Examples of Energy Conservation and GHG Reduction
Up to 60% Energy Savings and GHG Reduction Achieved
with Induction-Heated Jacket Rolls（※）
Induction-Heated Jacket Rolls operate without the need for piping, boilers, or circulation pumps, enabling highly efficient operation with minimal energy consumption.
By eliminating heat loss from piping and the energy consumption of circulation pumps, energy savings and greenhouse gas (GHG) emission reductions of up to 60% compared with conventional oil-heated rolls have been reported.
(※Based on Tokuden case studies.)
Energy Consumption Comparison between Induction-Heated Jacket Rolls and Oil-Heated Rolls
Operating Cost and GHG Reduction Case Studies
| Oil-Heated Roll (1) | Oil-Heated Roll (2) | Oil-Heated Roll (3) | Hot Water Roll | |
|---|---|---|---|---|
| Roll Dimensions | Φ200x2400mm | Φ300x1800mm | Φ900x1100mm | Φ200x2400mm |
| Application | Film Stretching | Film Lamination | Film Heat Treatment | Film Lamination |
| Fluid Temperature | 130℃ | 160℃ | 200℃ | 90℃ |
| Heat Source | Electric Heater | Electric Heater | Steam | Electric Heater |
| Pump Power Consumption (Measured Value) | 3.8 kW | 2.8 kW | 5.5 kW | 1.8 kW |
| Piping Heat Loss (Calculated Value) | 0.4 kW | 0.5 kW | 1.5 kW | 0.3 kW |
| Total Energy Loss | 6.0 kW | 5.8 kW | 8.2 kW | 3.3 kW |
| Operating Cost Reduction by Switching to Jacket Roll | US$6,500.00 | US$10,000.00 | US$3,600.00 | US$5,900.00 |
| Jacket Roll Power Consumption | 10 kW | 14 kW | 9 kW | 7 kW |
| Energy Reduction Rate | Approx. 38% | Approx. 29% | Approx. 48% | Approx. 32% |
| Annual GHG Emissions (24 hr × 350 days) | Approx. 22 tons | Approx. 21 tons | Approx. 33 tons | Approx. 12 tons |
Annual GHG Emissions from Energy Loss (Calculation)
The GHG emissions per kWh are calculated using the emission factor published by the Ministry of the Environment, Japan (0.000433 ton/kWh), as shown below:
0.000433 × 6 × 24 × 350 = 21.8 tons ≈ 22 tons