Sharp Corporation

Sharp Corporation

February 2012

8

New Energy

T r i p l e - j u n c t i o n c o m p o u n d s o l a r c e l l a c h i e v e s arecord-breaking 36.9% conversion efficiency.Convers ion efficiency of a non-concentrated solar cel l at theresearch stage as of November 2011

C om p a r e d w i t h p o l y c r y s t a l l i n e s i l i c o n s o l a r c e l l , atr iple-junct ion compound solar cel l is able to convert a wider a n g e o f s u n l i g h t t o e l e c t r i c i t y , t h u s a c h i e v i n g h i g hconversion efficiency.

Developing Solar Cells to AchieveRecord-breaking 40% Conversion EfficiencyDeveloping Solar Cells to AchieveRecord-breaking 40% Conversion Efficiency

There are high expectations regarding solar cells as

a means of renewable energy. To continue the spread

of the i r use , fur ther enhancement of module

conversion efficiency is critical. For many years, Sharp

Corporation has been committed to conducting

research and development on a variety of solar cells,

such as compound solar cells, through the Research

and Development of Photovoltaic Power Generation

Technology project launched by NEDO in 2001.

Applying the expertise it acquired through NEDO’s

project, Sharp developed triple-junction compound

solar cells which today are the primary solar cells

mounted in satellites used around the world. In 2002,

the company’s triple-junction compound solar cell

was certified by the Japan Aerospace Exploration

Agency (JAXA), which has led to its widespread use in

the aerospace industry. In 2004, cells were installed in

a small scientific satellite named "REIMEI" 2009, they

were adopted for the greenhouse gas observation

satellite "IBUKI".

As a result of its research and development efforts,

Sharp achieved a solar cell conversion efficiency of

35.8% in 2009, a world record. In 2011, the company

broke this record by increasing cell conversion

efficiency to 36.9%. Today, Sharp is continuing its

research and development efforts toward achieving a

cell conversion efficiency of 40% (non-concentrated)

and 50% (concentrated) by 2025. The company is

also working to move its concentrated photovoltaic

power generation system to the practical application

stage. The concentrated solar module has a target

conversion efficiency of more than 40%, which will be

achieved with concentrated solar power through the

use o f a spec ia l l y des i gned l ens and o the r

components.

・Research and Development of Photovoltaic Power GenerationTechnology/Research and Development of Advanced SolarCell Technology/Development of Manufacturing Technologiesfor Ultra-high Efficiency Crystalline Compound Solar CellModules (FY2001‒FY2003),etc.

Triple junction compoundsolar cells for space use

Polycrystalline silicon solarcells for residential use

Energy conversion efficiency

Solar photo-energy distribution

Top

Middle

Bottom

KANEKA CORPORATION

　Solar power generation, which uses sunlight̶an infinite source of energy̶has been receiving a great amount of attention as we continue to move toward becoming a low-carbon society.　Since 2003, solar cell production has grown rapidly at an annual rate of 30 to 50%. In Japan, government poli-cies to increase instal led solar power generation capacity have revived subsidies earmarked for house-holds that have installed solar power generators since 2009.　Amidst mounting expectations for the expansion of the solar cell market, Kaneka Corporation has focused on solar cell development, most recently launching a new HYBRID™ solar module, which incorporates the compa-ny’s unique technologies.　Generally, two types of materials are used in the pro-duction of a solar cell; amorphous silicon and thin-film microcrystalline silicon. The former efficiently absorbs short-wavelength ultraviolet rays; the latter absorbs long-wavelength infrared rays. To make use of the merits in which their effective wavelengths and conditions for use differ, Kaneka developed a hybrid tandem-type solar panel, which is composed of dual layers of amorphous silicon and thin-film microcrystalline silicon.　The most important aspect of solar cell performance is conversion efficiency. Kaneka’s new HYBRID™ solar cell boasts a conversion efficiency that exceeds that of normal tandem-type cells by efficiently capturing light through the use of transparent interlayers.　Conserving resources, improving production efficiency and lowering costs are important factors in the solar cell business. In particular, improving a solar cell’ s conversion efficiency maximizes cost reductions.　Kaneka has already started producing large modules for European countries, including Germany. In Japan, demand is growing for solar cells that can integrate into and blend well with their surroundings. Thus, Kaneka is focusing its efforts in this area. In 2010, the company released a line of solar cells with an energy output equivalent to 55 MW and demand is steadily increasing.

New Hybrid Solar Cells: Promising Technology for the Solar Cell MarketNew Hybrid Solar Cells: Promising Technology for the Solar Cell Market

KANEKA CORPORATION

March 2009

New HYBRID™ photovoltaic panel

Photovoltaic modules incorporated into tiles

・Development of Technology to Accelerate the D i s s e m i n a t i o n o f P h o t o v o l t a i c P o w e r Generation Systems (FY2000‒FY2005)

Glass

Transparent electrode

Amorphous silicon

Transparent interlayers

Thin-film microcrystalline silicon

Back electrode

Sunlight

Cross-section of Kaneka’s New HYBRID™ solar cellSunlight is captured and sandwiched between transparent interlayers, thus enhancing its conversion efficiency.

New Energy

9

　The development of renewable energy is gaining

momentum as a solution to the depletion of fossil

fuels and global warming. Renewable energy is

expected to play a key role in alleviating or resolving

these problems, and solar cells of varying materials

and power-generating mechanisms are being devel-

oped amid fierce competition throughout the world.

　There is one solar cell for which specific goals have

been set towards resolving issues associated with

their development and performance, namely improv-

ing energy conversion efficiency, establishing stable

manufacturing technologies and reducing costs. Con-

tinuous progress is being made to achieve these goals

with development and performance enhancements

being rapidly applied to an innovative new solar cell

that shows great promise̶the CIS thin-film solar cell

under development by Show Shel l Sekiyu . CIS

denotes the components that comprise the solar cell;

copper (Cu), indium (In) and selenium (Se).

　Showa Shell Sekiyu started developing this solar cell

as part of the New Sunshine Project, which was

launched in 1993. In subsequent NEDO projects, the

company sought to realize the high potential that is

unique to CIS-based solar cells by developing large-ar-

ea structurally-integrated solar cells. By consistently

improving the manufacturing process and optimizing

the technology’s design, the company was successful in

achieving goals that were set for each project.

　In 2006, Showa Shell Sekiyu formed a wholly-owned

subsidiary, called Showa Shell Solar, to operate its

CIS-based thin-film solar cell business. In 2007, the

subsidiary started manufacturing and distributing the

CIS-based cells and sales continue to increase globally

(In April 2010 the subsidiary was renamed Solar Fron-

tier). In 2011, Showa Shell built its third solar cell man-

SHOWA SHELL SEKIYU K.K.

February, March 2010

Thin film laminated on glass substrate

Mass Production of New Non-silicon Solar CellsMass Production of New Non-silicon Solar Cells

SHOWA SHELL SEKIYU K.K.

ufacturing plant, the world’s largest, with an annual

production of 900 MW, which expanded the compa-

ny’s overall production scale into gigawatts. Through

Solar Frontier, Showa Shell is utilizing technologies

developed through NEDO projects to continue to

expand its solar cell business, which has become one

of its core businesses.

・New Sunshine Project/Research and Development of P ho t o vo l t a i c Powe r Gene r a t i o n Te chno l o g y (FY1993‒FY2000),etc.

Solar cells

Silicon

Chemicalcompound

Organic

Crystallinesilicon

Amorphoussilicon

III-V compoundmulti-junction

CIS

Cadmium telluride(CdTe)

Monocrystalline silicon

Polycrystalline silicon

Multi-junction tandem(hybrid type)

Microcrystallinesilicon

Thin-filmsilicon

Main types of solar cells

10

New Energy

Mitsubishi Heavy Industries, Ltd.

Until now, the race to develop solar cells hasfocused mainly on energy conversion efficiency. How-ever, numerous other factors determine solar cell pro-duction costs. The main challenges the industry isseeking to address are reducing large-area solar cellsproduction times and achieving continuous produc-tion.Mitsubishi Heavy Industries (MHI) has taken on

these challenges from the viewpoint of monozukuri(manufacturing), Japan’ s competitive advantage intechnology, focusing its endeavors on the develop-ment and production of silicon based thin-film solarcells that use small amounts of silicon, a material usedin most solar cells. Through collaborative NEDO proj-ects between industry and universities, MHI developeda technique for manufacturing solar cells with largesurface areas (1.4 m x 1.1 m) as well as a technologyto enhance film deposition speed. The result of thiscollaboration is a film deposition speed that is aboutfive times faster, with an actual production yield of97%.The solar cells manufactured by MHI are being

exported to countries such as Germany and Spain,which have been quick to adopt a feed-in tariff systemfor renewable energy. As of the end of 2011, MHI hadsold a total of about 100 MW of energy. In Japan, thecompany’ s technology is being used to generate elec-tricity at a variety of theme parks, educational facilitiesand MHI offices.Once solar cell manufacturing is carried out on a

global scale, high-performance manufacturing equip-ment will be needed to produce them. Applying itstechnological expertise acquired in developing andmanufacturing “machines that make machines” for themarine, aviation and industrial sectors, MHI promotesdevelopment of solar cells and the manufacturingequipment required to make them.

Development of Large-area High-speed Film DepositionTechnology for Sharply Enhancing Solar Cell ProductivityDevelopment of Large-area High-speed Film DepositionTechnology for Sharply Enhancing Solar Cell Productivity

Mitsubishi Heavy Industries, Ltd.

March 2010

・Development of Advanced Manufacturing Technology forP h o t o v o l t a i c P o w e r G e n e r a t i o n S y s t e m s(FY2000‒FY2001),etc.

Plasma CVD system for manufacturing amorphous silicon solar cellsThe star-shape enables short, tandemly-arranged lines and minimizes theimpact from any process in the line that has stopped.

Eco Sky House(Yokohama,Kanagawa)

Improvement rates in large-area high-speed filmdeposition technology for solar cells

Film deposition speed

(Substrate size x film deposition speed)

Productivity improves by 42 times

Film deposition speed

Today

New Energy

11

2

1

3

4

CASE

01Reported in：January 2016

New Energy

Success Story

08

1. The portable SOKODES. This device can detect connection failures in solar panels and estimate the location of failures. 2. The device in the middle is the Ground Fault Detector 20G, which can detect ground faults, a type of short circuit. The device on the right is the SOKODES GF, which can detect the location of connection failures and ground faults in solar panels. 3. A mega solar power plant in Kyushu, where the integrated SOKODES model is installed to provide remote monitoring of the status of faults. 4. Chairman and CTO Hiroshi Date showing an example of a fault in a solar panel. Faults can be created by even small separations of soldering in solar panels.

The First of Its Kind in Industry! SOKODES Was Developed for Use with Solar Panels to Quickly Detect Faults and Estimate Their Location

System JD Co., Ltd.New Energy Venture Technology Innovation Project, etc.

Japan’s shrinking semiconductor industry The path that one startup chose

After hitting a peak in the late 1980s and early 1990s, Japan’s semiconductor industry, which held the largest share of the global semiconductor market, has been shrinking since 1995. However, the market for solar panels, a type of semiconductor product, continues to expand globally. According to the Renewables 2014 Global Status Report, the amount of power produced by crystalline silicon type solar cells, which are the major component of solar power generation, increased by more than 20 times from 1.9 million kW in 2005 to 43 million kW in 2013. A company that paid close attention to this trend was System JD Co., Ltd., a semiconductor venture company located in Fukuoka.

The company originally produced test programs for semiconductor inspections and supplied them to manufacturers. However, it became necessary for the company to shift its business focus because the need for semiconductor inspections decreased as demand for semiconductors declined. The founder and current chairman, Hiroshi Date, tried to find a way to compete in the field of solar power, which is still continuing to grow. At that time, it was commonly said that solar panels did not develop faults and that maintenance was not required until long after a solar panel had been installed. Mr. Date, with his extensive experience in semiconductor inspec-tions, doubted such claims for a long time. He believed that because semiconduc-tors that are carefully produced in clean rooms can develop faults, solar panels

used outside must develop faults as well. When he had the opportunity, he asked a question about this at a seminar on solar power generation. In response, a seminar participant from a manufacturing company explained that it was very difficult to detect defects in solar panels at installa-tion sites. He also said that if there was a simple fault tester available, it would be helpful. After hearing this, Mr. Date decided to develop a system that could easily detect faults in solar panels by utilizing the semiconductor inspection technology developed by his company.

Topics CASE 01 New Energy

■New Energy Venture Technology Innovation Project(FY2009-FY2012)NEDO’s Role

7.

5

7

6

For The Future

09

From Hokkaido to Okinawa with an experimental model

After attending the seminar, Mr. Date was able to participate in joint research with the National Institute of Advanced Industrial Science and Technology(AIST). He then learned from AIST about one of NEDO’s New Energy Venture Business Technology Innovation Program projects that had been publicly announced.

Realizing that this would be a good opportunity to help promote his company’s technology, Mr. Date and his colleagues applied to participate in the project. His company then began the development of a fault detection system from 2009 as a commissioned project.Mr. Date and his colleagues produced an

experimental model of a solar panel fault detector and then traveled across Japan

to inspect solar power facilities. Over three years, they inspected all of the panels of the 18 solar power plants owned by Kyushu Electric Power Company.During repeat inspections of many sites,

it was found that there were actually more faults in solar panels than previously thought. It made sense that faults would be found in solar panels that had been used for a number of years, but faults were also discovered in new panels as well.The most common cause of faults was

connection failure in the circuits. It is difficult to solder wires to solar panels, so vibrations can cause the wires to tear away and disconnect when they are not soldered correctly. In addition, it was discovered that there was a danger of fire from a wire igniting if open circuits are neglected.

After obtaining this information and continuing to make improvements to the detector, SOKODES, a portable detector that can estimate the location of faults in solar panels in a short period of time, was finally completed. Furthermore, an integrated detector for large-scale facilities was developed by employing the technology of the portable detector.

With the integrated model, measure-ment data is automatically sent to a monitoring center via the Internet, which enables remote monitoring of solar panels to be performed.

Further Continuing to improve the product improvement and starting then taking it overseas marketing and sales

Even after the product was developed, technological improvements continued. A new device capable of detecting earth faults, a type of short circuit, as well as open circuits was developed and introduced to the market. Also, in consideration of an expanding global market, plans were made to start overseas marketing and sales. Since 2015, the company has partici-pated in NEDO’s Demonstration of Photo-voltaic System Remote Maintenance project and has carried out basic research related to the demonstration in Thailand.Because it is predicted that, as the use of

solar energy expands globally, the demands for maintenance management of solar panels will increase as well, this company is aiming to expand sales of this devices inside and outside Japan.

7. SOKODES being tested. For the integrated model, the green circuit boards are installed in junction boxes at a mega solar power plant.

5. Technological development at System JD. Toshiyuki Shigemura, Director, Engineering and Development Department and sitting in the foreground, played a key role in product development.6. COO Shigenori Matsuo explaining the structure of the integrated SOKODES model installed at a mega solar power plant.

Since FY2007, NEDO has aimed to support venture business activities in new energy fields and foster related industries in order to promote technology develop-ment utilizing potential technology seeds of small and medium-sized enterprises as well as venture companies. NEDO also provides assistance for creating business plans and expanding business domains, thereby improving the efficiency of the

new energy industry and increasing the depth of the industrial structure for alternative energy.During a project, NEDO utilizes a stage

gate system having multiple stages so as to refine technology seeds having a high level of potential for commercialization based on various conditions in society. In each stage, NEDO provides hands-on support in cooperation with outside special-

ists in technology, intellectual property, and management in order to support the basic research necessary for commercial-ization, such as the creation of prototypes and the measurement of data, and all research and development themes needed to achieve commercialization. In this way NEDO aims to further promote the development, introduction, and popular-ization of innovations in new energy fields.

2

1

3

4

CASE

01Reported in：January 2016

New Energy

Success Story

08

1. The portable SOKODES. This devicecan detect connection failures in solar panels and estimate the location of failures. 2. The device in the middle is the Ground Fault Detector 20G, which can detect ground faults, a type of short circuit. The device on the right is the SOKODES GF, which can detect the location of connection failures and groundfaults in solar panels. 3. A mega solar power plant in Kyushu, where the integrated SOKODES model is installed to provide remote monitoring of the status of faults. 4. Chairman and CTO Hiroshi Date showing an example of a fault in a solar panel. Faults can be created by even small separations of soldering in solar panels.

The First of Its Kind in Industry! SOKODES Was Developed for Use with Solar Panels to Quickly Detect Faults and Estimate Their Location

System JD Co., Ltd.New Energy Venture Technology Innovation Project, etc.

Japan’s shrinking semiconductor industry The path that one startup chose

After hitting a peak in the late 1980s and early 1990s, Japan’s semiconductor industry, which held the largest share of the global semiconductor market, has been shrinking since 1995.However, the market for solar panels, a

type of semiconductor product, continuesto expand globally. According to the Renewables 2014 Global Status Report, the amount of power produced by crystalline silicon type solar cells, which are the major component of solar power generation, increased by more than 20 times from 1.9 million kW in 2005 to 43 million kW in 2013. A company that paid close attention to this trend was System JD Co., Ltd., a semiconductor venture company located in Fukuoka.

The company originally produced test programs for semiconductor inspections and supplied them to manufacturers. However, it became necessary for the company to shift its business focus because the need for semiconductor inspections decreased as demand for semiconductors declined. The founder and current chairman, Hiroshi Date, tried to find a way to compete in the field of solar power, which is still continuing to grow.At that time, it was commonly said that

solar panels did not develop faults and that maintenance was not required until long after a solar panel had been installed. Mr. Date, with his extensive experience in semiconductor inspec-tions, doubted such claims for a long time. He believed that because semiconduc-tors that are carefully produced in clean rooms can develop faults, solar panels

used outside must develop faults as well.When he had the opportunity, he asked a question about this at a seminar on solar power generation. In response, a seminar participant from a manufacturing company explained that it was very difficult to detect defects in solar panels at installa-tion sites. He also said that if there was a simple fault tester available, it would be helpful. After hearing this, Mr. Date decided to develop a system that could easily detect faults in solar panels by utilizing the semiconductor inspection technology developed by his company.

Topics CASE 01 New Energy

■New Energy Venture Technology Innovation Project(FY2009-FY2012)NEDO’s Role

7.

5

7

6

For The Future

09

From Hokkaido to Okinawa with an experimental model

After attending the seminar, Mr. Date was able to participate in joint research with the National Institute of Advanced Industrial Science and Technology(AIST). He then learned from AIST about one of NEDO’s New Energy Venture Business Technology Innovation Program projects that had been publicly announced. Realizing that this would be a good opportunity to help promote his company’s technology, Mr. Date and his colleagues applied to participate in the project. His company then began the development of a fault detection system from 2009 as a commissioned project. Mr. Date and his colleagues produced an experimental model of a solar panel fault detector and then traveled across Japan

to inspect solar power facilities. Over three years, they inspected all of the panels of the 18 solar power plants owned by Kyushu Electric Power Company. During repeat inspections of many sites, it was found that there were actually more faults in solar panels than previously thought. It made sense that faults would be found in solar panels that had been used for a number of years, but faults were also discovered in new panels as well. The most common cause of faults was connection failure in the circuits. It is difficult to solder wires to solar panels, so vibrations can cause the wires to tear away and disconnect when they are not soldered correctly. In addition, it was discovered that there was a danger of fire from a wire igniting if open circuits are neglected. After obtaining this information and continuing to make improvements to the detector, SOKODES, a portable detector that can estimate the location of faults in solar panels in a short period of time, was finally completed. Furthermore, an integrated detector for large-scale facilities was developed by employing the technology of the portable detector.

With the integrated model, measure-ment data is automatically sent to a monitoring center via the Internet, which enables remote monitoring of solar panels to be performed.

Further Continuing to improve the product improvement and starting then taking it overseas marketing and sales

Even after the product was developed, technological improvements continued. A new device capable of detecting earth faults, a type of short circuit, as well as open circuits was developed and introduced to the market. Also, in consideration of an expanding global market, plans were made to start overseas marketing and sales. Since 2015, the company has partici-pated in NEDO’s Demonstration of Photo-voltaic System Remote Maintenance project and has carried out basic research related to the demonstration in Thailand. Because it is predicted that, as the use of solar energy expands globally, the demands for maintenance management of solar panels will increase as well, this company is aiming to expand sales of this devices inside and outside Japan.

7. SOKODES being tested. For the integrated model, the green circuit boards are installed in junction boxes at a mega solar power plant.

5. Technological development at System JD. Toshiyuki Shigemura, Director, Engineering and Development Department and sitting in the foreground, played a key role in product development.6. COO Shigenori Matsuo explaining the structure of the integrated SOKODES model installed at a mega solar power plant.

Since FY2007, NEDO has aimed to support venture business activities in new energy fields and foster related industries in order to promote technology develop-ment utilizing potential technology seeds of small and medium-sized enterprises as well as venture companies. NEDO also provides assistance for creating business plans and expanding business domains, thereby improving the efficiency of the

new energy industry and increasing the depth of the industrial structure for alternative energy. During a project, NEDO utilizes a stage gate system having multiple stages so as to refine technology seeds having a high level of potential for commercialization based on various conditions in society. In each stage, NEDO provides hands-on support in cooperation with outside special-

ists in technology, intellectual property, and management in order to support the basic research necessary for commercial-ization, such as the creation of prototypes and the measurement of data, and all research and development themes needed to achieve commercialization. In this way NEDO aims to further promote the development, introduction, and popular-ization of innovations in new energy fields.

NTT FACILITIES, INC

September ～ December 2012

Realizing Energy Conservation with “DC for DC”‒ Leave it up to a stable supply of electricity!Realizing Energy Conservation with “DC for DC”‒ Leave it up to a stable supply of electricity!

NTT FACILITIES, INC

Currently, most of the electronic appliances that are

commonly used operate on a direct current, and

although the alternating current coming from an outlet

is converted with an adaptor, as this creates a conver-

sion loss, if the direct current could be used directly,

effects of energy conservation can be expected. Espe-

cially gathering attention is putting this to use at data

centers where direct currents, from such as accumula-

tors for measures against power failures and solar

powered generators, a representative example of new

energy electricity, can be used as is.

NTT Facilities has been focusing on such character-

istic of direct currents for a while, and in proceeding

with research and development of the “High Voltage

Direct Current Power Supply System (DC380V)”, by

obtaining the support of NEDO, participated in the

world’s first pioneering verification studies conducted

using direct currents at the Tohoku Fukushi University

(located in the city of Sendai, Miyagi Prefecture) and

neighboring areas. In these studies, the realized effect

of energy conservation was as high as 30%. The

Great East Japan Earthquake also occurred during the

verification experiments. Even when subject to a

historical disaster, results miraculously displayed sta-

bility of the power supply. Shaken by quakes of

upper-6 on the seven-point Japanese scale during the

Earthquake, although power failures lasted for 3 days

with nearby commercial power supplying networks,

the supply of power was never lost at the verification

site. Currently as of April, 2013, this system has been

implemented throughout Japan at 10 locations includ-

ing the verification sites, at 35 locations throughout

the world, and in recent years, has been adopted for

use at a commercial data center.

・New Electrical Power Network System Verification Studies /Quality-Based Electrical Power Supply System VerificationStudies (FY2004-FY2007)

The solar power battery integration converter (left) and accumulator(right) installed within the verification site.

Inside the server center,all internal wirings are done using direct currents.

12

New Energy

Fuji Heavy Industries Ltd.

　Wind turbines, which harness the power of the wind to create energy, may look the same at first glance, but upon closer inspection their composition exhibit innovative differences in intricate technological design. The development of wind turbines in Japan, which are well-suited to the geography of this island country, has resulted in a variety of technical achievements that are contributing to the next-generation of wind power production.　In 1999, NEDO launched a project to develop wind turbines designed for Japan’s remote islands. The result of the project was a 100 kW wind turbine developed by Fuji Heavy Industries (FHI). Since then, the company has continued to build upon this achievement and has developed 2 MW models.　Today, mainstream wind turbines are typically of the upwind type, in which the rotating blades are located in front, or on the upwind side of the support tower and nacelle, a structure that houses the generator. The blades are also parallel to the pole, so that wind sweeping along the ground hits the blades head-on. Initially, FHI developed upwind turbines, but realizing that most high-speed winds, which are effective for power generation on Japan’s complex terrain, have high uplift or are winds blowing uphill, the company started developing a unique wind turbine with the rotor located behind both the nacelle and support pole. The rotor plane is tilted so that it directly faces winds blowing uphill. This unique innovation is called a downwind design. FHI also focused on dividing the nacelle, as well as reducing the lift weight of the main components, which has made transportation and con-struction much easier.　FHI has since sought to quickly develop practical applications for this large wind turbine, incorporating existing technologies and also focusing its develop-ment efforts in such a way to clearly differentiate the company from other wind turbine manufacturers. 　The most significant difference between FHI and other manufacturers is this downwind turbine, the cul-mination of research built upon from the initial NEDO

Fuji Heavy Industries Ltd.

September ～ November 2010

project. This unique wind turbine is considered to be promising for power generation in mountainous areas as well as offshore wind power generation. FHI expected to ship 21 small-scale 40 and 100 kW wind turbines as well as 58 large wind turbines jointly developed with Hitachi, Ltd. by the close of 2011.

From Wind Power Generating Systems for Remote Islands to Large Downwind TurbinesFrom Wind Power Generating Systems for Remote Islands to Large Downwind Turbines

2 MW wind turbine installed 50 m from shore

・Technology Development of Advanced Wind Turbine Systems for Remote Islands (FY1999‒FY2002)

Wind

Upwind method　Downwind method Upwind method　Downwind method

Wind Wind

Sea surface

Turbine tilts downward depending on wind thrust(tends to face the wind in downwind method)

Downwind method is better for blade extension as the gap between the blade and the tower is maintained more easily.

Low-rigidity blades

Downwind method advantages for floating wind turbines (left)Downwind method advantages when extending plates (right)

New Energy

13

Zephyr Corporation

　Wind powered generation is a representative exam-ple of new energy. However, conventional compact wind turbines had issues with power generating per-formance and durability, making practical applications difficult.　By obtaining support from NEDO, Zephyr has devel-oped the “Airdolphin”, a new-model wind turbine. Realizing an extremely compact size and weight reduction that enables installment in a variety of loca-tions, on top of the cutting edge carbon fiber blades and its electronic control by highly advanced software, concepts of biomimetics (imitation of biological sys-tems) have been incorporated in creating a new idea for a wind turbine. A swing rudder developed based on hints obtained from how a carp deflects streams of water coming from its side using its tail fin, and a new mechanism to reduce rotational noise created based on an imitation of the structure of an owl’s wings have been implemented. Additionally, durability and safety has been improved by adopting a new screw-less casing structure based on hints gathered from tradi-tional Japanese crafts of detailed woodwork.　Also, with the obtained support of NEDO, truck tests of the AIST have been performed to verify reli-ability during the period of the project. These devel-opments have come to completion due to the industri-al-academic-government cooperation of 14 organiza-tions with Zephyr in the center. This system that starts to generate electricity from low wind speeds realizes a safe non-stopping operation even in strong and violent winds such as with typhoons, and is being sold since spring of 2006. Even after this, starting with Erimo-Misaki in Japan, field tests are being conducted throughout the world to collect data and continue development of an optimal control system.　This system is domestically being sold to private homes, industries for energy conservation, selling of electricity, and emergency applications, local govern-ments for hybrid street lights used along with solar power, and to schools for use as teaching materials

July ～ September 2012

Zephyr Corporation

for environmental education. Additionally, with sup-port from the Innovation Network Corporation of Japan, this system is actively being developed over-seas where applications that can only be seen over-seas, such as with mobile base stations and non-pow-ered regions of developing countries, have continued to grow, currently marking a total sales of 3,000 units as of March, 2013.　In the renewable energy fixed price purchasing system made effective in 2012, the Airdolphin was the first model to obtain certification as a compact wind turbine.

Highly Efficient General Compact Wind Powered Generation SystemHighly Efficient General Compact Wind Powered Generation System

The swing-rudder method

・Industrial Technology Practical Application Development Support Project / Research and Development Type Venture Technology Development Support Project (FY2003-FY2005)

Reliability tests being performed on the AIST test course

14

New Energy

　Treatment of ever-increasing urban waste and sewage sludge is a challenge that all cities share. As a means of resolving urban waste problems, use of processing facilities capable of both incinerating waste and using the energy produced is on the rise. However, incinerating sewage sludge produces carbon dioxide (CO2) as well as nitrous oxide (N2O), which emits 310 times more greenhouse gas than CO2.　In 2003, with the support of the Tokyo Metropoli-tan Government Bureau of Sewerage, Tokyo Metro-politan Sewerage Service Corporation and Hokkaido University, METAWATER launched a NEDO-funded joint project with the Institute of Applied Energy and Mitsubishi Heavy Industries to develop a gasification system for sewage sludge. The goal of the project was for the new system to use the energy produced by sewage sludge while also emitting fewer green-house gases. The system, which is now in use at the Tokyo Metropolitan Bureau of Sewerage’s Kiyose Water Recycling Center, has successfully achieved this goal.　Since sewage sludge is accumulated at the treat-ment site, the installation of new systems to collect and transport was not required. Sewage sludge is a resource that is easy to use compared to other forms of biomass. However, it can also present a challenge because it contains large amounts of water. MET-AWATER’s gasification system for sewage sludge incorporates dehydration /sludge drying, gasification, property modification, gas refining, power generation and heat collection.　Installed at the Kiyose Water Recycling Center in July 2010, the system now processes about 100 tons of sewage sludge daily. Because combustion heat is collected and used to dry the sludge, no other fuel is needed. Some of the facility’s power is also generat-ed during gas property modification. The primary advantage of this method, however, is that it sharply

October 2011

reduces N2O emissions. This has contributed to an annual reduction in greenhouse gas emissions of 87%, equivalent to 12,500 tons of CO2.

METAWATER Co., Ltd. / Bureau of Sewerage Tokyo Metropolitan Government

World’s First Gasification System for Sewage Sludge Transforms Fuel Gas into PowerWorld’s First Gasification System for Sewage Sludge Transforms Fuel Gas into Power

Sludge dryer using waste heat

Gas engine

・Development of Technology for High Efficiency Biomass Energy Conversion (FY2003‒FY2005)

New Energy

15

METAWATER Co., Ltd. Bureau of Sewerage Tokyo Metropolitan Government METAWATER Co., Ltd. Bureau of Sewerage Tokyo Metropolitan Government

Chugai Ro Co., Ltd.

“Woody biomass energy sources” such as wood chips, wood offcuts and timber from forest thinning are energy resources that are attracting attention as carbon-neutral fuels that wil l contribute greatly to reducing CO2 emissions. Chugai Ro Co., Ltd., a leading industrial furnace

manufacturer, started research and development of woody biomass energy-based gasification power generation systems as a technology to alleviate global warming through uti l izat ion of Chugai Ro’s own technologies, in response to the adoption of the Kyoto Protocol in 1997. Japan has many biomass resources, but gathering biomass in large amounts is difficult, and it is necessary to establish systems that are suited to local characteristics such as the types and amounts of biomass generated. Against this background, Chugai Ro Co., Ltd. has been

pursuing the development of gas ificat ion power generation systems as a means for local production and consumption type biomass energy utilization. Chugai Ro Co., Ltd. participated in the NEDO Project in FY2002 and achieved 500 hour-continuous operation and an energy conversion efficiency of 60% (electric energy = 20%, thermal energy = 40%) in February 2005 at the demonstration test facility (5 tons/day, 180kW) in Yamaguchi City of Yamaguchi Prefecture. In February 2013, Chugai Ro Co., Ltd. constructed a

“Biomass Gasification Tri-generation System” (7-9 tons/day, 180kW) in Yokote City of Akita Prefecture, which not only generates electricity and utilizes heat but also produces fuel at the same time. Chugai Ro Co., Ltd. has been conducting demonstration tests using this system (“Tri-generation System Demonstration Project Utilizing Un-utilized Biomass in Snowy Mountainous Areas,” which is a project entrusted by the Ministry of the Environment as part of the “Model Project for Intensive Support for the Development of Low-carbon Areas”). Because this system utilizes the vast amount of timber

from forest thinning in Yokote City, which is a city with active forestry industry, as a biomass fuel, it is attracting

Octorber 2013

Chugai Ro Co., Ltd.

attention not only as a technology to alleviate global warming but also as a means of vitalizing the forestry industry of the city.

Biomass Gasification Power Generation System that Contributes to Reducing CO2 Emissions and Enhancing the Local Vitality Biomass Gasification Power Generation System that Contributes to Reducing CO2 Emissions and Enhancing the Local Vitality

・Verification Tests and Results Survey for Biomass and Other Untapped Energy (FY2002-2005) ,etc.

Biomass gasification power generation system developed by Chugai Ro Co., Ltd.

Perspective of the Gasification Furnace Developed by Chugai Ro Co., Ltd. for Biomass Gasification Power Generation Systems (Source: Chugai Ro Co., Ltd.)

Rotary Kiln Capable of Gasifying (Pyrolyzing) Biomass of Various Types at the Same Time (Source: Chugai Ro Co., Ltd.)

16

New Energy

Biomass (un-utilized resource) Transformed into electric and heat energy

Gasification through pyrolysis

The carbides are completely incinerated and the waste heat is utilized.

Pyrolysis of biomass of various shapes and sizes using rotary kiln

High-efficiency energy collection using gas engines

Utilization of dried biomass

Carbides

Flammable gas

Electric energyHeat energy

Woodchips

Plantbiomass

Sawn wood, remnant wood, sawdust

Barks

Bamboo Tea leaveresiduals

Waste mushroom bedsStrained leesof vegetablesand fruits

Coffee grounds Chaff Shochu distillerybyproduct

Bagasse

　To prevent global warming, there is an urgent need to reduce CO2 emissions in communities. One innova-tive technology that can contribute to achieving CO2 reductions is ENE-FARM. ENE-FARM is a home fuel cell cogeneration system that generates electricity at private residences and the heat it gives off is used for home heating and hot water as opposed to focusing efforts to conserve energy through the use of conven-tional energy-efficient appliances and equipment. Until now, high-efficiency fuel cells were mainly used in space development, manufacturing plants and office buildings. To enable user-friendly and safe use in homes, it will be necessary to ease regulations govern-ing use, ensure durability, and reduce purchase prices and operation costs. Along with the electronic manu-facturers involved in the development of ENE-FARM equipment, Tokyo Gas, an energy company that sup-plies fuel (such as city gas) to ENE-FARM users, contin-ues to address the challenge of developing and distributing fuel cells through NEDO projects.　Compared to conventional methods of using elec-tricity generated from thermal power plants, and hot water supply and heating from city gas, the ENE-FARM fuel cell system reduces primary energy consumption by approximately 35% and CO2 emissions by approxi-mately 48% by utilizing thermal energy that had previ-ously been lost through power transmission and exhaust heat. As a result of a large-scale demonstra-tion project that involved installing 3,307 units throughout Japan and the technology’s market release in 2009, more than 10,000 units are currently in operation in Japan. However, ENE-FARM is still expensive and costs must be further reduced through the simplification of its internal system. Looking toward the day when ENE-FARM is commonly used in homes, the challenge to develop and improve ENE-FARM continues.

TOKYO GAS Co., Ltd.

March 2011

TOKYO GAS Co., Ltd.

High-efficiency Power Generators That Use Hydrogen:Development of Fuel Cells for Household UseHigh-efficiency Power Generators That Use Hydrogen:Development of Fuel Cells for Household Use

Home fuel cell cogeneration system “ENE-FARM”

・Establishing Platforms for the Widespread Use of Fuel Cells (FY2000‒FY2004),etc.

System evaluation testing for ENE-FARM cogeneration systems to ensure durability for the 40,000 hours required for household use.

Implementation status of large-scale demonstration projectAdvances in development has led to cost reductions as well as reductions in subsidy prices per unit, resulting In an increase in the number of units installed.

Projectduration

Subsidies

FY2005 FY2006 FY2007 FY2008

Phase 1 Phase 2

Number ofunits installedthroughsubsidies

480 1,257 2,187 3,307

6 millionyen/unit 4.5 million

yen/unit 3.5 millionyen/unit 2.2 million

yen/unit

New Energy

17

Osaka Gas Co., Ltd.

　Solid oxide fuel cells (SOFC) are extremely efficient

power generators, and the new type of ENE-FARM

equipped with this is gathering attention. By installing

ENE-FARM, power transmission loss can be prevented

as electricity will be generated at home, and also as

heat and electricity is generated simultaneously, both

forms of energy can be consumed without being

wasted. As the SOFC type ENE-FARM varies its

output depending on the demand for electricity, it

better suits homes that are interested in prioritizing

power generation more than their hot-water supply.

Additionally, as the power generator unit and the

hot-water storage unit are relatively compact in size

enabling a design with a small dimension of depth, it

is perfect for being installed in densely populated

locations.

　With regard to the durability of the cell which is an

important component of an SOFC, NEDO integrated

the wisdom of industrial-academic-government coop-

eration together with Kyocera, a manufacturer of the

cells, in efforts of research and development. As a

result, progress was made in unraveling the effects of

impurities on a level of mechanism, accordingly

improving the durability and reliability of cells. Addi-

tionally, using the SOFC type ENE-FARM equipped

with the cells by Kyocera and developed by AISIN

SEIKI, Osaka Gas participated in the verification tests

conducted by NEDO. Systems were installed through-

out Japan to verify its long-term durability, reliability,

and efficiency, etc. As a result, durability and reliability

were improved, power generating efficiency was

proved as 46.5% while efficiency as a co-generation

system combined with supplying hot-water was

90.0%, and an endurance time of 100,000 hours was

March 2013

Osaka Gas Co., Ltd.

achieved. Osaka Gas has currently achieved sales of

approximately 700 units as of March, 2013 since the

start of sales in March, 2012, and continues aiming for

popularized expansion throughout Japan.

Development of a Residential Fuel Cell System using a High-Efficiency Solid Oxide Fuel Cell (SOFC)Development of a Residential Fuel Cell System using a High-Efficiency Solid Oxide Fuel Cell (SOFC)

・Solid Oxide Fuel Cell System Technology Development (FY2004-FY2007),etc.

A generator unit undergoing an endurance test

18

New Energy

“Fuel cell vehicles” are vehicles that are high in energy efficiency, capable of traveling distances equivalent to distances gasoline-based vehicles can travel and do not emit any CO2 or harmful substance as they travel. Fuel cell vehicles had been regarded as “dream vehicles” for a long time. However, the production and sale of fuel cell vehicles for general users is scheduled to start in 2015. As a result, the development of “hydrogen stations” for supplying fuel cell vehicles with hydrogen (the fuel for fuel cell vehicles) has become an urgent task, and efforts are being made by the industry, academia and government organizations towards the goal of developing 100 hydrogen stations throughout Japan by 2015, including efforts to provide hydrogen stations on the premises of existing gas stations and efforts to develop transportation and distribution networks for liquid hydrogen. An important factor in the development of hydrogen stations is the mode of supply of hydrogen to hydrogen stations. There are two modes of supply of hydrogen to hydrogen stations; the “onsite” supply wherein the hydrogen is produced on the premises of hydrogen stations from liquefied petroleum gas (LP gas) or town gas and the “offsite” supply wherein the hydrogen is brought to hydrogen stations using trailers in the form of liquid hydrogen and compressed hydrogen. Mitsubishi Kakoki Kaisha, Ltd., a plant provider that has been producing large-scale industrial hydrogen production equipment for many years, had been developing onsite hydrogen production equipment since 1998 utilizing its experience. However, to install hydrogen production equipment on the premises of existing gas stations so that hydrogen can be used as easily as gasoline, it had been necessary to develop smaller and higher-performance hydrogen production equipment. Therefore, Mitsubishi Kakoki Kaisha, Ltd. participated in the “Development of Technologies for Systems for Producing, Transporting and Storing Hydrogen and Other Technologies” Project of NEDO in FY2008 and endeavored to develop small hydrogen production equipment of one half the size of existing equipment and with a reforming efficiency of 85% (production efficiency: 80%). As a result, the company succeeded

Mitsubishi Kakoki Kaisha, Ltd.

December 2013

in commercializing hydrogen production equipment called “HyGeia-A.”The first commercial unit of HyGeia-A was installed in a hydrogen station provided on the premises of a gas station located in Midori Ward of Nagoya City of Aichi Prefecture. Long-term demonstration operation of that unit was started in 2013 as part of the “Development of Technologies for Local Hydrogen Supply Infrastructures and Social Demonstration of the Developed Technologies” Project of NEDO.

Mitsubishi Kakoki Kaisha, Ltd.

Development of Small High-performance Hydrogen Production Equipment for Hydrogen Stations for Fuel Cell Vehicles that will become Popular in the Future Development of Small High-performance Hydrogen Production Equipment for Hydrogen Stations for Fuel Cell Vehicles that will become Popular in the Future

・Development of Technologies for Hydrogen Production, Delivery, and Storage Systems(FY2008-2012)

The “HyGeia-A” hydrogen production equipment installed in an area of the Kaminokura Hydrogen station

The reformer, which is the heart of the hydrogen production equipment

New Energy

19

Fuel cells are coming into wider use in so-called “ENE-FARM” residential fuel cell cogeneration systems (Micro-CHP) and other applications. The key to diffusing fuel cell systems is developing system components that are energy-efficient, durable, and inexpensive. This project focused on the blower, a major fuel cell system component used to move system gases. Two types of innovative blowers were put to commercial use: one for boosting gas pressure and the other for recirculating hydrogen.

Extending the life of an electromagnetic diaphragm blower for boosting gas pressure

Durability is essential for promoting residential fuel cell systems (Micro-CHP) such as ENE-FARM because once installed, they are expected to be in continuous operation for a long period of time. Prerequisites for the widespread use of fuel cell systems in ordinary households also include energy efficiency and low cost. In light of the above, Techno Takatsuki Co., Ltd. focused on the develop-ment and commercial application of gas booster blowers, an auxiliary fuel cell system component designed to move fuels such as city-supplied natural gas and liquefied petro-leum gas. Using an electromagnetic diaphragm blower, a highly efficient, friction-free pump originally designed for water tank use, Techno Takatsuki conducted accelerated life testing in a NEDO project to estimate actual blower

lifetime by exacerbating conditions that would cause degradation. This led to realization of a gas booster blower for fuel cell systems characterized by low power consumption, low cost, and long life. The blower also features rubber diaphragms capable of withstanding repeated expansion and contraction during 40,000 hours (approximately four and a half years) of continuous opera-tion.

Returning to basic research to realize a safe hydrogen recirculation blower

Fuel cell systems for vehicles use pure hydrogen for fuel and therefore require strict safety controls. Since hydro-gen gas causes materials to experience hydrogen embrit-tlement, a phenomenon that decreases material strength, Techno Takatsuki improved the blower structure and conducted fundamental research jointly with Kyushu University on the hydrogen embrittlement of rubber, resin, and other materials used in the blower. As a result, efforts to prevent hydrogen embrittlement, including coating of permanent magnets inside the blower found to become brittle, led to realization of a hydrogen recircula-tion blower with a flow rate of 100 L/min. Today, steadily increasing numbers of hydrogen recirculation blowers are being used in industrial vehicles, auxiliary power supplies, and other systems with a view toward their introduction in fuel cell vehicles for the general public.

New Energy

Blowing a Breath of Fresh Air to Realize a Hydrogen-Based Society

New Energy Venture Business Technology Innovation Program

Techno Takatsuki Co., Ltd.

Development of Innovative Blowers for Fuel Cell Systems Indispensable for Realization of a Hydrogen-Based Society

Left: The workings of the elec-tromagnetic diaphragm blower. The blower has a structure that features a pair of gas compres-sion spaces, one on the right and the other on the left.

Top right: The gas intake port (left) and gas exhaust port (right) were set at different heights in order to discharge drops of condensed water vapor contained in the mixed gas.

Bottom right: The hydrogen recirculation blower for fuel cell systems developed during NEDO’s project

Diaphragm in electromagnetic diaphragm blower

Exhaust portExhaust port

Intake portIntake port

08 09SUCCESS STORIESNEDO PROJECT SUCCESS STORIES 2017