Sharp Corporation’s state-of-the-art Kameyama Plant No. 2 became operational in August of this year. This LCD manufacturing facility uses 8th generation glass substrates, the world’s largest (2,160 X 2,460 mm), and the 52V- and 46V-inch LCD TVs using panels produced from these substrates will be introduced simultaneously around the world.
As a Super Green Factory with a high level of environmental performance designed to minimize impacts on the environment to the greatest extent possible, the Kameyama Plant features an energy supply system based on integrating diverse power sources distributed within the plant into a single large-scale system independent of the utility power grid. These power sources include the world’s largest photovoltaic power system and one of Japan’s largest fuel-cell and cogeneration systems.This system covers about one-third of the total electric power requirements for the entire Kameyama Plant, and reduces CO2 emissions from the plant by approximately 40% compared to the level from conventional power sources. In addition, all wastewater from manufacturing processes is recycled. Taken together, these measures result in one of the world’s most advanced, environmentally conscious manufacturing facilities. Additionally, at Plant No. 2, we have constructed a system to ensure continuous round-the-clock operation by minimizing the potential impact of natural disasters, such as installing a seismic damping system that absorbs shocks even when an earthquake measuring 7 on the Japanese intensity scale occurs, and installing the world’s largest superconducting magnetic energy storage system that prevents momentary power drop-outs that sometimes occur when lightning strikes from affecting production equipment. Today, the world stands on the threshold of the age of digital images, and demand for large-format, high-definition LCD TVs with low power consumption is increasing markedly. Sharp is supplying AQUOS LCD TVs to the world from this Kameyama Plant, which has been designed to be as eco-friendly as possible, and is aiming to become an environmentally advanced company of the 21st century. Major Features 1. Generate approximately one-third of the electrical power used in the plant in-house by installing a distributed power system that integrates power from diverse sources, the largest of its kind in Japan. And, reduce CO2 emissions by approximately 40% compared to conventional levels.
1) Installed the world’s largest photovoltaic power system (approx. 5,210 kW, equivalent to the power generated by approx. 1,300 typical residential PV power systems), slashing CO2 emissions by about 3,400 tons per year.
2) Installed one of Japan’s largest fuel cell systems (1,000 kW), reducing CO2 emissions by around 3,000 tons per year.
3) Installed one of Japan’s largest cogeneration systems (approx. 26,400 kW), reducing CO2 emissions by around 76,000 tons per year.
4) Installed one of the industry’s largest wastewater recycling systems, purifying and recycling 100% of the manufacturing process wastewater (28,300 tons per day).
2. Prevent the impact of natural disasters by introducing state-of-the-art technologies to ensure round-the-clock uninterrupted operation.
1) Installed the world’s largest superconducting magnetic energy storage system (10,000 kW) to handle momentary power interruptions resulting from lightning strikes, etc.
2) Installed a seismic damping system that absorbs shock waves from earthquakes.
Outstanding Features 1. Generate approximately one-third of the electrical power used in the plant in-house by installing a distributed power system that integrates power from diverse sources, the largest of its kind in Japan. And, reduce CO2 emissions by approximately 40% compared to conventional levels. 1) Installed the world’s largest photovoltaic power system (5,210 kW, equivalent to the power generated by approx. 1,300 typical residential PV power systems), slashing CO2 emissions by about 3,400 tons per year. (Power output of the new photovoltaic power system installed at this time is 5,150 kW.) In addition to the 60-kW photovoltaic power system already installed, a new 5,150-kW PV system covering a total of approximately 47,000 m2 in area (equivalent to three times the playing surface of the Koshien Stadium baseball park) was installed on the rooftop (polysilicon solar cells) and walls (thin-film “see-through” solar cells) of the large-screen LCD TV assembly facility and distribution center, and on Plant No. 2. The electricity generated is used in the LCD TV assembly processes in addition to providing electric power for lighting inside the manufacturing facility. This system makes it possible to cut CO2 emissions by about 3,400 tons annually, equivalent to the amount of CO2 absorbed in one year by a forest covering 960 ha (a surface area approximately 30 times larger than the plant site). [Thin-Film Solar Cells]
Newly developed “see-through” thin-film solar cells have been installed on the curtain walls of Plant No. 2. Because the heat from solar radiation is moderated by the slight shading effect provided by these cells, the electric power load from air-conditioning can also be reduced. In addition, these cells have a structure in which a crystalline thin-film silicon solar cell is stacked on top of an amorphous silicon solar cell on the same glass substrate. This design makes it possible to effectively use light from a wider band of wavelengths, improving conversion efficiency to 11%, about 50% higher than Sharp’s conventional cells (7% conversion efficiency). The thickness of these new solar cells is about one one-hundredth of a typical crystalline solar cell, using an extremely small amount of silicon, and the fact that they allow sunlight to pass through gives them the potential to be used in application products offering outstanding design characteristics. 2) Installed one of Japan’s largest fuel cell systems (1,000 kW), reducing CO2 emissions by about 3,000 tons per year. Four molten carbonate fuel cells have been installed (power output: 250 kW). Total power generated is 1,000 kW, one of the highest output levels in Japan. All power is used for production processes within the plant. In addition, waste heat thrown off in conjunction with power generation is captured and used to generate steam. This system makes it possible to reduce CO2 emissions by about 3,000 tons per year compared to the conventional approach of purchasing electricity from an electric utility. Because electricity can also be generated during nighttime hours and on rainy days, it forms part of a hybrid system along with the PV power system that ensures a stable electricity supply. [Fuel Cells]
Fuel cells are a clean power generating system that converts fuel directly into electrical energy without combustion based on the chemical reaction between oxygen in the air and hydrogen contained in city gas. The outstanding features of these systems include higher power conversion efficiency (47%) than conventional electric generators, and the fact that they generate almost no nitrogen oxides or sulfur oxides (SOx), gases which cause air pollution. These systems represent the next generation of clean, environmentally friendly sources of energy. 3) Installed one of Japan’s largest cogeneration systems (approx. 26,400 kW), reducing CO2 emissions by around 76,000 tons per year. Kameyama Plant No. 1 generates about 12,000 kW of power in-house and Plant No. 2 about 14,400 kW using LNG (liquefied natural gas). The waste heat generated in the process is used as a source of energy to power the heating and air conditioning system as well as supply hot water. [Cogeneration System]
Cogeneration systems use clean city gas to generate electrical power, while the waste heat created in the process is captured and used as a source of energy for heating and air conditioning, and supplying hot water, as well as for steam-generated electric power production. The result is more efficient use of energy. This energy utilization efficiency is higher than conventional methods of supplying energy from thermal power plants, and reduces CO2 emissions by about 76,000 tons per year. In addition, the LNG to fire the cogeneration system is supplied via a pipeline connected directly to the gas company (total length of 17 km from Suzuka City to Kameyama City). This approach eliminates vehicle exhaust emissions that would be generated by fuel tanker trucks making many round-trips daily between the plant and a fuel terminal. 4) Installed one of the industry’s largest wastewater recycling systems, purifying and recycling 100% of the manufacturing process wastewater (28,300 tons per day). Large amounts of water are used in manufacturing processes at the Kameyama facility, for example, washing the glass substrates at the LCD panel plant. Accordingly, a wastewater recycling system to purify all of the wastewater from manufacturing processes has been installed. A biotechnology-based wastewater collection facility was set up with a capacity to purify and recycle up to 15,300 tons of wastewater a day from Plant No. 1 and up to 13,000 tons per day from Plant No. 2 (assuming a glass substrate input of 30,000 sheets per month). In addition, offensive odors are removed using a biofiltration technology based on peat moss harvested from the Ishikari River delta in Hokkaido, and the amount of solid waste emissions is reduced using the latest systems designed to reduce the volume of organic sludge generated in the water treatment process. 2. Prevent the impact of natural disasters by introducing state-of-the-art technologies to ensure round-the-clock uninterrupted operation. 1) Installed the world’s largest superconducting magnetic energy storage system (10,000 kW) to handle momentary power interruptions resulting from lightning strikes, etc. This system is designed to counter momentary voltage sags (line-drops) that result from lightning strikes, etc. As the temperature of the superconducting coil is cooled to –269°C, the electric resistance of the coil approaches zero, allowing electrical energy to be converted into magnetic energy and stored. The installation of a 10,000-kW superconducting magnetic energy storage system makes power instantaneously available at high current levels, making it possible to prevent the effects of voltage drops and momentary power interruptions. 2) Installed a seismic damping system that absorbs shock waves from earthquakes. A design was adopted for the entire building to mitigate the effects of seismic vibrations by absorbing the shocks and shaking resulting from earthquake tremors. The Kameyama facility is prepared for any contingency while maintaining an optimal production environment, including minimizing damage even from an earthquake measuring 7 on the Japanese intensity scale. |
