin
(Improper turn)
Shaft

Bush (Improper slide)
Bearing (Improper turn)ForwardBackward

Connected ancillary part

Monitoring the cylinder approximates to monitoring the entire facility

Always monitoring all 350 cylinders of the model line

3. Development of the predictor management system
Fig. 3. Viewpoints on Predictor Management for Cylinders
In monitoring the cylinder operating speed, the[This means][Conventional means]system illustrated in Fig. 4 was built.
Collection and Accumulation Visualization
Signal collection and data processing
Relay PC Accumulation Visualization
Signal collection
Conventionally, there were no sequencers directly
processing
connected to a network, requiring an exclusive PC
to relay the data. In addition, it was necessary tomeasure an operating time on the part of theHigh cost and expertise required
existing sequencer in order to collect operating→ Difficult introduction
Inexpensive and no expertise required→ Easy rollout
speed signals and process the data, and a high[Concept for this development]This will solve collection and processing of
cost and a lead time for remodeling were required,
24-hour monitoring data.
making introduction difficult. This time, byNow, how should the defect predictor(Difficulties)
be presented?
employing a new commercially available network<Internal and external benchmarks>- External: There is commerciallysequencer capable of simply collecting the data,
available software, but it is expensive
to introduce it into many facilities.
measurement of the operating time has been
- Internal: Still in the consideration phase<Points to facilitate collection and processing>and not materialized yet.
CylindeNetwork
sequenceenabled any time through a simple program. In
Directly connectable
addition, Excel has been used to internally produce
Created by maintenance personnel,
to network
using familiar Excel.
Capable of always
a cylinder operation visualization tool.
Browsable from any PC.
Input only
measuring operating time
Network sequencer

Use 13 PLC units

Use 13 PLC units

ServerMotion board, etc.

ProgramOverall investment (¥N million)

Cylinder operation

Concept

Informationcollection,
processing

Inexpensive
Easy

Presentation of
defect predictor

Generalpurpose

Viewpoint

How to collect

No need to renew sequencer Use existing sequencer’s signals. Inquire withdedicated
No use of exclusive software Use sequencer software.
manufacturer.
Manufacture program inInternally: System
No outsourcing
maintenance department.
Group
Externally: DedicatedUtilize factory internal network.
Browsable by anyone
manufacturer
Can be rolled out to internal
Easy rollout
manufacturing line.

Solenoid valve Valve A

Sensor C
Sensor D
Auto Switch

Create with
Excel.

Major reprogramming
No renewal ofsequencer

Requirement

Operatingside(1)Which part

Objective investment cost: Lower than 1/10 of conventional cost
(Time to set up investment: 1 year or less)

Valve B

ServerInvestment (¥1/10N million)

Major reprogramming
Renewal of sequencer
requiredexisting
signal(2)
Since when

Valve A
Valve B
Sensor C
Sensor D

Caulk L-tank(3)
How much,
How

Defect4. Visualize effects

Alarm

3. Remedy
Measured
value
Alarm
value
Normalvalue

Datewith simple program

Internally produced visualization capable ofunderstanding defect predictor at glance.

Fig. 4. Predictor Management System Configuration

4. Operation of the predictor management system

BP10
Defective part

Operating time
Red zone:+2.5 sec.

No. of cylinders being alarmed
Clarify defective
cylindersImmediate part check/Maintenance:
3.2 sec.
Respond after production
1.2 sec.

Yellow zone:+0.5 to 1 sec.
Standard value:
Average value of good time

Check effects

Always monitor
350 cylinders.

0.7 sec.

Visualize by graph
Date

Alarm

Operator’s motion

Alarm ON: Confirm a defectoccurrence at theoperation panel.
Alarm continued: Immediately confirm
the details in themonitor screen.
Yellow: After production: Part check→ Cleaning, lubrication,
simple replacement work

Red zone<Maintenance timing
determination>- Red (urgent): Operating- Yellow (soon): After
production

Operation delay increased abruptly from here
and alarm turned on
Yellow zone
Standard value

Capable of confirming a defect predictor trend

Reset: Confirm the effect in the monitor screen.

Fig. 5. Operation Method andProcessing Workflow

Fig. 6. Predictor Monitor Screen

Fig. 5 shows a method to operate the predictor management system and a processing workflow. Setting a standard
operating time (average value when operating normally) for each cylinder, an alarm is output to inform the occurrence of adefect when reaching this standard and causing a delay. Two defect thresholds are set: a “red zone” (standard value + 2.5
seconds) requiring immediate cylinder check and maintenance and a “yellow zone” (standard value + 0.5 to 1.0 second)
requiring a response after daily production. In order to increase the reliability, the alarm is output when exceeding thethreshold for 10 cycles running.
Next, Fig. 6 shows the predictor monitor screen which always monitors 350 cylinders. The screen displays (1) the numberof cylinders being alarmed and (2) a defective part and clarifies the defective cylinder in (3) yellow. Movements of thisyellow cylinder are visually graphed (4) to allow operators to confirm a defect predictor trend. This graph in the figure shows
an example of outputting the alarm “yellow” due to an abruptly increased operation delay from (5). In response to this alarm,a production line operator checks, cleans and lubricates the cylinders after daily production, including simple replacement
work of packings, etc. depending on the situation, to normalize cylinder operation.

Effects or Remarks(1) Production line under cylinder/sensor predictor management (assembly and leak tests): Reduced electric energy by 85
MWh/year. (Crude oil equivalent: 20 kL)(2) Production line under furnace predictor management: Reduced electric energy by 234 MWh/year (Crude oil equivalent: 55 kL)
Cylinder predictor management
When fully rolled out within the department: 612 MWh/year expected (Crude oil equivalent: 153 kL, 0.7% of the entire department)u Awards received(1) FY2015 METI/ARNE Director General’s Prize of the Successful Case of Energy Conservation in Factory & Building(Industrial sector)(2) FY2017 METI/ARNE Director General’s Prize of the Successful Case of Energy Conservation in Factory & Building(Industrial sector)
Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
The developed predictor management system is scheduled to be introduced
into the 800-unit facilities in the department by the end of the FY2021. Also,
it can be easily rolled out for internal and external facilities and productionlines having predictor management target parts such as cylinders andsensors, with large effects on energy conservation being expected. We willcontinue to globally promote further energy conservation activities, thereby
contributing to realization of a carbon-neutral society.

Activity plan
Cylinder predictor
management

FY2018 FY2019 FY2020 FY2021
4 lines completed
Dept. internal facilities≈ 800 units

Furnace predictor
2 lines completed
management
1 line completedSensor predictor
management
Expanded rollout of
4 facilities
predictor managementtarget parts(9 categories)

38 facilities

Fig. 7. Predictor Management Rollout Plan

Contact:

Manufacturing Planning Office, Thermal Management Unit Manufacturing Department,
DENSO CORPORATION
Tel: +81-563-55-1603 Fax: +81-563-55-1960
e-mail: akihiko.yamamoto.j2w@jp.denso.com

Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html
Keywords

system or software

Y4electricity

Z4

S8

advanced urban system

F35

heat supply
TOKYO TOSHI SERVICE COMPANY

Efforts for Higher-efficiency Heat Supply Plant Utilizing the “Energy Balance Flow”
FeaturesOur heat supply plants in 19 districts have different requirements such as load fluctuations and utilization ofrenewable energy, depending on the plant scale and the application of the customer’s building. To solve theissues of each plant, it was necessary to consider measures for stable supply and higher efficiency
individually for each plant in the 19 districts.
For this reason, we have launched reviewing and enhancing systems, tools, etc. in order to spursmall-group (energy conservation) activities at each plant.
u Small-group activities for energy conservation and higher efficiency at the plant- Building an energy management structure- Enhancing support of plant energy conservation activities at the main and branch offices- Enhancing management and support across the company
u Introduction of an energy balance flow: Visualizing a heat flow by creating the “Energy Balance Flow”
using the measurement data
Basic Concept or Summaryu Summary of our heat supply business- Supply cold and hot water produced at the heat supply plant using electric heat pump system andlarge-capacity heat storage tanks to multiple buildings in the district through district conduits.
- 19 districts centering on the Tokyo metropolitan area (6 of them utilize renewable energy)
Outline drawing of District Heat Supply System
Residential building
Hotel/Hospital
Office building
Heating
tower

Utsunomiya (Substation exhaust heat)

Cooling
tower

Takasaki

Cold
water

(Underground water)

Utilization of exhaust heat
Utilize the urban unused exhaust heat
discharged and dumped from a plant,
substation, subway, etc.

Honkomagome Hakozaki (River water)
Nishishinjuku
Shinkawa (Substation exhaust heat)
Kanda
Shibaura
Ginza 2, 3
Osaki
Ginza 5, 6
KyobashiHarumiHot
water

Commercial building

Heat storage tankHachioji
Fuchu

Makuhari(Treated sewage)

Atsugi

District conduit
Heat pump

Utilization of temperature differenceenergyRiver water, treated sewage,
underground water, etc. are cooler insummer and warmer in winter,compared with the outside temperature.
Extract this temperature differenceenergy by a heat pump to utilize.

(Recycled sewage) Yokohama
Yokosuka

Hot water
pipingHot water
pipingCold water
pipingCold water
piping(Return pipe)(Return pipe)(Feed pipe)

Heat supply plantArea utilizing the renewable energy(Feed pipe)

Heat transport piping

Cold/hot water producing machineu Small-group activities for energy conservation and higher efficiency at the plant<Plant>- Appointing “efficiency management personnel”
as an efficiency improvement activity leader.
- Devising an operating method based on daily
operation results.
- Discussing the issues for higher efficiency and an
improvement method therefor.

<Main office>- Efficiency management personnel
Plant supervision, technical support,
meeting, Plant managers meeting→Progress check, information sharing
review of implementation results- Commendation of the monthly most valuable
person→Higher motivation, spread of successful cases- Budgeting of special facility renovation
Branch Branch(challenge) limit

Main
officeOverall management, strategy
planning, implementation support

Small-group
activities

Branch<Branch>- Setting an efficiency improvement goal
- Drafting an improvement activity plan
- Responding to consultation and request for
support from the plant

Plant (P)Realization of industrial top-level
plant efficiency

BP11

Plant manager
Operation supervisor
Members (Efficiency management personnel)
Membersu Introduction of the energy balance flow
- In addition to a heat flow of cold and hot water, summarize all in-coming and out-going energies at theplant such as heat losses of the heat storage tank and conduits, and power consumption of the heatsource machine (heat pump) and transfer pump in one sheet for visualization.
- Examine and analyze the causes for heat losses, etc. based on the created energy balance flow.
- Discover losses and waste left unnoticed so far by comparing with other plants.
Out-going heat
(Exhaust heat)

BP11

24. Radiation amount

Cooling tower

In-coming heat
(Electric power)

Up to now…

18. Cooling tower fan
Electric energy

Cooling water pump
7. Heat source machine
Main machine electric energy

Operation Results Table
16. Cooling water pump
Electric energy

1. Cold water sales
heat quantity

Secondarypump[Standard]

12. Heat loss
(Heat loss +in-plant cooling)

Other electricenergy(Ventilation fan,lighting, etc.)

14. Primary pump
Electric energy

8. Secondary pump 10. Heat loss
Electric energy[Subtraction]

4. Hot water sales
heat quantity

13. Heat loss
9. Secondary
pump
Electric energy
15. Primary pump
Electric energy

17. Brine pump
Electric energy

19. Heating tower fan
Electric energy

11. Heat loss

Heat collection
amountIn-coming heat
(Cold water)

Visualize
heat flow

Secondary pump

Management
based on tables
and graphs

Heat loss +in-plant heating[Subtraction]

Out-going heat
(Hot water)

25. Heat collection amountIn-coming heat
(Air heat)

Effects or Remarksu Effects of small-group activities at the Kanda Surugadai district heat and cool supply center (hereinafterreferred to as the Kanda DHC)
The following three items were improved based on realization obtained by utilizing support of energy
conservation activities and the energy balance flow.
1. Reduced transfer power
2. Recovered efficiency of the heat exchanger in each heat source machine
3. Reduced standby electric power
Annual Energy Conservation Effects (Kanda DHC)
Item

FY2016 before improvement

FY2018 after improvement

Reduced amount

Reduction rate (%)

1

187

164

23

12

2

244

230

14

6

3

8

0

8

100

Total

439

394

45

10
* Crude oil

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Scheduleu Approaches by small-group activities- Improved heat losses by operational change of hot water in summer- Higher efficiency by cleaning the heat exchanger of the water-cooled chiller with chemicals- Lower transformation loss by operational change of the transformer- Smaller hot water supply pump
- Program change to control the number of supply pumps

Contact:

TOKYO TOSHI SERVICE COMPANY
Harumi Island Triton Square Y 15th Floor, 1-8-11 Harumi, Chuo-ku, Tokyo
E-mail: tts-customer-ml@tts-kk.co.jp URL: https://www.tts-kk.co.jp/

Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html

BP12

Keywords

Y3

equipment or facility

Z4electricity

F29

maufacturer of electrial machinary,equipment and supplies

Panasonic Corporation Tsu Factory

Energy saving activities at mother factory combining BCP measures~Implementation of advanced air control, etc. and guidance to other factories~
Features
Global warming is progressing, and natural disasters are occurring frequently. In particular, the number of large
earthquakes is increasing in Japan, and there is an urgent need for infrastructure development in consideration ofearly restoration in order to minimize the damage.
In addition, Panasonic must accelerate its energy-saving activities in order to reverse the ratio of "energy usedand energy created" by 2050.
The Tsu Factory is adjacent to Ise Bay, and there is an urgent need to promote energy saving and develop
factory infrastructure in combination with BCP for business continuity.
<Results of Activities>[Tsu Factory] CO2 emissions basic unit: △ 8.2% decrease, 23.0t/100 million yen (FY2014) → 21.1t/100 million yen(FY2018)[Instruction / deployment to other sites] Proposal contents for FY2016-2018: CO2 reduction amount of 800t, energy
saving amount of 400kL (estimate, expected)

Basic Concept or Summary
In pursuit of our company’s environmental policy of "combining comfort and eco-friendliness," the Tsu Factory
contributes to reducing its environmental impact as a base for manufacturing wiring equipment.
It acquired "ISO14001" in 1996, and all the personnel carry out continuous energy saving and environmental
activities. While promoting further energy-saving activities, the know-how cultivated as a mother factory is being
spread horizontally to domestic and overseas sites.
500m from the coast (Ise Bay)In the event of an emergency, the air supply needs to be restored alongwith the restoration of electricity, so when the compressor was renewed, it
was relocated to the top floor of the building. As a result, even in the eventof an emergency such as a tsunami, air can be supplied to the factory at an
early stage, reducing the risk of disasters.
Maximum tsunami height at time of Nankai Trough earthquake:3.4m (1st floor is submerged)

Effects or Remarks
The point of energy saving is "advanced air control in collaboration with external companies"
Upper floor installation of compressor<Effect of setting up the upper floor of the building>
Reduction of disaster risk, and measures against pressure loss of air supply by shortening piping routes① Analysis of air consumption for advanced air control in collaboration with an external company
Currently, air is supplied to each building from the air supply facility, but it was found that about half of the factory air isused for the molding floor on the 4th floor. Furthermore, it was found that a large amount of air was used in the deburring
process of direct pressure molding on the molding floor. Even at the end of the month when the operation was low, it was
consumed in large quantities, which was also the cause of the deterioration of the basic unit.
② Reduction of air power consumption by introducing a low-pressure compressor exclusively for direct pressure molding
When introducing the compressor, we set the optimum air pressure for deburring in cooperation with the manufacturer,
production technology, and manufacturing department. The supplied air pressure was reduced from 0.50Mpa to 0.45Mpa.
At the time of production adjustment at the end of the month, the basic unit was improved by completely stopping the
low-pressure compressor and installing a switching valve between factory pressure air and low-pressure air.
③ Advanced air control in collaboration with external companies
The air leak investigation, which is an invisible improvement activity, continues to play cat and mouse with the site. We
must continue to identify and repair leaks early. In collaboration with an electric power company, we adopted ahigh-precision leak detector to realize "visualization of leak points and leak amount". All the members are continuing torepair and address such leaks.
In addition, in collaboration with an air equipment manufacturer, we succeeded in improving the continuous air blow in
direct pressure molding after trial and error so that the quality would not be affected. A pulse blow device was attached tothree of the seven nozzles, and two of the remaining four were stopped, reducing the amount of air used by 50%.

④ Reduced compressor powerby optimal unit control
Of the six compressors, threewere always in full operation, twowere being controlled and one
was stopped as a spare. When
updating the control panel of thecompressor, we changed thenumber that could be controlledfrom two to five, and the optimum air supply system was realized according to the load.
<Initiatives in collaboration with equipment manufacturers and related departments>
In line with the renewal of air conditioners, we worked to reduce the power consumption of constanttemperature and humidity air conditioning in the mold workshop in collaboration with the manufacturing
department. We proposed mitigation of temperature and humidity conditions with reference to the air conditions
at the head office of the mold workshop. After confirming with the machine tool manufacturer, the allowabletemperature was expanded to ± 2 °C and the humidity was revised to 70% or less without affecting the accuracyof the mold. As a result, the amount of electric power consumed could be reduced by 40%. In addition, in
cooperation with the mold design department, we were able to increase the number of molded parts from 8 to 12.
The production efficiency was improved and the production power was reduced.
<Installation of Solar power generation facilities and use of LEDs to reduce lighting power consumption>
A solar power generation facility was installed in the building designated as a nearby evacuation building in theevent of an emergency, and storage batteries were added. Power supply as an emergency power source andenergy saving were realized. It has become possible to supply 30 KWh (12 hours) of electricity.
In addition, although it is not a BCP measure, a solar carport is adopted in the parking lot. With an annual
power generation capacity of 373 MWh, it contributes to the spread of renewable energy.
We are also a manufacturer of lighting devices. We therefore replaced old lighting with new LEDs, which were
our industry's highest level products, and we were able to significantly reduce the amount of electricity. From2016 to the present, the cumulative power reduction amount has reached 1,047 MWh per year, achieving acumulative LED conversion rate of 95%. We have also adopted "PiPit dimming equipment" in workplaces andoffices that can bedimmed for each
unit andcontribute tofurther energy
saving by
reducing theilluminance at theplaces with nopeople,equipment andparts shelves.

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Records of Domestic andOverseas Introduction
As the mother factory, Tsu
factory has carried out steadyenergy saving activities.
We have developedenergy-saving improvements for
air, air conditioning, lighting,production equipment and so on
by closer cooperation with otherdepartments. Based on ourpossessed know-how, we havecreated the energy-saving survey guideline and the air leak survey procedure manual. Now we are expanding theseto overseas factories. The establishment of these methods has led to the development of human resources toaccelerate the localization of overseas factories.

Contact:

Panasonic Corporation Tsu Factory
URL: https://www.panasonic.com/jp/top.html

BP12

Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html

BP13

Keywords

Y4

system or software

Z3/4

natural gas/electricity

F33

production, transmission & distribution of electricity
JFE Engineering Corporation

Multi-site Integrated Energy Network Services for Energy Saving
Features
As a new energy conservation promotion measure in the industrial sector, we are developing multi-site
integrated energy network services (JFE-METS) as a product.
n Analyzes the actual energy consumption conditions at multiple bases, such as business units and area
units, rather than individual basesn Deploys integrated energy-related facilities in each basen Implements energy sharing including remote areas⇒ It provides the energy service that generates energy conservation in a comprehensive manner.
By expanding our JFE-METS as a product, we aim to achieve annual energy saving of 200,000 kL(equivalent to 500,000 tons per year of CO2).

Basic Concept or Summary
In the industrial sector, promotion of energy conservation is an important theme, and the person in charge
is making efforts to further wring out the "dry rag" in order to achieve energy conservation as much as
possible by making full use of all measures. JFE-METS, by changing our viewpoint so far, analyzes theactual energy consumption conditions at multiple bases, such as business units and area units, rather than
individual bases, and deploys integrated energy-related facilities in each base. By implementing energy
sharing including remote areas, it provides the energy service that generates energy conservation in acomprehensive manner.
The effects of this service are as follows:À high operation rate of facilities for reduction of fossil fuels such as cogeneration
Á reduction of fuel cost by overall contract management
Â rationalization by overall energy management
These realize energy saving at the same time as energy cost reduction.
We are developing JFE-METS as a business model that can accommodate a variety of groups and various
energy facility structures depending on the companies or areas, and we believe that we can contribute tosocial energy conservation by disseminating this business model through sales efforts.

Effects or Remarks

BP13

In order to disseminate this business model, the promotion to the food, chemical, and pharmaceuticalindustries, which have relatively large heat demand and generates large energy saving effect in the
production activity, is considered to be the first thing. Assuming that the model can be disseminated to 10%
of businesses in these industries, the market size can be 70-140 billion yen per year. Assuming an energy
saving rate of 10%, energy can be reduced by 100,000-200,000 kL per year, and CO2 can be reduced by
250,000-500,000 tons per year.
Looking at the period up to 2050, as a means of further expanding JFE-METS, it is possible to plan andimplement more energy-efficient models by creating more effective combinations of models by integrating
individual units into multiple operators or multiple areas. In order to achieve this, not only further developing
the control systems, but also deregulation is necessary, such as enabling the exchange of power between
different operators utilizing the existing transmission and distribution networks. In this regard, we would liketo aim for CO2 reductions of 1 million tons per year by 2050.

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Notes for Introduction- Using a lot of Steam and/or hot water- Easy access to natural gas infrastructure

Records of Domestic and Please see the following websites for examples and details
Overseas Introductionn Japan's First! Optimization of Energy from Procurement to Supply at All
Production Bases of The Nisshin OilliO Group, Ltd. Nationwide - 17%
Reduction of CO2 Emissions and Reform of Cost Structure https://www.jfe-eng.co.jp/en/news/2017/20171013.html
n JFE-METS Receives 2019 Energy Saving Award, Minister of Economy,
Trade and Industry Award - Realizing Energy Saving by Collectively
Managing Energy at Multi-site
https://www.jfe-eng.co.jp/news/2020/20200130.html

Contact:

JFE Engineering Corporation
URL: https://www.jfe-eng.co.jp/

Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html
Keywords

Y4

system or software

Z1/2/4solid fuels/oil/natural gas

S8advanced urban system

F35

heat supply

Nagoya City Energy Co., Ltd./Nikken Sekkei Ltd./Nikken Sekkei Research Institute/Shinryo Corporation

Achievement of district energy conservation and load leveling throughthe best mix of electricity and gas usage and utilization of reclaimed sewage water
FeaturesThis district heating and cooling (DHC) system project for the Sasashima Live 24 District (Nakamura and Nakagawa
Wards, Nagoya City, Aichi) has delivered a distinctive energy conservation model that combines the following major
features: utilization of unused energy (heat from reclaimed sewage water) for running the heat supply plant, apartnership program with the City of Nagoya; nighttime thermal storage (water thermal storage tank) using a centrifugal
chiller; and gas engine cogeneration systems (CGS). It has been designed to achieve the best mix of the advantages ofelectricity and gas heating through joint efforts of participating companies while increasing the District’s disaster
preparedness, mainly through securing an emergency power supply.
This model highlights the adoption of reclaimed sewage water as a heat source. It takes advantage of the resource’s
property of remaining at a constant temperature throughout the year to provide winter heating and summer cooling withhigher energy efficiency.

Basic Concept or Summaryu Basic Concept

Sasashima Live 24 District is located approximately 1km south of Nagoya Station. After the Sasajima Freight Station
was closed in 1986, the City of Nagoya began a land redevelopment project. This became the current redevelopedarea with the theme of “Hub for international hospitality and exchange”.
The energy center has a plant area of approximately 2,600 m2. It is located in the basement of the Lecture Building
and the Welfare Building of Aichi University, and supplies heat to the following buildings:• Global Gate: A building with state-of-the-art office, hotel, and conference facilities and commercial facilities.
• Aichi University Nagoya Campus buildings: An urban-type campus comprised of the Main Building, the Lecture
Building, the Welfare Building, and the Global Convention Hall.
• CHUKYO TV. BROADCASTING : A designated terrestrial core broadcasting operator for television broadcasting
covering the Chukyo region broadcasting area.
mi

a
on

A

u
-raib

tion

Lin

e

To NagoyaStationJICA
Chubu International
Center

Sta

ima

ash

Sas

Aichi University
Lecture Building
Aichi University
Welfare Building

Energy plant

Park

Zepp
NagoyaMarketSquareSasashima

Global Gate

CHUKYO TV
BROADCASTING

Aichi University
Main Building(Research Building)Global Convention Hall

Nagoya Expressway Route 5 Manba RouteSupply area

Area conduits

District heating/cooling supply area (Total supplied floor area: 252,700 m2)

u Equipment configuration and features• Approximately 30,000 m3/day of reclaimed sewage water is introduced and is used as heat source water for the water
source heat pump in the winter and as cooling water for chillers, etc. in the summer.
• A water thermal storage tank (3,800 m3) is installed, and by rated operation of the centrifugal chiller during the night,
operating efficiency is improved and cooling water is manufactured.
• CGS (600kW x 2 units) are installed. Normally, they are utilized to supply generated power and the exhaust heat isused as a cold water/hot water heat source. In the event of a disaster, they can be used as a safety power source forthe energy plant and Aichi University.
• Preheating of the central hot water supply for commercial facilities is performed using solar thermal collector panels.

Aichi University Lecture
Building, Welfare Building

Aichi University Main Building,Research Building

CHUKYO TV.
BROADCASTING

Global Gate

Cold water
Hot water

Heat recovery
centrifugal chiller(inverter)

Steam

Electricity

BP14

Steam/hot water
heat exchanger

Centrifugal chiller(inverter)

Small through- Heat exchanger using
flow boiler
CGS exhaust heatGas engine cogeneration system

Exhaust heat
(Hot water)

Tsuyuhashi Wastewater
Treatment Center

Exhaust-heat-input typegas-absorption
water chiller-heater

Heat exchanger forheat storage radiation
Multi-connectedcomplete mixing-typewater heat storage tankHeat pumpcentrifugal chiller(inverter)

Reclaimed sewage
water(heat utilization)

500RT×1

Water source heat pump

1,600RT×1

Exhaust-heat-input typegas-absorption water
chiller-heater

1,000RT×1

Nakagawa Canal ship pool

1,000RT×2,700RT×1

Steam boiler

2.5t/h×6

Water thermal storage tank

3,800m3

Gas engine CGS

600kW×2

Solar thermal collector panels

Utilization of waterlandscape facilities
Nakagawa Canal water
discharge(water quality improvement)

800RT×1

Water source heat pump(heat recovery)

Gas-absorption water
chiller-heater

Solar heat utilizationequipment
Gas-absorption
water chiller-heater

Centrifugal chiller

120m2

Effects or Remarks

BP14

u Use of reclaimed sewage water (unused energy)

aL

i ne

• In conjunction with the complete renovation of the Tsuyuhashi Wastewater Treatment Center of Nagoya City Waterworks& Sewerage Bureau, reclaimed sewage water (30,000 m3/day) is discharged into the Nakagawa Canal ship pool adjacentto the area, and heat utilization was achieved in collaboration with the City of Nagoya.
• During the summer, operating patterns for maximum utilization as cooling water were devised and implemented.
• In addition to utilization as a heat source, water quality improvement and utilization as a city park landscape has also beenachieved. For this multipurpose use and use of the upper space, the City of Nagoya received the Circulation Route
Sewage Works Award Grand Prize from the Ministry of Land, Infrastructure, Transport and Tourism in 2019.
Na
g

oy

Area heat supply plant(heat utilization)

Ki

nte

tsu

Sasashima-raibu
Station

Komeno Station

Ka

mi

na

Ao

te

al Ga

Glob

Heat pump

Aichi
University

e
Lin

Line
Line
ya Main ido Shinkansenu NagoMeitets ido Line, Toka
JR Toka

ain

iM

a
ns

30,000 m3/day

Cold water
Hot water

CHUKYO TV.
BROADCASTINGe

Lin

Municipal park
(Landscape use)

Heat exchanger

Heat demand customers

Area heat supply plant (heat utilization)
Municipal park (Landscape use)

30,000 m3/day

Tsuyuhashi Wastewater
Treatment Center

5,000 m3/day

25,000 m3/day
Nakagawa Canal(water purification)

Nakagawa Canal(water purification)
Reclaimed sewage
water pipe (600φ)

Tsuyuhashi Wastewater
Treatment Center

5,000 m3/day
Nakagawa Canal (water purification)u Energy conservation effects(1) Energy conservation performance
Including the energy conservation effect of reclaimed sewage water (approx. 10% annually), as a result of efforts forhigh-efficiency operation, the system COP of this plant has become approx. 1.1.
(2) Effects of electricity load leveling
During summer cooling load peak periods, water thermal storage tank, reclaimed sewage water, gas-absorption water
chiller-heaters, etc. are used to supply more than 40% of cold heat. In addition, at customers to whom power is supplied,
during summer peak periods almost 80% of the customer’s power demand was supplied by CGS.
(3) Establishment of Energy Conservation Committee
The Committee consisting of Nagoya City Energy, the City of Nagoya, and customers analyzes and shares information onenergy production and use conditions, and promotes energy conservation.
u Awards• 2019 Aichi Environmental Award (Aichi Prefecture): Silver Medal
Achievement of top-class COP (system efficiency) through “Utilization of reclaimed sewage water” and “Best mix ofelectricity and gas usage”• 2019 Cogeneration Award (Advanced Cogeneration and Energy Utilization Center JAPAN): Excellence Award (Consumer
Division)
Improvement of district energy conservation and disaster prevention preparedness through energy-saving combined heatsource systems such as cogeneration and utilization of reclaimed sewage water.
• 2020 HPTCJ Award for Demand Side Management (Heat Pump and Thermal Storage Technology Center of Japan):
Director of HPTCJ Award
Achievement of district energy conservation and load leveling through the best mix of electricity and gas usage andutilization of reclaimed sewage water

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Notes for Introductionu Collaboration with the City of Nagoya (Realization of urban planning)

Records of Domestic andOverseas Introduction

In Sasashima Live 24 District, we started to supply heat to all customers from October 2017.

Contact:

Expansion of area energy usage and utilization of unused energy, etc. are included aspolicies in the City of Nagoya’s “Second Action Plan for Low-Carbon City Nagoya
Strategy”. Sasashima Live 24 District is the most important base of Nagoya's
redevelopment project, and supply of energy by our company helps promote theimplementation plans of these policies.
u Utilization of subsidies
A subsidy for “The Leading Project for Promoting CO2 Reduction in Housing and Building”
from the Ministry of Land, Infrastructure, Transport and Tourism was received, andthrough construction with the highest level of environmental technology andhigh-efficiency energy systems, we have increased the regional energy conservation andenvironmental quality, and have become one of the nation’s leading projects.

Technology Division, Nagoya City Energy Co., Ltd.
Tel.: +81-52-737-2100 ootani@nc-energy.co.jp URL: http://www.nc-energy.co.jp/index.html

Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html
Keywords

BP15

system or software

Y4

Z4

electricity

S3

ZEB/BEMSK

Real estate Goods Rental and Leasing

Nippon Steel Kowa Real Estate Co., Ltd./Nihon Sekkei, Inc./Akasaka Intercity Management Co., Ltd.

Initiative to Achieve Super High-rise Smart Wellness Offices in Akasaka Intercity AIR,and Energy Conservation that Transcends the Boundaries of Development Areas
Features• Realization of a new urban environment design that transcends the boundaries ofdevelopment areas, centered on “green networks” and “area-based energy use”.
• For large scale redevelopment in regions adjacent to existing district heating andcooling areas, a favorable cooperative relationship has been established among thethree parties consisting of redevelopment business operators, heat supply business
operators, and energy service business operators. Through DHC area expansion
type area-based energy use centered on cogeneration, energy conservation andurban development with disaster-resistant self-sufficient energy have been achieved
for the entire surrounding area.
Exterior Building Appearance• The aim is to improve the health and comfort of working residents and create smart
wellness offices by creating a super high-rise tenant building with high competitive power and added value.
• Business operators, facility managers, engineers, contractors, and automatic control manufacturers participate incommissioning. In addition, verification of overall performance and implementation of operational improvements are
conducted in coordination with both energy service business operators and heat supply business operators.

Basic Concept or Summaryn DHC area expansion type area-based energy use

Normal Heat Source System Case

New Large Scale
Development

Existing DHC

Cogeneration is installed in the building as an energy supply systemwith the aim of urban development with self-sufficient energy.
Additionally, for large scale redevelopment in regions adjacent to
Problemexisting district heating and cooling areas, area-based energy use by
of Supply
Capacity
DHC area expansion has been introduced. Electricity and exhaust
heat hot water from the cogeneration system are supplied to cover thebase load of hot and chilled water used on the building side, andOne-way Heat Supply
Independent DHC
Main Plant
Subplant
or Independent
Heat Source
exhaust heat steam is supplied to district heating and cooling. Heatsharing is conducted for steam among three plants, and for chilledwater among two plants. High-efficiency equipment can be operated
DHC Area Expansion Type Area-based Energy Use Case
efficiently in accordance with loads, and high-efficiency heat can besupplied to existing buildings in the vicinity which had been supplied by
Expanded DHC
AKASAKA
INTERCITY AIR
Existing DHC
existing plants.
n Medium temperature chilled water use systems in coordination
with existing DHC
In order to achieve ultra-high efficiency operation of chillers, aSharing of
high-efficiency supply of medium temperature chilled water in an
Steam and
Chilled Water
existing DHC district has been achieved for the first time in Japan,
Two-way Heatthrough coordination with building-side medium temperature chilled
Sharing of Steam
Main Plant
Subplant
3rd Plant
water use systems. In this method, air conditioner coils are cooled in
two stages by medium temperature chilled water and chilled water.
Conceptual Image of DHC Area Expansion
They are precooled by 15°C medium temperature chilled water to 18 Type Area-based Energy Use
20°C, and then further cooled by chilled water to 16°C for outdoor air
conditioners and 12°C for air conditioners. Outdoor air conditioners forstores are cooled only by medium temperature chilled water to 20°C, and air is supplied.
Gas
Electricity (Medium pressure)

DHC Area after Expansion

Gas
Electricity (Medium pressure)

Cooling Operation of General Air-conditioning System
Air Conditioner

Cooling Coil Heating Coil

Outdoor Air
35°C

AKASAKA INTERCITY AIR
Outdoor Air Conditioner
Supply Air
16°C

High Performance Energy Saving
Air-conditioning System

Return Air
26°C

Other Consumers

Cooling Operation by Medium Temperature Cold Water
Use Air-conditioning System
Cooling and Heating Coil

Cooling Coil

Outdoor Air
35°C
Return Air
30°C

Outdoor Air Conditioner
Supply Air
16°C
Air Conditioner
Supply Air
12°C

15°C
23°C
Medium Temperature
Chilled Water(Hot water when heating)Medium Temperature Chilled Water
Hot
ChilledChilled Water
Steam Water
Water
Electricity

Existing Adjacent
Building(approx. 75,000m2)

7°C
15°C
ChilledHot Water
Water (Stop when cooling)

Air Conditioner

Building Facility

Existing DHC Area

Main Plant

Chilled Steam
Water

Steam Boiler

Building
Facility
ChilledWater Steam

Subplant

GT
CGS

Steam

Absorption
Chiller

Energy Service

Heat Sharing
Steam
3rd Plant

Absorption Chiller
Centrifugal Chiller

Absorption Chiller

Ice Storage

Centrifugal Chiller

Chilled Water

Conceptual Image of Medium Temperature
Chilled Water Use

Electricity

Medium-pressure Gas

Electricity

Steam

Inverter Centrifugal Chiller
Absorption Chiller Water Storage

7°C
15°C
Chilled Water

Up to roughly 50% can be covered by medium temperature chilled waterGE
CGS

Newly established

Energy Supply System

Electricity

n High performance energy saving air-conditioning systems to support smart wellness offices

Offices on typical floors are equipped with high performance energy
Control of optimal outdoor air intake volume according to COconcentration, and unit quantity control of outdoor air conditioners
equipped with total heat exchanges, and outdoor air conditioners
saving air-conditioning systems to support smart wellness offices.
Outdoor Air Conditioner with Total Heat Exchanger
These systems use a CO2-saving air-conditioning design method thatCO
Sensorincreases the ratio of medium temperature chilled water use andTotal Heat Exchanger
optimizes equipment capacity, and consist of: a 3-zone
Outdoor Air
air-conditioning system created to meet tenant needs and reduce
Conditioner
Air Conditioner
waste; a functionally differentiated multi-duct air-conditioning systemthat can respond to various requirements by differentiating and freely
Plug Fan IPM Motor
Variable Air Volume
combining ventilation/humidity adjustment functions and temperature
Control of Restroom
Exhaust Fan
adjustment functions; an ultra-large supply air temperature difference
To Outside
Duct for Pass
Floor Suction byvariable air volume intermittent air-conditioning system with a supply
Efficient odor
Perimeter Return
removalFan (Winter only)
air temperature difference of approximately 19°C; an air-conditioning
Terminal forsystem with optimal outside air volume control conducted by outdoor AirGridSupply
Ceiling, Compatible<Perimeter><Interior><Core Side> Hallway
Men’s
Women’swith Large Air Volume
air conditioner sharing; and a unit toilet lining exhaust system with
Restroom Restroom Reduction of restroom
and Large Temperature
air exchange rate byDifference
local exhaust
motion sensor control.
n Selectable-environment tenant eco-support system
High Performance Energy Saving Air-conditioning System
An energy use monitoring system which allows tenants to visualize
energy consumption via devices such as PCs or smartphones through tenant-service servers has been introduced to support
energy conservation. With plans that charge air-conditioning fees according to the amounts of heat and electricity consumed, it
is a selectable-environment type system that can return the reduction effects of energy-efficient operation by tenants back tothose tenants as cost benefits.
n Compatible with 200-hour continuous operation of emergency generators by using disaster-resistant medium-pressure gas
As a power supply measure in case of power outages, cogeneration and a dual fuel gas turbine that can use two types of fuelhave been introduced. In addition to cogeneration and storage of heavy oil A sufficient for 72-hour operation, it also uses
disaster-resistant medium-pressure gas, and can supply roughly 70% of electric power during 200 hours of continuous operation.
2

2[Correction 3] Evaluation at newly-constructed building
cogeneration facility(Plant efficiency 1,275)
Applicable Building
Chilled
Water

Other Consumers

Other Consumers

ChilledWater Steam

ChilledWater SteamHot Water

Adjustment and operational improvement, and ZEB evaluation ofarea-based energy use, are carried out by commissioning in theoperation stage. As a result of these efforts, the primary energy
consumption rate in FY2019 was 1,093 MJ/m2-year, and the correctedvalue from plant efficiency conversion, which reflects the effects ofarea-based energy use and medium temperature chilled water use,
was 965 MJ/m2-year, fulfilling the ZEB Ready standard which specifies
a 50.0% reduction from reference levels (achieved 54% reduction).
n Major awards received[Results] Past plant results(Published value for Tokyo)(Plant efficiency: 0.75)

Medium Temperature
Chilled Watern Primary energy consumption rate and ZEB evaluation

Chilled Water

Effects or Remarks

Electricity
Medium-pressure Gas

Hot
Water

Chiller

CGS

EnergyService

Steam

Main Plant

Subplant

ChilledWater

3rd Plantn Adoption of subsidized projects• Ministry of Land, Infrastructure, Transport and Tourism, FY2013 Promotion Projectfor Urban Development with Self-sufficient Energy• Tokyo Metropolitan Center for Climate Change Actions, Tokyo Environmental PublicService Corporation
Project for Promotion of Energy Creation and Energy Management at Office
Buildings and other Sites

n Environmental certifications• CASBEE Smart Wellness Office Evaluation Certification Rank S

Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule

Primary Energy Consumption Rate (MJ/m2-year)• 17th Environmental and Equipment Design Awards, City and LandscapeMedium-pressure Gas Electricity
Electricity
Electricity
Design Division, Grand Prize (Association of Building Engineering and[Correction 1] Evaluation at overall[Correction 2] Evaluation at Subplant
Equipment)
DHC Plant+ 3rd Plant(Plant efficiency: 0.787)(Plant efficiency: 0.945)• 8th Sustainable Architecture Awards, Large Scale Architecture Division,
Review Committee Honorable Mention (Institute for Building Environment
Boundary Setting Pattern for ZEB Evaluationand Energy Conservation)• 2019 Cogeneration Awards, Consumer-use Division, Chairman’s Award (Advanced
Incoming electricity
CGS gasCGS steam
DHC chilled water
DHC medium temperature cold water
DHC steamCogeneration and Energy Utilization Center JAPAN)
Solar powerPrimary energy
Primary energy• 58th Society of Heating, Air-Conditioning and Sanitary Engineers Awards, Building
Equipment Division, Technology Award (The Society of Heating, Air-Conditioning
and Sanitary Engineers of Japan)• 8th Carbon Neutral Awards, Kanto Branch, Honorable Mention (Japanese
Association of Building Mechanical and Electrical Engineers)* Results from April 2019 – March 2020
DECC (nationwide) weighted average used as reference
EnergyDesign value
conservation
standard

Reference

Actual result Correction 1 Correction 2 Correction 3
Plant
efficiency

Plant
efficiency

Plant
efficiency

Plant
efficiency

Comparison and ZEB Evaluation of Primary Energy
Consumption Rate

Notes for Introduction• Introduction of cogeneration which applies energy service businesses
Reduction of construction costs and improvement of project planning for redevelopment
projects, and introduction and operation of high-efficiency cogeneration systems• Cooperation in redevelopment, heat supply, and energy service businesses• Utilization of environment-related subsidies
Application to promote leading initiatives, improve business balance, and implement
commissioning after completion
Akasaka Intercity AIR
Records of Domestic and Overseas Introduction

Contact:

Nippon Steel Kowa Real Estate Co., Ltd.
Shota Osame +81-80-1983-5449 shota.osame@nskre.co.jp URL: https://www.nskre.co.jp/

BP15

Source:JASE-W Japanese Smart Energy Products & Technologies

https://www.jase-w.eccj.or.jp/technologies/index.html

BP16

Keywords

Y4

system or software

Z4

electricity

S1electric power system

F33

production, transmission & distribution of electricity

Chugoku Electric Power Transmission & Distribution Co., Inc.

“The Oki Hybrid Project”: Expanding the introduction of renewable energy,
cooperating with the community, and utilizing Japan's latest technology
Featuresu Leading effort for introducing the first "hybrid storage battery system" in Japan• In order to deal with both "short term fluctuations" and "long term fluctuations" caused by renewable energy
at the lowest cost, we had constructed a "hybrid storage battery system" that combines 2 different types ofstorage batteries, the first effort of its kind in Japan.
• We have achieved the supply-demand operation that automatically controls the batteries and internal
combustion generators from the Energy Management System (EMS), all on a commercial-use power system.
u Efforts united with the community• We have introduced a large-scale mega solar farm cooperating with the local government,.
Basic Concept or Summary
1. Basic Concept
In remote islands such as Oki Islands, which are not connected by transmission lines to mainland Japan, thefluctuation caused by renewable energy is significant, because of the small scale of electricity usage. Therefore,
in order to expand the introduction of renewable energy in remote islands, measures to adjust the fluctuation
caused by renewable energy, such as batteries, are required.
This project is a plan adopted for subsidization by the Ministry of the Environment in FY 2014*, which aims, forthe first time in Japan, to introduce a hybrid storage battery system combining 2 different types of batteries, NaS
and Li-ion batteries, to accept a total of 11,000 kW of renewable energy, exceeding the Oki Islands' annual
minimal demand (10,000 kW).
* FY 2014 battery demonstration project for promoting the introduction of renewable energy on remote islands

Figure 1 Overview of major power facilities in the Oki Islands

2. Oki Hybrid Project(1) The Hybrid Storage Battery System
There are 2 types of fluctuations caused by renewable energy, the "short term fluctuations" due to the fluctuation of thesolar radiation or the wind velocity, and the "long term fluctuations" due to the position of the sun, requiring measures forboth phenomena.
In this project, we have constructed a hybrid storage battery system, which absorbs the short term fluctuations by highpower Li-ion batteries, and the long term fluctuations by large capacity NaS batteries.

Figure 2 Hybrid BESS (Battery Energy Storage System)

(2) The Energy Management System (EMS)
We have connected the batteries, diesel power stations, and renewable energy facilities to an Energy Management
System (EMS) via a communication network, achieving supply-demand operation that automatically controls the batteries
and internal combustion generators from the EMS, gathering data such as the power demand and system frequency, all on acommercial-use power system.
The functions of the EMS are “Forecast of renewable energy generation and demand”, “Charge/discharge control ofbatteries”, “Control of the internal combustion generators”, and so on, and coordinated control between storage batteries
and internal-combustion power is executed by means of unmanned automatic operation.

Figure 3 Configuration diagram of energy management system (EMS)(3) Efforts united with the community• Cooperating with the local government, we held open recruitment for a renewable energy company at the former
grounds of the airport and introduced a large-scale mega solar farm.
• By constructing the special website and promotion hall, we had not only introduced this project but also promoted the Oki
Islands, with the approach of "the fusion of the latest technology and nature".

Effects or Remarks
u Improvement of the power supply stability
While ensuring the quality of electricity, we have expanded the introduction of renewable energy from2,300kW (before the project) to 8,000kW (as of March, 2019).
u Reduction of environmental impact
Reduced fossil fuel diesel power generation consumption, therefore reducing CO2 emissions.
u Activation of the local community
This project is the first challenge of its kind in Japan, and had led to increase in the number of visitors toOki.
u Awards
2019 “New Energy Award” - “Agency for Natural Resources and Energy Commissioner’s Award(Renewable Energy Introduction Sector)”
Introduction to Other Companies- Notes for Introduction- Installation in Practice or Schedule
Records of Domestic and Technical knowledge accumulated through this project is expected to contribute
Overseas Introduction
to solutions for remote islands for both domestic/overseas cases.

Contact:

Chugoku Electric Power Transmission & Distribution Co., Inc.
“The Oki Hybrid Project”
URL: https://www.energia.co.jp/nw/safety/facility/okihybrid/

BP16