Using an Energy Management System for automated,
optimized control of energy equipment in factories
to achieve even greater energy efficiency
VISION01 An Energy-saving Society
Expanding the possibilities of energy. Using affordable and safe power, electricity and heat, whenever necessary and only as much as necessary
Our Products, Services and Support for VISION 01
We contribute to the optimization for facility-wide energy use via the fuel efficiency diagnostics and analysis of energy operational status. This is how we help to achieve energy efficiency.
We develop ultra-high fuel efficient high-power engines to expand our compact industrial engine sector. These engines are also compatible with the latest European Stage V standards.
Social challenges to be solved related to VISION 01
Contributing Through Business
YANMAR ENERGY SYSTEM CO., LTD.
Using an Energy Management System for automated,
Marutai Co., Ltd. is a food manufacturer located in Fukuoka, and was considering further energy efficiency and CO2 emissions cuts through a control of the varied fuel efficiency equipment installed in their plant. Furthermore, they viewed reduction of annual energy usage levels to less than 1,500 kl (barrel of oil equivalent) to be an issue including their Fukuoka and Saga plants in order to comply with Japan's "Act on the Rationalization etc. of Energy Use (Act on the Rational Use of Energy)."
In addition to fuel efficiency devices such as the Yanmar gas cogeneration system and air-conditioning equipment (GHP), Marutai's Fukuoka plant also incorporates solar power generation equipment, hot water heaters utilizing solar heat, and other equipment that utilizes renewable energy. Yanmar Energy System Co., Ltd. aimed to address the customers' issues by proposing an Energy Management System (EMS) capable of efficient control over all these elements.
The EMS equips sensors on each article of energy equipment, including the gas co-generator, gas heat pump, and combined heat and power link, analyzing plant-wide electricity and gas usage levels. The system is capable of automatically creating optimized operating plans a day in advance based on data such as utility rates and weather forecasts, and automatically adjust energy equipment loads on the day of operation. The system offers centralized control over energy usage status and device operational status from the energy management system monitor, and allows for remote, real-time data sharing with Yanmar technical representatives for quick responses in the event of trouble.
By adopting the EMS, Marutai was able to both suppress annual energy usage for FY2019 to levels less than 1,500 kl, and also level electrical demand at afternoon peak times via control over demand values (maximum electrical demand). Furthermore, automation of energy equipment settings that used to be performed by experienced managers reduced energy losses, allowing for even more precise control. This mitigated the levels of daily professional duties for management, and the analytical data the system accumulates is also useful for long-term operational planning.
CO2 emissions will decline further with Yanmar's high-fuel efficiency devices and energy management systems while distributed energy expands across society. We are now registered as an "Energy Management Business Operator (energy control support service business)" under the "Energy Use Optimization Support Business" system promoted in Japan as a means to address energy efficiency. Yanmar contributes toward global warming solutions by supporting companies that are working on energy efficiency, using our proposals for fuel efficiency devices such as energy management systems to cut CO2 emissions.
YANMAR ENERGY SYSTEM CO., LTD.
Contributing to reducing the risk of heat stroke at school
and improving the evacuation shelters by introducing GHP.
Recently in Japan, the rising temperature in summer has increased the risk of heat stroke especially at school. The average daily temperature and the highest daytime temperature in July in 2010s rose about 2℃ compared to those in the 1970s, and the number of extremely hot days has been more than doubled since the 2000s.*1 *2 For this reason, it is an urgent issue to install air conditioning in classrooms and gymnasiums. In addition, gymnasiums are used as evacuation shelters in event of a disaster, so it is also important to keep the shelter condition comfortable for evacuees.
- *1Source: Meteorological data in Tokyo, edited from Japan Meteorological Agency data.
- *2Data for the 2010s: From January 2010 to September 2018
Since the classrooms and gymnasiums are in use only during the day, the operating time of air conditioning at school is shorter than at hospitals, stores and offices, and air conditionings are rarely used during long vacations. Taking this into consideration, Yanmar Energy System proposes gas heat pump (GHP).
General air conditioning uses 90% of the energy for the drive source of the compressor. However, the power consumption of GHP is only 10% of a general electric heat pump air conditioner (EHP), because GHP drives a compressor with a gas engine. So, our clients can reduce the electricity bill down to 10% and pay for the gas they used. So, it saves operating cost significantly.
In addition, natural gas which is the source of city gas and LP gas used for GHP, emits less CO2 that causes global warming than coal and petroleum, and is the cleanest energy among fossil fuels.
When a gymnasium is used as an evacuation shelter, the GHP which functions as a standby generator to operate an air conditioner can improve the shelter condition. Also, even in the event of a power outage, GHP air conditions and generates electricity so that the evacuees can charge mobile devices and secure power for lighting.
GHP-installed shelter in a power outage
Environmental impact of GHP, L series
CO2 emissions of the L series (High-efficient model) and the K series (General model) GHP
Calculated for a 500-horsepower facility under the conditions below.
- Annual gas consumption and power consumption are calculated based on JIS B 8627 APFp calculation standard.
- CO2 emission factor Electricity: 0.66kg/kWh Gas: 2.23kg/m3 (45MJ/m3 HHV)
- K series model: YNZP450K1 (16 horsepower)
L series model: YNYP450L1 (16 horsepower)
<At a 500-horsepower facility>
- CO2 absorption per cedar tree in a year: 14kg
From the Forestry Agency, the Ministry of the Environment, "Measures for Green Sinks to Prevent Global Warming"
Climate change due to global warming has been affecting our lives in various ways in recent years. Health damages including heat stroke in summer, and natural disasters such as floods of river or inundation due to torrential rain, and landslide are occurring all over Japan. We strive to contribute to reducing CO2 emissions of a whole society by providing and prevailing our GHP. Not only the GHP with standby generator strengthens the functions of evacuation shelters such as securing power in the event of a disaster but various private companies are introducing GHP for their BCP. We are committed to improving the environment of education and creating a disaster-resistant society.
YANMAR POWER TECHNOLOGY CO., LTD.
Developed "EU Stage V" exhaust emission
standards-compliant industrial diesel engine
that achieves high power density and fuel efficiency
In relation to climate change, the compact industrial engine and commercial marine engine fields currently require compliance with various tightening emissions regulations and cuts to CO2 emissions. Furthermore, as almost all machines equipped with powerful engines are intended for professional use, they also face major challenges such as stress-free, comfortable work, limits on downtime, compact emission aftertreatment devices and smaller running costs.
Yanmar Power Technology developed the "4TN107" industrial diesel engine with 155 kW of peak power to comply with the EU non-road engine stage V emissions standards (EU Stage V) that entered effect in 2019.
This new engine synthesizes direct injection diesel combustion technologies cultivated over the years at Yanmar, a powerful proprietary structure, and exhaust aftertreatment control technology developed to comply with the Tier 4 regulations of the US Environmental Protection Agency. These technologies improve fuel economy for the new engine by about 10% as compared to models with the same engine displacement from other companies*1, cut CO2 emissions, and help mitigate running costs for customers. For its exhaust aftertreatment device and control technologies, the engine uses a DPF*2 system with proven performance that complies with US Environmental Protection Agency Tier 4 standards and an SCR*3 system that utilizes urea water. This keeps the engine running without work stopping for the customer under everything from light to heavy loads, in settings such as at elevation, or in low temperature environments.
Furthermore, we are also improving work machine comfort while enhancing environmental performance. We set the specifications of the "4TN107" to incorporate a two-stage turbocharger, giving it a best-in-class power density*4 of 34 kW/L. Through optimization of the turbocharger and combustion technologies, the engine also achieves the torque performance required in fields including construction and agricultural equipment. On other fronts, the engine also helps customers improve visibility and comfort during work with its compact exterior settings that take work machine chassis designs into account, and its miniaturized exhaust gas aftertreatment device.
- *1Comparison of results from testing performed by Yanmar with those for engines in the same class
- *2DPF: Diesel Particulate Filter. A filter that removes particulate matter found in diesel exhaust gas, such as ash
- *3SCR: Selective Catalytic Reduction. A technology that reduces, purifies, and neutralizes the NOx found in diesel exhaust gas, using ammonia produced from urea water
- *4Output (kW) per unit of engine displacement (L)
EU Stage V Standards
EU Stage V features stronger cuts to NOx and PM emissions as compared to Stage IV. For example, engines in the 19-37 kW output range must limit NOx emissions by about 37% (7.5 > 4.7 g/kWh), and PM emissions by about 97% (0.6 > 0.015 g/kWh). Furthermore, standards are now mandatory for PM particulate numbers (PN), as are measures for prevention of emissions overages due to insufficient maintenance or illegal modifications.
Our engine has acquired EU Stage V certification, and is expected to produce emissions cuts that meet or exceed standards. Sales of the engine started with the implementation of the standards in 2019 and is helping to limit atmospheric pollution as it steadily replaces equipment compliant with the old emission standards (Stage IV). There are plans for future regulatory reinforcement in North America, Europe, China, India, and other regions, and Yanmar will develop products that comply with these local emission standards. We will also further enhance our contributions to CO2 emissions cuts with even more improvements to engine fuel efficiency and emissions reductions.