challenge3 plant zero co2 emission challenge · low co2 production technologies daily kaizen...
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Challenge3
Plant Zero CO2 Emission Challenge
CO2 emissions under BAU
2001 2030 2050
Development and introduction of low CO2 production technologies and daily Kaizen activities" and "Renewable energy and hydrogen use" are keys to zero CO2 in 2050
Plant CO2 emissions ⇒ Aiming for zero in the long run
Reduced by low CO2-emitting production
technologies and daily Kaizen activities
Reduced by using renewable energy and hydrogen
2001 2020 2030
( Index) 100
50
0 Present 2015
Initiatives for reduction by low CO2 production technologies and daily Kaizen activities
Reduction of CO2 emissions per vehicle at a new plant
Approx. 1/3
Aiming for reduction to approx. 1/2 by 2020, and to approx. 1/3 by 2030
Low CO2 production
technologies
Daily Kaizen activities
[Simplification and streamlining]
・thorough shortening of production process
・minimization of moving parts
・energy saving of moving parts
[Improvement of energy use efficiency]
・recovery of wasted energy
・storing of energy
・elimination of unnecessary/inconsistent/
unreasonable efforts
・unpowered/low-thrust operation energy
Painting
Casting
Machining
Machining
Entire process
Examples
Initiatives for reduction by low CO2 production technologies and daily Kaizen activities
Battery production
Machining
Casting
Body painting
CO2 emission ratio by production process
Parts painting
Other
Stamping
Body
Molding
Assembly
Plastic coating
Air conditioning
Parts
Thermal process
Forging
Approximately 60% of the total
In addition to body painting, casting, and machining, which are major contributors to CO2 emissions, battery production which will
grow in the future will be an important issue of technological development
Amount of CO2 emission by production process (FY2013)
Volume
▲50% CO2 reduction
▲30% CO2 reduction
▲10% Energy saving ⇒ CO2 reduction by 40%
Downsize equipment Harden sand mold at low temperature
Existing (2001)
Development (2020)
organic sand mold
harden at high
temperature
Existing
inorganic sand mold
harden at low
temperature
Development
Low CO2 production technology (Casting process)
Low CO2 production technology (Machining process)
The number of equipment
▲30% CO2
reduction
▲40%
Recovery of excess energy
▲10%
CO2 reduction
▲10%
Energy saving ⇒ CO2 reduction by more than 50%
Reduce the number of equipment by speeding processes Recover energy with no waste
Existing (2001)
Existing
Development
Development
Energy emission
Recovery of energy
Daily kaizen - initiatives for Karakuri mechanism
What is “Karakuri Kaizen” ?
Wisdom &
Ingenuity
Utilize for Production equipment
・unpowered ・low-thrust
Karakuri doll
Gravity (weight)
Magnetic force
cam
link balance
Differential action
gear
spring
Daily kaizen - initiatives for Karakuri mechanism
TPS Promotion Center “Studio of Karakuri ideas”
Karakuri group
training
On the job
training
(OJT)
Information
sharing
Field
training by
instructors
Toyota challenges the use of renewable energy and hydrogen energy
Renewable energy use Hydrogen energy use
Direct use of solar power generation
and wind-power generation
Power generation from CO2-free hydrogen
Use of liquid hydrogen evaporation heat air conditioning
Use hydrogen combustion in the production process
Renewable energy
Liquid hydrogen tank
Hydrogen power generation etc.
CO2-free hydrogen
Cold heat & combustion
electricity electricity
Filling
Initiatives at new plants for the Zero CO2 Challenge
Reduce production energy use with the latest innovative
lowCO2 Technology and promote using of renewable energy
Reduce more
than 40%
New plant in Mexico
CO2 emissions
2001 Around 2020
Steady adoption of the
latest innovative
low CO2 technologies
Proactively use
renewable energy
with consideration
for local
characteristics
and economic
efficiency
Renewable energy use
As the first process, wind power generation will be introduced in domestic plants by around
2020, for zero CO2 in the FCV production line
Local (Business and residential)
Motomachi Proof Test Share electricity
& heat
Purchase from renewable energy operators
・Wind power
・Solar power
・Biomass
・Geothermal, hydro power, etc.
Toyota de Brazil in Brazil will be the first plant to start the use of100% renewable energy from
2015
Power transmission infrastructure
On-site renewable energy
Improve amount per unit
・Accelerate low CO2 innovative technology
・Daily Kaizen
・Energy conversion (Steam, airless)
Toyota Group In-house, and on the premises
Production plants & office buildings
Power transmission Power company
Hydrogen use Image of hydrogen production supply and use technologies aimed at 2020
A proof test of hydrogen technology will be launched at the FCV production line in 2020
Launch technological development and demonstration by
Toyota Group companies
Low CO2 hydrogen production
・Hydrogen byproducts
・Fossil fuels
・Reformed hydrogen
Liquid hydrogen tank
Vaporization equipment
Pressurization equip. FCV filling
Hydrogen power generation etc.
FCV Development & evaluation facility
gas burner
air conditioning equipment
Liquid
Hydrogen production with
surplus electricity
CO2-free hydrogen production
Heat treatment furnace etc.
Review of hydrogen use technology ・Thermal catalyst use ・Oxidation use, etc.
Heat use Gas mixture burning
Cold heat use For air conditioning, etc
Electricity use ・Ultra efficient power generation ・Hydrogen power generation
H2 Gas Cold heat
Hot H2 Gas
Liquid hydrogen truck
Liquid
electricity
Plant use of hydrogen Hydrogen production & supply
More efficient Compressed
hydrogen production
Gas (CH4 etc.)
Spread to new and existing plants worldwide
Aiming to spread zero CO2 clean processes to all plants worldwide
Plant Zero CO2 Emission Challenge
Thoroughly reduce the amount of energy use Use of renewable energy & hydrogen +
First plant in Japan First plant in Brasil
再生可能エネルギーとCO2フリー水素活用による 人と自然が共生する未来づくり