Heat Pump & Thermal Storage Technology Center of … - Pioneering... · Heat Pump & Thermal Storage...

Heat Pump & Thermal Storage Technology Center of Japan

3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013 1

3rd Conference of AHPNW “Research and Development of

Heat Pump and Thermal Storage Technologies

in Industrial and Residential Sectors”

Pioneering

Industrial Heat Pump Technology

in Japan

Dr. Choyu Watanabe

Chubu Electric Power Co., Inc.



1 Introduction

2 Apparatus technology 1) Definition and types of industrial heat pumps

2) High temperature heat pumps

3) Refrigerants for high temperature heat pumps

4) Thermal storage technology

3 System technology and application 1) Distributed heat pumps and heat recovery in industrial

processes

2) Two examples of the introduction to the industrial process

of heat pumps

4 Conclusions

Contents


3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013

Heat pump technology important for boosting

Reducing CO2 emissions

Reducing primary energy consumption

Increasing the amount of renewable energy used

Scope of industrial applications Expected to expand,

further enhancing these effects

Introduction

3



Pioneering

Industrial Heat Pump Technology

in Japan

for hot water supply

for hot air supply

for re-heating of circulating water

for steam generation

4



IEA (International Energy Agency)

HPP (Heat Pump Program)

HPP operates under the IEA and was founded in 1978 as one

of the international technology collaborations on the basis of

implementing agreements.

HPP is a non-profit organization under which participants in

different countries cooperate in projects in the field of heat

pumps and related heat pumping technologies such as air

conditioning, refrigeration and working fluids (refrigerants).

The current member countries are Austria, Canada, Denmark,

Finland, France, Italy, Germany, Japan, the Netherlands,

Norway, South Korea, Sweden, Switzerland, United Kingdom

and the United States.



The objective of the annex is to reduce the use

of energy and emissions of greenhouse gas

emissions by the increased application of heat

pumps in industry.

Start date: May 2010, End date: April 2014

IEA HPP Annex 35

(Application of industrial heat pumps)



IEA HPP Annex 35 National expert meeting of Japan

Objectives

・Mutual exchange of information on industrial heat pumps

・Providing a country report for Annex activities

Members

・Organized by stakeholders of industrial heat pumps

・21 people from universities, research institutes, electric power

utility, engineering and manufacturing companies

Representative organizations for the IEA HPP

・NEDO (New Energy and Industrial Technology Development

Organization )

・HPTCJ (Heat Pump & Thermal Storage Technology Center

of Japan)



1 Introduction






processes


of heat pumps

4 Conclusions

Contents



Definition of Industrial Heat Pumps

Heat pumps used for

recovery and heat upgrading

in industrial processes

and for

heating, cooling and air-conditioning

in industrial buildings



closed-cycle mechanical heat pump open-cycle mechanical vapor

recompression heat pumps

open-cycle thermal vapor

recompression heat pumps closed-cycle absorption heat pumps

Four General Types of Industrial Heat Pumps [1]

[1] US Department of

Energy: "Industrial Heat

Pumps for Steam and Fuel

Savings", DOE/GO-

102003-1735, 2003.



1 Introduction






processes


of heat pumps

4 Conclusions

Contents



High Temperature Heat Pumps

Closed-cycle mechanical heat pump

• CO2 transcritical cycle

• Single-stage compression reverse Rankine cycle

• Two-stage compression reverse Rankine cycle

• Cascade reverse Rankine cycle

Open-cycle mechanical vapor recompression heat pumps

Open-cycle thermal vapor recompression heat pumps

• Hybrid vapor recompression system

Closed-cycle absorption heat pumps

• Type-2 absorption heat pump



1.0 1.2 1.4 1.6 1.8 2.0

0

50

100

150

Entropy： S(kJ/(kg*K)

Tem

per

atu

re：ｔ(℃

)

Liquid & GasGas

Critical Point

Super Critical

Hot Water (Air) Supply

3.5MPa

12MPa

Cool Water (Air)

CO2 Transcritical Cycle

13



Water-Source CO2 Transcritical Heat Pump

Mayekawa Mfg. Co., Ltd.

delivering hot air, with screw type compressor

14



PE02

H01

PE03

Valve

TE02

Evaporator

TE01

Ball valve

Compressor

PE01

Evaporator

Charge port

Gas cooler

Internal heat exchange

TE03

TE04

TE05

PS01

strainer

FS01

TE

07

TE

06

Heat

sou

rce

wate

r ou

tlet

Heat

sou

rce

wate

r in

let

strainer

Ball valve

Air

Hot air

Eco-Sirocco Piping diagram

Type：ES-HAW12 Ver.1.1

Valv

e

High pressure refrigerant

Heat source water

Low pressure refrigerant

Symbol Equipment name

EXV01，EXV02 Electronic expansion valve

H01 Oil heater

PS01 Pressure switches

PE01 ～ PE03 Pressure transmitter

TE01 ～ TE07 Resistance Temperature Detector ( RTD )

FS01 Fluid sensor

EXV01

EXV02
















Single-stage Reverse Rankine Cycle (R134a)

17

1.2 1.4 1.6 1.8 2.0 0

50

100


Tem

per

atu

re：ｔ(℃

)

Liquid + Gas Gas

Critical Point

Liquid

Hot Water

0.5MPa

1.5MPa

Cool Water (Air)



Heat Pump for Washing Process

18

Zeneral Heat Pump Industry Co., Ltd.
















Two-Stage Compression

Reverse Rankine Cycle (R134a)

20

1.2 1.4 1.6 1.8 2.0 0

50

100


Tem

per

atu

re：ｔ(℃

)

Liquid + Gas Gas

Liquid

Hot Water

Cool Water

Critical Point



System flow

Heat source water

Outlet temperature

Heat source water

Inlet temperature

10 ~ 50 ℃

Heat source

the quantity of heat

Q1

The maximum hot water

Inlet temperature

90 ℃

Hot water

Hot water

the quantity of heat

Q2 = Q1 + W

Electric power W

Economizer

Turbo compressor

Hot water heat pump

ETW － L

The main

expansion valve

Vice-expansion valve

The first step impeller The second step impeller

Evaporator Condenser

Waste Heat Recovery Heat Pump Water Heater

Two-Stage Turbo-Compressor System with Economizer

Mitsubishi Heavy Industries, Ltd.

Refrigerant: R-134a



Waste Heat Recovery Heat Pump Water Heater

Two-Stage Turbo-Compressor System with Economizer

Mitsubishi Heavy Industries, Ltd.

Heating capacity(kW) 376 545 547

Cooling capacity (kW) 266 400 405

Electrical output of Compressor motor (kW)

104 136 133

Condenser

Entering water temperature (oC)

50 65 80

Leaving water temperature (oC)

60 75 90

Evaporator

Entering water temperature (oC)

15 35 50

Leaving water temperature (oC)

10 30 45

Specifications



Two-Stage Compression Reverse Rankine Cycle

(R245fa)

23

1.2 1.4 1.6 1.8 2.0

50

100

150


Tem

per

atu

re：ｔ(℃

)

Liquid + Gas Gas

Critical Point

Liquid

Hot Water (Steam)

0.4MPa

2.3MPa

Cool Water

1.0MPa



Refrigerant Compressor

Expansion

Valve

Condenser Evaporator

Flash

Tank

Waste Hot

Water (65oC)

Water

Supply

(20oC)

Steam, 120oC,

0.1MPa Gauge,

0.51t/h Heat Pump Unit

Steam-Generating Heat Pump SGH 120 Model

24

370kW, COP3.5 Industrial Process

Kobe Steel, Ltd.



Steam-Generating Heat Pump SGH 120 Model Supply 0.0 to 0.1 MPa Gauge steam, lifting up waste heat at 35 to 65oC

Flash Tank

Kobe Steel, Ltd.



Refrigerant Compressor

Expansion

Valve

Condenser Evaporator

Steam Compressor

Flash

Tank

Waste

Hot Water

(70oC)

Water

Supply

(20oC)

Steam

100-110 oC

Steam, 165oC,

0.6MPa Gauge

0.89t/h

Heat Pump Unit

26

660kW, COP2.5


Industrial Process Kobe Steel, Ltd.



Steam-Generating Heat Pump SGH 165 Model Supply 0.2 to 0.8 MPa Gauge steam, lifting up waste heat at 35 to 70oC

Flash Tank

Kobe Steel, Ltd.




Installed at Electric Power Engineering Research Laboratory

of Central Research Institute of Electric Power Industry (CRIEPI),

Yokosuka City, Japan
















Cascade Reverse Rankine Cycle For Reheating Circulating Hot Water

R134a

cycle

R410A

cycle

45oC

7oC

88oC

40oC

100

60

0

-20

120

40

20

80

Tem

pera

ture

(oC

)

100 200 300 400 500

Enthalpy (kJ/kg)

Cool

Water

or Air

Hot

Water

or Air



Supply unit

1st stageHeating in the compressor

2nd stageFurthermore, heating in the compressor

( Image )

Heat source unit

Circulation pump

Washing machine ・Heating system etc.

Circulation

heating

Heat of

the air

Heat of

the air

Heat of

the air

The reuse of the cold air

is possible, too

Cascade Heat Pump System for Reheating Circulating Hot Water

Toshiba Carrier Corporation

Heating capacity 14.0kW

COP 3.5*

Leaving water temperature 50- 90 oC



Heat source unit (R410A, Twin Rotary Compressor)

Cascade Heat Pump System for Reheating

Circulating Hot Water

Supply source unit (R134a, Twin Rotary Compressor)

Toshiba Carrier Corporation
















Hybrid Vapor Recompression System Mayekawa Mfg. Co., Ltd.

Thermal vapor recompression

Mechanical vapor recompression
















Solution temperature

Sat

ura

ted t

emper

ature

Hot waterCooling water Steam

Q

QQ

Q

Abs.

Gen.

Eva.

Con.

(ABSORPTION HEAT TRANSFORMER)

Type-2 Absorption Heat Pump

Duhring diagram



Absorber

GeneratorEvaporator

Condenser

Steam

Hot

Water

80-90oC

Cooling

Tower

40oC

Tem

pera

ture

Refrigerant

vapor

Refrigerant

lift

temperature

Refrigerant

vapor

Strong

Solution

Solution Heat

Exchanger

Weak

Solution

Feed

Water

temperature

difference

120oC

WASTE HEAT RECOVERY STEAM GENERATOR

(ABSORPTION HEAT TRANSFORMER)

Type-2 Absorption Heat Pump



Type 003 006

Steam

Production 385 kg/h 770 kg/h

Temperature 120 °C

Pressure 0.2 MPa (Absolute)

Feed water temperature 80 °C

Hot water 88 → 79.3 °C

895 L/min 1790 L/min

Cooling Water 25 → 30 °C

775 L/min 1550 L/min

Power source 3φ200 V × 50/60 Hz

Operating weight 6 ton 9 ton

Size (mm) L2100 × W1800

× H2550

L3600 × W1800 ×

H2550

EBARA Refrigeration Equipment &Systems Co., Ltd.

Specifications of waste heat recovery steam generators



Waste Heat Recovery Steam Generator (Type 006) EBARA Refrigeration Equipment &Systems Co., Ltd.



Waste hot water

Steam Header

Equipment

A

Equipment

B

Absorption

heat transformer

Boiler A Boiler BCooling

Tower

Ejector

2.0MPa 92

0.5MPa 134Process

89100Fuels

47

0.1MPa 42

number : energy ratio

Block Diagram of the System Installed

Heat Recovery Steam Generator (Type 006) EBARA Refrigeration Equipment &Systems Co., Ltd.



1 Introduction

2 Apparatus technology 1) Types of industrial heat pumps





processes


of heat pumps

4 Conclusions

Contents



Basic Characteristics of Refrigerants

for High Temperature Heat Pump Applications

Refrigerant Chemical formula GWP Flammability Tc oC

Pc MPa

NBP oC

R744 CO2 Carbon dioxide 1 none

30.98 7.3773 -78.40

R1234yf CF3CF=CH2 2,3,3,3-

tetrafluoropropene 4 weak 94.7 3.382 -29.48

R134a CF3CH2F 1,1,1,2-

tetrafluoroethane 1430 weak 101.06 4.0593 -26.07

R1234ze(E) CFH=CHCF3 trans-1,3,3,3-

tetrafluoropropene 6 weak 109.37 3.636 -18.96

R1234ze(Z) CHF=CHCF3 cis-1,3,3,3-

tetrafluoropropene <10 none 153.7 3.97 9.76

R245fa CF3CH2CHF2 1,1,1,3,3-

pentafluoropropane

1030 none 154.01 3.651 15.14

R365mfc CF3CH2CF2C

H3 1,1,1,3,3-

pentafluorobutane 794 weak 186.85 3.266 40.19

for low GWP



Saturated Vapor Pressure Curve

R134a R1234ze(E)

R245fa R1234ze(Z)

R365mfc



1 Introduction






processes


of heat pumps

4 Conclusions

Contents



If

Heat generated with heat pumps

Waste heat exhausted in plants

Stored in a thermal storage material,

We can expect

Improvement of disparities between day(peak) and

night(off-peak) power loads

Further utilization of waste heat

Normally

Water or ice are used as thermal storage materials.

But

Thermal storage materials

Over a wide temperature range from -3 to 250 oC

Thermal Storage Materials



Thermal

storage material

Melting point

(oC)

Latent Heat

(kJ/kg)

Application method and

field

Trehalose

C12H22O11

0 to -3 Nearly 210 Ice slurry (0 to 30 wt. %),

Cold storage of food

Tetra-n-butyl ammonium

bromide Type 1

5 to 8 193 Hydrate slurry

(13 to 20 wt. %),

Air conditioning of

machine parts factories

Parafin

(tetradecane)

5.9 229.1 Ice slurry (10 wt. %),

Air conditioning of

machine parts factories

Sodium acetate trihydrate

CH3COONa•3H2O

58.8 247 - 255 Thermal storage for solar

water heater or waste

heat of 60°C

Erythritol

HOCH2 (CHOH)2CH2OH

118 320 Thermal storage for waste

heat of a temperature

below 200°C Mannitol

HOCH2(CHOH) 4 CH2OH

165.5 303.7

Characteristics and Application of Thermal Storage Materials



1 Introduction






processes


of heat pumps

4 Conclusions

Contents



Steam Supply Service in a Manufacturing Plant

Producing cars, auto parts, electrical equipment, food, etc.

Steam is produced in the energy center

Supplied to some factories and all areas of each factory

Used in the manufacturing process

48

Energy Center

Factory Factory Factory

Factory Factory Factory

Manufacturing Plant

Steam Supply Service



Total Energy Efficiency of Steam Supply Service

generally low (e.g. 20%-40%) due to

Boiler loss

Heat loss from piping

Steam leakage loss in traps

Drain recovery loss

49



Steam Supply Service in a Factory

The most commonly used steam temperature

zone is in the range e.g. 55-80℃

Many electric heaters are used for these

processes for which temperature control is

required

50



Distributed Heat Pumps Significant energy savings are expected by

Replacing some steam supply service and electric heaters

With distributed high-temperature heat pumps

51

Heat Pumps Heat Pumps,

Preheating



Heat Recovery Simultaneous utilization of cooling and heating

Utilization of waste heat

52

Heat Pump Heat Pump,

Preheating

Steam

Generating

Heat Pump

Waste Heat Refrigeration Cooling



Type of industry Process

Temperature (oC)

40 60 80 100 120

Non-electrical machine

Drying

Washing

Degreasing

Electrical machine

Drying

Washing

Degreasing

Transport equipment Washing

Drying

Food

Boiling

Sterilization

Washing

Beverage Washing

Sterilization

Air

Water

Steam

Temperature of Heat Demand in Industrial Processes



1 Introduction






processes


of heat pumps

4 Conclusions

Contents



nearly 20oC nearly 60oC

Cutting Process and Washing Process

Cutting and washing process of machinery parts

Cooling water-soluble cutting oil with chillers

Heating washing liquid by boiler steam



Heat Pump for Washing Process

56

Zeneral Heat Pump Industry Co., Ltd.



Ground Plan of Machine Parts Factories

with Heat Pump Installed

East Factory West Factory

8 heat pumps with heating power of 44kW

Heating power of 22kW

6 heat pumps with heating power of 22kW

AISIN AW Co., Ltd., Gamagori plant



Operation Results of Heat Pumps for Washing Process

in the Machine Parts Factories

Energy Consumption [GJ/year]

CO2 Emission [ton-CO2/year]

Conventional System

20,238 1,340

Developed System

5,515 194

Rate of Reduction

73% 86%

Reduction of 89 % in running cost

Payback time of Investment is 3 or 5 years

Gamagori plant, AISIN AW Co., Ltd.



Temperature of the Heat Demand in General Painting

Process in Car Production Factory



Hot water tank

Booth(Recycled air)Booth(Fresh air)

SA

EA EA

Fresh air

conditioner

SA

EA EA

Fresh air

conditioner

RA

RA

Conventional system

Steam boiler

Absorption refrigerator

Steam coil Hot water coil

INV

Booth(Fresh air) Booth(Recycled air)

Steam drain

Heat recovery

heat pump

Modified system

Steam boiler

Absorption refrigerator

Heat Pump Introduction to Painting Process in Car Production

Hamura No4 plant, Hino Motors, Ltd. <Engineering>

Taikisha Ltd.

Tokyo Electric Power Co., Inc.



Type HEM-150Ⅱ

Cooling capacity 456 kW

Heating capacity 566 kW

Refrigerant HFC407E

Compressor Starting system

Inverter

Type Semi-hermetic twin-screw

Input 110.1 kW

Rated COP Cooling 4.14

Heating 5.14

Quantity 1

Heat Recovery Heat Pump

Annual operating time

4,880 hr.

Hamura No4 plant,

Hino Motors, Ltd.

<Engineering>

Taikisha Ltd.




Effects of Introduction of the Heat Pumps

Compared with the Conventional System

A reduction of 63％ in running cost

A reduction of 47％ in CO2 emission

A reduction of 49% in primary energy

Payback time of Investment is 3 or 4 years

Hamura No4 plant,

Hino Motors, Ltd.

<Engineering>

Taikisha Ltd.




1 Introduction






processes


of heat pumps

4 Conclusions

Contents



Pioneering high-temperature heat pumps in Japan




• Cascade Rankine cycle



The energy efficiencies of steam supply service and

electric heaters in manufacturing plants are often

low.

Significant energy savings are practicable by

distributed heat pumps and heat recovery.

64

Conclusions



In order to apply heat pumps for industrial applications,

• Investigate the required heat condition at end

demand, waste heat, operation time, installation

space, etc. for each manufacturing process

carefully

• Identify and quantify energy savings, economic

benefits, etc.

In order to disseminate industrial heat pumps,

• Provide many examples of application which show

the benefits of the heat pumps clearly

65

Prospects



Thank you for your attention !

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