Super Therm Japan Industry Case Studies

Nissan, Japan: Super Therm® Energy Saving Coating

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 

Original report

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)

AreaCompanyIndustry
Tohoku District Tohoku NEC Corporation Manufacturer of Electric 
Machinery and Equipment 
Chubu District Sony Koda CorporationManufacturer of Electric
Machinery and Equipment
Kinki DistrictOsaka Gas Co., Ltd.Gas Provider
Chugoku DistrictSeibu Oil Co., Ltd Yamaguchi Oil FactoryManufacturer of Petroleum and Coal Products
Kyushu DistrictMiyazaki Tourist HotelAccommodation

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

AreaCompanyIndustry
Tohoku DistrictTohoku Paper Industry Co., LtdManufacturer of Paper and
Paper Products
Tohoku DistrictMiyagi Oki Electric Industry Co., LtdManufacturer of Electric
Machinery and Equipment
Kanto DistrictRicoh Co., Ltd Gotenba BranchManufacturer of general
Machinery and Equipment
Kanto DistrictAsahi Glass Co., Ltd. Sagami BranchManufacturer of Glass Products
Kanto DistrictTorii Pharmaceutical Co., Ltd.Sakura Factory Chemical Industry
Kanto DistrictTopcon CorporationManufacturer of Precision
Machinery and Equipment
Chubu DistrictMelco Inc. Kakegawa FactoryManufacturer of Electric
Machinery and Equipment
Chubu DistrictShowa Gousei Co., Ltd.Manufacturer of Transport
Machinery and Equipment
Chubu DistrictDenso Corporation Nishio FactoryManufacturer of Transport
Machinery and Equipment
Hokuriku DistrictBFU Co., Ltd.Manufacturer of Electric
Machinery and Equipment
Chugoku DistrictKanebo Ltd. Boufu FactoryChemical Industry
Chugoku DistrictJapan Tobacco Inc. Yonego Factory.Tobacco Manufacturer
Shikoku DistrictTeijin Ltd. Matsuyama BranchChemical Industry
Kyushu DistrictBank of Saga Ltd.Banking and Trust

Application of Insulation Coating on Factory Roofs 

Factory Information

Capital¥2000 Million  ($17 Million)
Contract Demand4,700kW 
Voltage 33kV
Site Area181,751 sqm
Building Area86,000 sqm
Main Product Video Camera
Electric Power Consumption Rate1,320,000kwh/ ¥1million 
% of Electricity Cost in Production Price 0.18% 
Workers2,500
Electricity Related Workers 7
Building NameArea (sqm)Note
Building 112,600
Building 212,600
Building 37,100Not applied
Building 4Not included
Middle Building4,400
Shipping Centre6,900
Dining Building2,400
Gym1,600Not applied
Energy Centre1,400
Total49,000

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 

Ceramic Insulation Coating was applied by spray in two layers to the surface of corrugated metal sheet roof. 
Composition: COOL THERM = Super Therm® in Japan
Water-Base Paint (Acrylic Resin + Urethane Resin + Four Kinds of Ceramics) 

Results

Energy Saving 

Condition: Fine day in summer Outside Temperature: 32C (90F) 

Outside Surface TemperatureRoom Surface Temperature
Before63C (145F) 61C (141F) 
After41C (105F) 38C (100F) 
Difference▲22C (40F) ▲23C (41F) 

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 (Period of Air-conditioning Used) × 6 months/year (Fine Sky Ratio) × 0.75 

= 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 

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 

Return on Investment

Thirteen (13) month payback savings to investment over the difference in cost of applying Bituminous Coating which has no insulation payback. 

Comparison of cost

Bituminous versus Super Therm®. Super Therm® is 20% more in cost but returns its total investment in 13 months compared to 0 return from Bituminous basing on the difference in cost of both systems. 

Super Therm® alone has a 6.16 year ROI. 

Nissan saving 75% energy consumption with Super Therm®

Nissan Factory in Yokahama, Japan with Super Therm®

Nissan Factory, Yokahama, Japan: 200,000m2

ApplicationMayJune
Before Super Therm® applied3,767 KW5,647 KW
After Super Therm® applied519 KW1,896 KW
TOTAL KW SAVINGS87%67%

Source: Daiko Shokai, Japan | See more Japanese Saving Case Study results (pdf)

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