Report of Effects of Adopting GHPs (Gas Heat Pumps)
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1 Project Promoting Application of Low Carbon Technologies to Small and Medium-Size Companies in India Report of Effects of Adopting GHPs (Gas Heat Pumps) March 4, 2014 Teruji Kaneko Guest Researcher IGES Kansai Research Center Engineering Department Yanmar Energy System Co., Ltd.
2 1. What is a GHP? Comparison with Electric HPs (EHPs) GHP (Gas Heat Pump Air-conditioner) - Compressor is driven by a gas engine. GHP outdoor unit Heat exchanger Indoor unit * Indoor unit is the same as an EHP. Exhaust heat recovery (when used as heater) Gas engine Compressor EHP (Electric Heat Pump Air-conditioner) * Compressor is driven by an electric motor. EHP outdoor unit Heat exchanger Indoor unit Electric motor Compressor
3 2. Characteristics of GHP Comparisons with Electric HP (EHP) Outdoor unit 1) Drives gas engine with natural gas Saves energy 2) Heater heat source = Outside air+engine waste heat Large heating capability when outside air is low 3) Control of cooling/heating capability = Control of engine speed Improves efficiency during partial capacity (inverter effects) Cooling/heating efficiency (cooling/heating capability/gas inflow passage) Cooling/heating capability rate (%) Indoor unit 4) Periodic inspection cycle: Engine running time = Every 10,000 hours Illustration of GHP installed in office building (Equivalent to approx. every 300,000 km traveled by car Covers weaknesses of engine type)
4 3. Yanmar s GHP Recreational facilities/ exhibition halls 7% Factories 9% Units delivered by facility type Medical facilities 9% Other 16% Companies/ offices 18% Schools 21% Shops/dept. stores/ supermarkets 20% Change in No. of GHP Units Sold (Based on outdoor units) Annual total Cumulative total units reached GHP manufacturers Titles omitted GHP manufacturer Mounted engine Indoor unit Yanmar Energy System Yanmar Daikin/Hitachi Panasonic (former Sanyo) Nissan/Mazda Sanyo Aisin Seiki Toyota/Daihatsu Daikin Mitsubishi Heavy Industries OEM by Aisin Mitsubishi Heavy Industries Hitachi Appliances OEM by Yanmar Hitachi Daikin Industries OEM by Aisin Daikin
5 4. GHP Technology Application Promotion Project Schedule FY2011 FY2012 FY2013 Selection of demonstration test site Conclusion of memorandum on demonstration test Equipment procurement and production 2 companies agree to demonstration tests Shipment Commencement at site GHP operation project Data measurement Existing electric air-conditioners Discussion with test site and capacity building Evaluation and proposal 1: Evaluation of candidate demonstration test sites: 5 companies 2: Discussion on GHP construction guidelines 3: Guidance on construction and test operations 5: Change of specifications of custom-made air filter of indoor unit (increased front surface) 5: Change of GHP operation control software: Standard (energy saving) software -> Software focusing on cooling/heating capability 6: Change of GHP operation control software: Software focusing on cooling/heating capability -> Standard (energy saving) software 7: GHP service training for demonstration test sites
6 5. Demonstration test sites 1) Location: Rajkot (Gujarat) Rajkot Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Avg Monthly avg. highest temperature ( C) Monthly avg. lowest temperature ( C) Osaka Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Avg Monthly avg. highest temperature ( C) Monthly avg. lowest temperature ( C) Afghanistan 2) Business type: Casting plant (Lost wax casting) 2 companies (Companies A and B) 3) Air-conditioner (cooling/heating) used in: (1) Wax injection work room (2) Mold drying room (3) Office (1 company only) Pakistan Rajkot Kashmir New Delhi Mumbai Nepal People s Republic of China Calcutta Chennai Sri Lanka Bhutan Wax Wax injection Wax tree assembly Coating/drying Heat/pressure Dewaxing Cutting Knocking out Casting Bangladesh Mold baking Myanmar 4) Switching to GHP: Select same cooling/heating capability and indoor unit model as existing electric air-conditioner
7 6. Installed State of Equipment (Company B) Wax injection room Indoor unit of existing E air-conditioner GHP indoor unit 2 GHP outdoor unit Existing E air-conditioner outdoor unit Drying room GHP indoor unit 2 in back E air-conditioner indoor unit in front Existing E air-conditioner outdoor unit GHP outdoor unit Part of existing electric air-conditioner is continuously used for GHP backup
8 7. Measurement Items and Measurement Points (Company A) Measurement work: Panasonic Eco Solutions Souken Measurement interval Power consumption: 60 min Temperature and humidity: 30 min Blow-off duct dumper Drying room Temperature/humidity data logger Wattmeter 3Φ4W Electric air-conditioner indoor unit (Back-up) Electric air-conditioner outdoor unit (Back-up) GHP indoor unit High frequency induction furnace Wax injection room GHP outdoor unit (Roof-top mount) Blow-off duct dumper For outside air Gas meter for GHP
9 8. Measurement Results (Monthly Power and Gas Consumption) (Company A) Electric air-conditioner (kwh/month) GHP gas amount (m 3 /month) GHP (kwh/month) Monthly avg. highest temperature (left side axis) No. of low operation days Electric air-conditioner GHP Measurement time of electric air-conditioner is short, so to compare both, cooling/heating load is calculated.
10 9. Measurement Data Classification Procedure 1) Horizontal axis Temperature during cooling/heating period Room temperature during cooling/heating period Cooled/heated floor area Cumulative temperature difference Representative value for cooling/heating load (heat quantity) Production amount Temperature Building structure cooled/heated Outside air temperature Cumulative temperature difference = Σ(Outside air temperature indoor temperature) 2) Vertical axis Power and gas consumption is corrected to equivalent of 35 C according to monthly average outside air temperature (GHP power consumption cannot be corrected due to fan power.) Indoor temperature ON time of air-conditioner remote control Correction factor of gas consumption Average outside air temperature during operations ( C)
11 10. Effects of Adopting GHP (1) Company A Unit India Reference: Japan Calculation conditions Gas Electricity Heat quantity (high) CO2 emissions factor Power generation efficiency (net system energy demand) CO2 emissions factor CO2 (tons/month) Electric air-conditioner GHP GHP (Change of operation software) CO 2 emissions: 56% of electric air-conditioner (4.2/7.5) PEI (MWh/month) Electric air-conditioner GHP GHP (Change of operation software) Cooling/heating load equivalent amount ( C-hours) Primary energy consumption: 53% of electric air-conditioner (21/40) Cooling/heating load equivalent amount ( C-hours)
12 10. Effects of Adopting GHP (2) Company B Unit India Reference: Japan Calculation conditions Gas Electricity Heat quantity (high) CO2 emissions factor Power generation efficiency (net system energy demand) CO2 emissions factor CO2 (tons/month) Electric air-conditioner GHP GHP (Change of operation software) CO 2 emissions: 55% of electric air-conditioner (8.0/14.5) PEI (MWh/month) Electric air-conditioner GHP GHP (Change of operation software) Cooling/heating load equivalent amount ( C-hours) Primary energy consumption: 53% of electric air-conditioner (40/76) Cooling/heating load equivalent amount ( C-hours)
13 11. Comparison of Operating Costs Gas charges Same operating costs Costs as of Nov 2011 at demonstration test site October 2013 charges 20% reduction compared to electric air-conditioner Apr 2013 charges Dec 2013 charges Electricity charges (Rs/kWh) Gas unit price: Increased by about 1.5 times in last 2 years Increased operating costs Improvement of rate of utilization of gas energy is indispensable
14 12. Expansion to India Market in the Future Improvement of rate of utilization of gas energy: Application of cooling/heating+hot water supply (using engine waste heat) system Max. output of warm water: 30 kw Warm water temperature: Below 70 C Based on the usage amount (March to December 2013) by purpose of natural gas at demonstration test site (casting plant), hot-water supply demands are considered adequate. Company A Company B For GHP For boiler
15 13. Calculation of Effects of GHP with Hot-Water Supply Function
16 <Calculation conditions> Used warm water heat quantity : 15% of gas input energy Boiler efficiency: 80% Gas charges Same operating costs Nov 2011 charges Dec 2013 charges 20% reduction compared to electric air-conditioner Apr 2013 charges 40% reduction compared to electric air-conditioner Oct 2013 charges (Higher heating value standard) Electric air-conditioner GHP GHP with hot-water supply function Electricity charges (Rs/kWh) CO2 (tons/year) PEI (MWh/year)
17 Thank you for your kind attention. We would like to express our heartfelt gratitude to all involved in promoting this project for their guidance, support, and cooperation.
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