Heat Pump & Thermal Storage Technology Center of Japan
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.
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Contents
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Introduction
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Pioneering
Industrial Heat Pump Technology
in Japan




for hot water supply
for hot air supply
for re-heating of circulating water
for steam generation
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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.
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
IEA HPP Annex 35
(Application of industrial heat pumps)
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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)
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Contents
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Four General Types of Industrial Heat Pumps [1]
[1] US Department of
Energy: "Industrial Heat
Pumps for Steam and Fuel
Savings", DOE/GO102003-1735, 2003.
closed-cycle mechanical heat pump
open-cycle thermal vapor
recompression heat pumps
open-cycle mechanical vapor
recompression heat pumps
closed-cycle absorption heat pumps
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Contents
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
CO2 Transcritical Cycle
Temperature：ｔ(℃)
150
100
Hot Water (Air) Supply
12MPa
Super Critical
50
Critical Point
Gas
Liquid & Gas
0
1.0
Cool Water (Air)
3.5MPa
1.6
1.2
1.4
1.8
Entropy： S(kJ/(kg*K)
2.0
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Water-Source CO2 Transcritical Heat Pump
Mayekawa Mfg. Co., Ltd.
 delivering hot air, with screw type compressor
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
PE
02
TE
06
TE
07
FS
01
Valve
Heat source
water outlet
Heat source
water inlet
Eco-Sirocco Piping diagram
Type：ES-HAW12 Ver.1.1
PE
01
PS
01
TE
01
TE
02
Compressor
H
01
PE
03
Evaporator
Evaporator
Charge port
Valve
Ball valve
Ball valve
TE
04
EXV
01
EXV
02
strainer
Air
TE
03
strainer
Gas cooler
Internal heat exchange
High pressure refrigerant
Low pressure refrigerant
Heat source water
Symbol
EXV 01，EXV 02
H01
PE01 ～ PE03
TE01 ～ TE07
FS01
PS01
TE
05
Hot air
Equipment name
Electronic expansion valve
Oil heater
Pressure transmitter
Resistance Temperature Detector ( RTD )
Fluid sensor
Pressure switches
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Single-stage Reverse Rankine Cycle (R134a)
Critical Point
Temperature：ｔ(℃)
100
Liquid
1.5MPa
50
Cool Water
(Air)
0
1.2
Liquid + Gas
Hot
Water
Gas
0.5MPa
1.6
1.4
1.8
Entropy： S(kJ/(kg*K)
2.0
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Heat Pump for Washing Process
Zeneral Heat Pump Industry Co., Ltd.
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Two-Stage Compression
Reverse Rankine Cycle (R134a)
Temperature：ｔ(℃)
Critical Point
Hot
Water
100
Liquid
50
Cool Water
0
1.2
Liquid + Gas
1.6
1.4
1.8
Entropy： S(kJ/(kg*K)
Gas
2.0
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Waste Heat Recovery Heat Pump Water Heater
Two-Stage Turbo-Compressor System with Economizer
Mitsubishi Heavy Industries, Ltd.
Electric power W
Hot water heat pump
ETW － L
System flow
The first step impeller
Heat source water
Inlet temperature
10 ~ 50 ℃
Turbo compressor
The second step impeller
Evaporator
Condenser
The maximum hot water
Inlet temperature
90 ℃
Economizer
Heat source
the quantity of heat
Hot water
the quantity of heat
Q2 = Q1 + W
The main
expansion valve
Q1
Heat source water
Outlet temperature
Vice-expansion valve
Hot water
Refrigerant: R-134a
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Waste Heat Recovery Heat Pump Water Heater
Two-Stage Turbo-Compressor System with Economizer
Mitsubishi Heavy Industries, Ltd.
Specifications
Heating capacity(kW)
376
545
547
Cooling capacity (kW)
266
400
405
Electrical output of Compressor
motor (kW)
104
136
133
Entering water
temperature (oC)
50
65
80
Leaving water
temperature (oC)
60
75
90
Entering water
temperature (oC)
15
35
50
Leaving water
temperature (oC)
10
30
45
Condenser
Evaporator
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Two-Stage Compression Reverse Rankine Cycle
(R245fa)
Critical Point
Temperature：ｔ(℃)
150
2.3MPa
100
Hot Water
(Steam)
1.0MPa
Liquid
Gas
Liquid + Gas
Cool Water
50
1.2
1.4
0.4MPa
1.6
1.8
2.0
Entropy： S(kJ/(kg*K)
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Steam-Generating Heat Pump SGH 120 Model
Kobe Steel, Ltd.
Industrial Process
Waste Hot
Water (65oC)
Steam, 120oC,
0.1MPa Gauge,
0.51t/h
Heat Pump Unit
Refrigerant Compressor
Evaporator
Expansion
Valve
370kW, COP3.5
Condenser
Flash
Tank
Water
Supply
(20oC)
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Steam-Generating Heat Pump SGH 120 Model
Supply 0.0 to 0.1 MPa Gauge steam, lifting up waste heat at 35 to 65oC
Kobe Steel, Ltd.
Flash Tank
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Steam-Generating Heat Pump SGH 165 Model
660kW, COP2.5
Industrial Process
Waste
Hot Water
(70oC)
Steam, 165oC,
0.6MPa Gauge
0.89t/h
Kobe Steel, Ltd.
Steam
Compressor
Steam
100-110 oC
Heat Pump Unit
Refrigerant Compressor
Flash
Tank
Evaporator
Expansion
Valve
Condenser
Water
Supply
(20oC)
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Steam-Generating Heat Pump SGH 165 Model
Supply 0.2 to 0.8 MPa Gauge steam, lifting up waste heat at 35 to 70oC
Kobe Steel, Ltd.
Flash Tank
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Steam-Generating Heat Pump SGH 165 Model
Installed at Electric Power Engineering Research Laboratory
of Central Research Institute of Electric Power Industry (CRIEPI),
Yokosuka City, Japan
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Cascade Reverse Rankine Cycle For Reheating Circulating Hot Water
120
100
Temperature (oC)
80
60
R134a
cycle
Hot
Water
or Air
88oC
40oC
40
45oC
R410A
cycle
20
0
-20
100
Cool
Water
or Air
200
300
400
Enthalpy (kJ/kg)
7oC
500
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Cascade Heat Pump System for Reheating Circulating Hot Water
Toshiba Carrier Corporation
Washing machine ・
Heating system etc.
Heat source unit
1st stage
Heat of
the air
Heating in the compressor
Supply unit
Heat of
the air
Circulation
heating
Heat of
the air
Circulation pump
The reuse of the cold air
is possible, too
( Image )
2nd stage
Furthermore, heating in the compressor
Heating capacity
COP
Leaving water temperature
14.0kW
3.5*
50- 90 oC
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Cascade Heat Pump System for Reheating
Circulating Hot Water
Toshiba Carrier Corporation
Heat source unit
(R410A, Twin Rotary Compressor)
Supply source unit
(R134a, Twin Rotary Compressor)
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
33
Heat Pump & Thermal Storage Technology Center of Japan
Hybrid Vapor Recompression System
Mayekawa Mfg. Co., Ltd.
Mechanical vapor recompression
Thermal vapor recompression
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
34
Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
35
Heat Pump & Thermal Storage Technology Center of Japan
Type-2 Absorption Heat Pump
(ABSORPTION HEAT TRANSFORMER)
Duhring diagram
Saturated temperature
Q
Q
Eva.
Abs.
Q
Con.
Gen.
Q
Cooling water
Hot water
Steam
Solution temperature
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Type-2 Absorption Heat Pump
WASTE HEAT RECOVERY STEAM GENERATOR
(ABSORPTION HEAT TRANSFORMER)
Steam
120oC
Absorber
Refrigerant
vapor
Evaporator
Cooling
Tower
40oC
Refrigerant
Solution Heat
Exchanger
Weak
Solution
Hot
Generator
Water
80-90oC
temperature
difference
Strong
Solution
Temperature
lift
temperature
Feed
Water
Refrigerant
vapor
Condenser
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Specifications of waste heat recovery steam generators
EBARA Refrigeration Equipment &Systems Co., Ltd.
Type
Production
Steam Temperature
Pressure
Feed water temperature
Hot water
Cooling Water
Power source
Operating weight
Size (mm)
003
385 kg/h
006
770 kg/h
120 °C
0.2 MPa (Absolute)
80 °C
88 → 79.3 °C
895 L/min
1790 L/min
25 → 30 °C
775 L/min
1550 L/min
3φ200 V × 50/60 Hz
6 ton
9 ton
L2100 × W1800 L3600 × W1800 ×
× H2550
H2550
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Waste Heat Recovery Steam Generator (Type 006)
EBARA Refrigeration Equipment &Systems Co., Ltd.
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Block Diagram of the System Installed
Heat Recovery Steam Generator (Type 006)
EBARA Refrigeration Equipment &Systems Co., Ltd.
2.0MPa
92
Ejector
Steam Header
Absorption
heat transformer
Process
0.5MPa
134
0.1MPa 42
Equipment
A
Equipment
B
47
Boiler A
Boiler B
Fuels
100
Cooling
Tower
Waste hot water
89
number : energy ratio
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Contents
1 Introduction
2 Apparatus technology
1) Types of industrial heat pumps
2) High temperature heat pumps
3) Refrigerants for high temperature heat pumps
4) Thermal storage technology
3 System technology and application
1) Distributed heat pumps and heat recovery in industrial
processes
2) Two examples of the introduction to the industrial process
of heat pumps
4 Conclusions
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
41
Heat Pump & Thermal Storage Technology Center of Japan
Basic Characteristics of Refrigerants
for High Temperature Heat Pump Applications
for low GWP
Refrigerant
Chemical formula
R744
CO2
R1234yf
CF3CF=CH2
R134a
CF3CH2F
R1234ze(E) CFH=CHCF3
R1234ze(Z) CHF=CHCF3
R245fa
CF3CH2CHF2
R365mfc
CF3CH2CF2C
H3
Carbon dioxide
Tc
C
Pc
MPa
NBP
o
C
30.98
7.3773
-78.40
weak
94.7
3.382
-29.48
weak
101.06
4.0593
-26.07
weak
109.37
3.636
-18.96
none
153.7
3.97
9.76
none
154.01
3.651
15.14
weak
186.85
3.266
40.19
GWP Flammability
1
2,3,3,34
tetrafluoropropene
1,1,1,21430
tetrafluoroethane
trans-1,3,3,36
tetrafluoropropene
cis-1,3,3,3<10
tetrafluoropropene
1,1,1,3,3pentafluoropropan 1030
e
1,1,1,3,3794
pentafluorobutane
none
o
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Saturated Vapor Pressure Curve
R134a
R1234ze(E)
R245fa
R1234ze(Z)
R365mfc
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Contents
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
44
Heat Pump & Thermal Storage Technology Center of Japan
Thermal Storage Materials
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Characteristics and Application of Thermal Storage Materials
Thermal
storage material
Melting point
(oC)
Latent Heat Application method and
(kJ/kg)
field
Trehalose
C12H22O11
0 to -3
Nearly 210
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
Mannitol
HOCH2(CHOH) 4 CH2OH
165.5
303.7
Thermal storage for waste
heat of a temperature
below 200°C
Ice slurry (0 to 30 wt. %),
Cold storage of food
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Contents
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
47
Heat Pump & Thermal Storage Technology Center of Japan
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
Manufacturing Plant
Factory
Energy Center
Factory
Factory
Steam Supply Service
Factory
Factory
Factory
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Distributed Heat Pumps
Significant energy savings are expected by
 Replacing some steam supply service and electric heaters
 With distributed high-temperature heat pumps
Heat Pumps,
Preheating
Heat Pumps
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Heat Recovery
Simultaneous utilization of cooling and heating
Utilization of waste heat
Steam
Generating
Heat Pump
Heat Pump,
Preheating
Waste Heat
Heat Pump
Refrigeration
Cooling
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Temperature of Heat Demand in Industrial Processes
Temperature (oC)
Type of industry
Process
40
60
80
100
120
Drying
Non-electrical machine
Washing
Degreasing
Air
Drying
Electrical machine
Washing
Degreasing
Transport equipment
Washing
Drying
Boiling
Food
Water
Steam
Sterilization
Washing
Beverage
Washing
Sterilization
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Contents
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
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
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
nearly 20oC
nearly 60oC
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Heat Pump for Washing Process
Zeneral Heat Pump Industry Co., Ltd.
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Ground Plan of Machine Parts Factories
with Heat Pump Installed
AISIN AW Co., Ltd., Gamagori plant
8 heat pumps with heating power of 44kW
Heating power of 22kW
West Factory
East Factory
6 heat pumps with heating power of 22kW
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Operation Results of Heat Pumps for Washing Process
in the Machine Parts Factories
Gamagori plant, AISIN AW Co., Ltd.
Conventional
System
Developed
System
Rate of
Reduction
Energy Consumption
[GJ/year]
CO2 Emission
[ton-CO2/year]
20,238
1,340
5,515
194
73%
86%
 Reduction of 89 % in running cost
 Payback time of Investment is 3 or 5 years
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Temperature of the Heat Demand in General Painting
Process in Car Production Factory
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Heat Pump Introduction to Painting Process in Car Production
Hamura No4 plant, Hino Motors, Ltd.
Conventional system
Modified system
<Engineering>
Taikisha Ltd.
Tokyo Electric Power Co., Inc.
Heat recovery
heat pump
Steam boiler
Steam boiler
Hot water
tank
INV
Steam drain
Absorption refrigerator
Absorption refrigerator
Fresh air
conditioner
Fresh air
conditioner
Hot water coil
SA
Booth(Fresh air)
EA
RA
RA
SA
Steam coil
Booth(Recycled air)
Booth(Fresh air)
EA
Booth(Recycled air)
EA
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
EA
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Heat Pump & Thermal Storage Technology Center of Japan
Heat Recovery Heat Pump
Type
HEM-150Ⅱ
Cooling capacity
456 kW
Heating capacity
566 kW
Refrigerant
HFC407E
Compressor Starting
Inverter
system
Type Semi-hermetic
twin-screw
Input
110.1 kW
Rated COP Cooling
4.14
Heating
5.14
Quantity
1
Hamura No4 plant,
Hino Motors, Ltd.
Annual operating time
4,880 hr.
<Engineering>
Taikisha Ltd.
Tokyo Electric Power Co., Inc.
3rd Conference of AHPNW, HUST, Hanoi, Vietnam, 8 October 2013
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Heat Pump & Thermal Storage Technology Center of Japan
Effects of Introduction of the Heat Pumps
Compared with the Conventional System
Hamura No4 plant,
Hino Motors, Ltd.




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
<Engineering>
Taikisha Ltd.
Tokyo Electric Power Co., Inc.
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Heat Pump & Thermal Storage Technology Center of Japan
Contents
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
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Heat Pump & Thermal Storage Technology Center of Japan
Conclusions
 Pioneering high-temperature heat pumps in Japan
• CO2 transcritical cycle
• Single-stage compression reverse Rankine cycle
• Two-stage compression reverse Rankine cycle
• Cascade Rankine cycle
• Hybrid vapor recompression system
• Type-2 absorption heat pump
 The energy efficiencies of steam supply service and
electric heaters in manufacturing plants are often
low.
 Significant energy savings are practicable by
distributed heat pumps and heat recovery.
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Heat Pump & Thermal Storage Technology Center of Japan
Prospects
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
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Heat Pump & Thermal Storage Technology Center of Japan
Thank you for your attention !
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