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Chinese manufacturers on the way towards low-carbon production
Source:Adsale Plastics Network    Editor:JK    Date:03.Dec.2021

China has been dealing with electricity shortage since September. As the world reopens from the COVID-19 pandemic, the demand for Chinese products surges. The factories in China hereby need more electric power for production. Although the electricity shortage is being resolved, it may ripple through industrial hubs as winter is approaching.

 

The problem, however, has also raised the social awareness and review of the energy supply distribution and low-carbon production. It is noteworthy that some Chinese manufacturers have already taken low-carbon and energy-saving production strategies into consideration and have even begun implementing these strategies.

 

Adoption of cold energy recovery systems

 

Sewage recycling treatment, thermal and cold energy recovery and use of renewable energy are now the important measures for the sustainable development of Joyson Electronics.

 

The factory of Joyson in Ningbo, China has lately adopted cold energy recovery system to reduce energy consumption and carbon emissions. The result is phenomenal with the overall electricity consumption of related workshops reduced by 40%.


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The factory of Joyson in Ningbo.


Joyson’s Ningbo factory is equipped with liquid nitrogen for manufacturing and testing electronic components. In the factory, next to the mold workshop are liquid nitrogen storage tanks which are important source of cold energy for the entire factory.

 

The cold energy recovery system has been used in the liquid nitrogen vaporization process, which is the first phase of the company's energy recovery project. The second phase of the project, scheduled to operate in 2022, is adopting thermal energy recovery systems in the injection molding process.


“The liquefiers released cold energy due to vaporization and they had a thick layer of ice on the surface,” said Chen Xuesheng, Director of Manufacturing Process Development at Joyson. “These ice layers are now gone as the factory has utilized the cold energy recovery system.”


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Cold energy recovery during nitrogen vaporization.


Reuse of cold energy is common in liquefied natural gas (LNG) cold chain logistics truck operations. The principle is also applicable to the manufacturing process of the factory. The cold energy recovered is reused in the factory's air-conditioning system, resulting in an obvious carbon reduction.

 

According to Joyson, the cold energy released during the liquid nitrogen vaporization process is converted into air conditioning cooling water for molds, surface mount, assembly and other workshops through the water circulation system.

 

Setup of smart energy control platform

 

Haier Sino-German Smart Manufacturing Park is a major production site of Haier for products like central air conditioners, rotary drum washing machines, special refrigerators and more. It has become the smart manufacturing base which received the German ROI-EFESO Industry 4.0 Award last year.

 

Integrating the technologies of Energy Interconnection, big data, cloud computing and 5G network, COSMOPlat has set up a smart energy control platform for the Park to realize flow of energy and carbon traceability.


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A production workshop in Haier Sino-German Smart Manufacturing Park.

 

COSMOPlat is a subsidiary of Haier specialized in industrial Internet platform operation, industrial intelligence research, intelligent equipment and control, and automation.

 

Through centralized monitoring and digitalized management of energy production, transmission and distribution, the energy balance and efficiency of the Park have been improved.

 

In terms of energy efficiency, with methods such as recovery of waste heat from air compressors, conversion of the machines in pump room and construction of a gas triple-supply system, the platform realizes cascade utilization of energy supplies. As a result, the annual CO2 emission reduction is about 32,200mu of tree planting.


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The photovoltaic power generation system of the Park.


Besides, a photovoltaic power generation system with a total installed capacity of 13.5MW was built on the roof of the Park, covering 130,000sqm. The annual power generation capacity is over 15 million kWh.

 

In the next step, a wind power system with three 3MW low-speed wind turbines is planned to be built in the Park. It is expected that the annual power generation will reach 40.8 million kWh and CO2 emission reduction will be 35,000 tons.

 

With the application of a series of energy-saving and carbon-reduction technologies, the Park achieves an energy efficiency of over 80%, a clean energy utilization rate of 41%, and a reduction of 32,200 tons of CO2 emissions.

 

Building of other green infrastructures

 

One of the subsidiaries of Lingyun Industrial Corporation Limited is dedicated to the processing and production of automotive parts. Relying on the fully automatic welding robot system, the company has an annual output of 10 million automotive parts.


The company has been actively engaging in smart manufacturing in recent years. It invested RMB 23.6 million in 30 welding robots and integrated automatic welding production lines and 5 sets of welding workstations, making the production standardized and flexible.

 

Meanwhile, it replaced all of its workshop lightings with green LED, which saves 8.11 million kWh of electricity per year and reduces CO2 emissions by more than 80 tons. The use of high energy consuming machines was also eliminated to save 22,900 kWh of electricity annually and reduce CO2 emissions by 28 tons.

 

The company has also built several green infrastructures in its sites such as photovoltaic roofing and panel lighting, large industrial ceiling fans, electric forklifts and a paperless office.

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