Good-Standing Factories in Energy Control

Improvement Case Examples

Japan

 

  

Factories that were awarded by

the Secretary of State for Trade and Industry-Director

and General of the Agency of Natural Resources and Energy.

 

( 1998  Electric Category : 19 Case Examples)

 

 

April, 1999

 National Electricity Saving Committee

Good-Standing Factories in Energy Control in 1998

Electric Category List of Awarded Factories

 

 

(1)   Secretary of State for Trade and Industry-Director (5 Cases) (by Area)

Area

Company

Industry

Tohoku District

Tohoku NEC Corporation

Manufacturer of Electric Machinery and Equipment

Chubu District

Sony Koda Corporation

Manufacturer of Electric Machinery and Equipment

Kinki District

Osaka Gas Co., Ltd.

Gas Provider

Chugoku District

Seibu Oil Co., Ltd

Yamaguchi Oil Factory

Manufacturer of Petroleum and Coal Products

Kyushu District

Miyazaki Tourist Hotel

Accommodation\

 

(2)   General of the Agency of Natural Resources and Energy (14 Cases) (by Area)

Area

Company

Industry

Tohoku District

Tohoku Paper Industry Co., Ltd

Manufacturer of Paper and Paper Products

Tohoku District

Miyagi Oki Electric Industry Co., Ltd

Manufacturer of Electric Machinery and Equipment

Kanto District

Ricoh Co., Ltd  Gotenba Branch

Manufacturer of general Machinery and Equipment

Kanto District

Asahi Glass Co., Ltd.  Sagami Branch

Manufacturer of Glass Products

Kanto District

Torii Pharmaceutical Co., Ltd. Sakura Factory

Chemical Industry

Kanto District

Topcon Corporation

Manufacturer of Precision Machinery and Equipment

Chubu District

Melco Inc.  Kakegawa Factory

Manufacturer of Electric Machinery and Equipment

Chubu District

Showa Gousei Co., Ltd.

Manufacturer of Transport Machinery and Equipment

Chubu District

Denso Corporation  Nishio Factory

Manufacturer of Transport Machinery and Equipment

Hokuriku District

BFU Co., Ltd.

Manufacturer of Electric Machinery and Equipment

Chugoku District

Kanebo Ltd.  Boufu Factory

Chemical Industry

Chugoku District

Japan Tobacco Inc.  Yonego Factory.

Tobacco Manufacturer

Shikoku District

Teijin Ltd.  Matsuyama Branch

Chemical Industry

Kyushu District

Bank of Saga Ltd.

Banking and Trust

   

Application of Insulation Coating on Factory Roofs   Factory Information

Capital

\2000Million

($17 Million)

Contract Demand

4,700kW

Voltage

33kV

Site

Area

181,751

sqm

Building

Area

86,000

sqm

 

 

 

 

 

 

 

 

 

 

Main Product

Video Camera

Electric Power Consumption Rate

1,320,000kwh/

\1million

% of Electricity  Cost in Production Price

0.18%

Workers

2,500

Electricity Related Workers

7

   

Factory Site Map

FACTORY SITE MAP

Bldg. Name

Area (sqm)

Note

Bldg.1

12,600

 

Bldg.2

12,600

 

Bldg.3

7,100

Not Applied

Bldg.4

Not Included

 

Middle Bldg.

4,400

 

Shipping Center

6,900

 

Dining Bldg.

2,400

 

Gym

1,600

Not Applied

Energy Center

1,400

 

TOTAL

49,000

 
*40,300sqm is applied so far.     Reasons for improvement   Out of all electric energy that this factory consumes, the energy used for air conditioning is high, and it takes up about 30%.  The energy consumption rate for air-conditioning in summer is especially increasing due to the automation of offices and factories.  There are nine buildings in this factory and the first construction of Building 1 began in 1973, and the construction of the roofs was corrugated metal sheets + paint.  Due to this roof construction, it had poor insulation performance, and it was a burden to the air conditioners in summer.    The temperature of the roof surface was very high due to the radiant heat, and the work environment was also poor.  They had to lower the temperature setting of the air conditioner.  Therefore, there was a need for improvement in energy saving.    Improvements     Due to the deterioration of coating, application was done as a part of the renovation project. (Change of Coatings)

Before:  

Roof Construction

  METAL SHEET ROOF

After:

Ceramic Insulation Coating was applied by spray in two layers to the surface of corrugated metal sheet roof.

 Roof Construction METAL SHEET ROOF-2       Composition: COOL THERM (SUPER THERM®) Water-Base Paint (Acrylic Resins + Urethane Resin + Four Kinds of Ceramics)    *Insulation Mechanism- Two kinds of ceramics repel sun light and surface heat- The third ceramic works as a vapor barrier and blocking heat conduction as well as sound reduction. - The fourth ceramic blocks Infrared (long wave) radiation. - Infrared represents 57% of heat gain into buildings
Results 1.      Energy Saving Condition: Fine day in summer    Outside Temperature: 32C (90F)

 

Outside Surface Temp

Room Surface Temp.

Before

63C (145F)

61C (141F)

After

41C (105F)

38C (100F)

Difference

°22C (71F)

°23C (73F)

 

Energy Saving Effect: 40,300sqm × 23C (73F) × 2.76Kcal/h sqm C (K Value: over-all coefficient of heat transfer for steel) = 2,558,244kcal/h 2,558,244kcal/h × 8h/day × 20 days/month × 6 months/year × 0.75       (Period of Air-conditioning Used)  (Fine Sky Ratio) = 1,841,760 Mcal/year   Calculation of Electricity: 1,841,760 × 103kcal/year 3,000kcal/h RT × 1.2kW/RT = 736,704kWh/year   Energy Saving Cost: 736,704kWh/year × \15/kWh = \11,050,560/year   2.      Prolongation of Life Span The re-painting cycle has extended from seven years to nine years.   Improvement Evaluation

 

Initial Cost for Improvement (\10,000)

(A)

Energy Saving Effect

(\10,000/year)

(B)

Pay-Back Period (year)

Excluding Interest

(A/B)

Ceramic Insulation Coating

6,850

Bituminous Coating

5,680

Difference

1,170

1,105

1.06

 

ROI :  Thirteen (13) month payback savings to investment.

  Comparison of cost: Bituminous versus COOL THERM / SUPER THERM®.  COOL THERM / SUPER THERM® is 20% more in cost but returns its total investment in 13 months compared to 0 return from Bituminous.