resource efficiency in plant structures · 6/28/2018 · 【case 2】 key requirement for gas...

© 2018 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Plenary Session 2

“Which KPIs for Using Materials Smarter, Less and Longer?”

World Materials Forum 2018

28 June 2018, Nancy, France

President and CEO, Shunichi Miyanaga

Resource efficiency in plant structures

© 2018 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2

Background

• MHI have partnered with WMF since the beginning.

• We have discussed on various topics since 2015. This time, we would like to discuss on"Which KPIs for Using Materials Smarter, Less and Longer?“ in other sectors.

(Conclusion)

Need to decouple economic

growth and use of materials

(Conclusion)

Decoupling is not enough,

value creation is a must

(WMF2015)

Overview on issues

and opportunities

(WMF2016)

Qualitative evaluation

Need to speak with data

(WMF2018)

Quantitative evaluation

KPIs availability in other sectors

(Conclusion)

It was agreed that Less Energy

is also effective as KPI in the

transportation field

(WMF2017)

Quantitative evaluation

KPIs for Use less, longer and smart


Current list of 9 KPIs

Source: WMF & Arthur D. Little analysis

Ｔhe scope of KPIs: decoupling materials efficiency from economic growth while creating value for all stakeholders involved.


Introduction of MHI Group business

• MHI Group conducts business in various social infrastructure fields such as power generation,steel manufacturing plant and transportation, etc.

【Case 1】 Steel manufacturing plant

【Case 2】 Power plant


【Case 1】 Background of the steel manufacturing plant industry

World

Trends

Steel

Market

Ecological & Safe Car

Light & strong steel

Electric Car

High-power big Motor

CO2 Reduction

Mass production of AHSS*2 & Electrical Steel*3Increase of EAF*1 steel

Solutions

High-productive Facility for green field Lower Energy

Consumption Facility

Source: Mitsubishi Motors website

ESP

(Endless Strip Production)

Use Smarter by Digitalization

*1 Electric Arc Furnace

(melt scrap by electricity)

Source: Volvo website

Scrap recycling promoted

(MHI Group)

*2 Advanced High Strength Steel (light and strong steel)

*3 Electrical steel (used for motor coil)

Quantum EAF

Digitalization


• Quantum EAF reuses exhausted heat from molten metal for preheating scrap.

• As a result, this latest system can reduce energy consumption by 30% compared with theconventional system.

Preheating system

Preheating

Scrap

Molten metal

Preheated

Scrap

Electrodes

Exhausted hot gas

Drop

Quantum EAF

Scrap yard

【Case 1】 Use Less Energy for melting scrap steel

Ele

ctr

icity c

on

su

mptio

n(k

Wh)

Conventional Quantum EAF (New Method)

-30% Reduction

Recirculating heat

saves thermal

energy consumption

Overview of Quantum EAF


• ESP(Endless Strip Production) combines conventional facilities and success continuousproduction and reduces production cost(€/ton) by 37%.

【Case 1】 Use Less Energy and raw material in rolling process

Overview of Endless Strip Production(ESP)

Conventional Facilities (Casting, Reheating, Hot Rolling)

Reheating Zone

600m

180m

ESP (Endless Strip Production)

Te

mp

era

ture（K

）

Facility length（m）

ESP Conventional

Conventional ESP

100

55

100

50

0

Conventional ESP

100

50

100

50

0

Reduces Heating Energy

Reduces Material Loss

(oxidized steel)

180m 600m


【Case 1】 Use Smarter and Longer by digitalization

• Digitalization contributes to smart, protecting workers from hazardous environment,enables service parts procurement onsite and reduce downtime by predictive maintenance.

Condition Monitoring

Reduced downtime

by predictive maintenance

Smarter for productivity

Procurement

of service parts

Increase productivity

without waiting

(Robot in severe environment)

(Augmented Reality)


【Case 2】 Key requirement for gas power plant

• MHI Group contributes to the further evolution of thermal power plants for the society thatrealizes renewable energy and low carbon emission.

(1) High efficiency gas firing

(Key requirement for gas power plant)

(3) Low Rare Metal Consumption

(2) Flexible and reliable operation

Total CO2 emissions (IRENA-IEA study)

Tota

l C

O2 e

mis

sio

ns (

Gt C

O2/y

r)

Power demand and supply in California (Hourly)

Dem

and/S

upply

(M

W)

Source: IRENA, IEA study concludes meeting 2˚C scenario possible with net positive economics, Green Car Congress

Hour

PV(Solar)

Wind

Gas

Hydro

Storage

Demand + Charging Demand


30km2

• We have announced last year that power generation efficiency of 63% has been achieved,but in reality we have already reached 64% in January 2018. By 2022 we will aim for 65%.

• Once the efficiency of power plants is increased, the amount of usage of resources cansignificantly be reduced.

【Case 2】 High efficiency of gas power plants

Source: Mitsubishi Hitachi Power Systems’ website

To achieve 65%

New materials

Advanced aerodynamics

Advanced cooling system

Turbine inlet temperature(℃)

Th

erm

al e

ffic

ien

cy o

f G

TC

C (

LH

V %

)

1200 1300 1400 1500 1600

55

60

65 Improve

efficiency

Product performance

Output: 700MW

1% 27,000 tonCO2 Only one 700MW LNG power plant

3,000,000

Cedar trees


• We have developed rapid start-up gas turbine system which can solve the instability ofrenewable energy such as PV and Wind.

• This improves availability of gas turbine plants.

【Case 2】 Use Smart the rapid start up of gas turbines

Previously over 30

minutes

Source: Asian Energy Outlook and Gas Turbine Development, MHPS, 2018.1.10


• We have developed a super alloy “MGA1700” which avoids the usage of Rhenium,one of rare metals, and is applied to gas turbine blades.

• This technology highly contributes to reducing consumption of critical material.

【Case 2】 Critical raw metal usage reduction in turbine blade

Rela

tive

th

erm

al fa

tigu

e life

0

0.5

1.0

1.5

2.5

Conventional

alloy MGA1700

2.0

×2

Rela

tive

In

cre

ase

of cre

ep

du

rab

le te

mp

era

ture

(℃)

-20

0

20

40

60

80

100

120

Conventional

alloy MGA1700

+100℃

Micro structure of turbine blade

(scanning electron microscopy)

Rhenium-free Super Alloy “MGA1700”

Usually Rhenium is

included between

2.4-6% (€7,500/kg)

＜Creep strength＞＜Thermal fatigue strength＞

Source: IGT AWARD ASME2017 honorably speech, ASME, 2017


Conclusion

Use Less

Use Longer

Use Smarter

Buy-to-use

% of recycled materials

End-of-life-recycling

Product lifetime

Resale price

% of innovative materials

Product performance / weight

Overall product usage

Steel manufacturing plant Power Plant

Energy

No usage of

critical raw metal

Improve efficiency

Improve efficiency

(Use less fuel)

Improve durability

The important factor for the pursuit of resource efficiency of infrastructure products is to improve efficiency and maintain safe and consistent product performance for a long period of time.

Lower energy

consumption

Reduces

material loss

Predictive

maintenance

Improve

productivity

resource efficiency in plant structures · 6/28/2018 · 【case 2】 key requirement for gas...

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