Sharp’s Kameyama Plant—The World’s Most Advanced Environmentally Conscious Manufacturing Facility

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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 were introduced simultaneously around the world starting from October 1, 2006.

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, they 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*3 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.

*1 As of September 19, 2006 for installations on buildings. Based on Sharp research.
*2 Compared to the case when electricity requirements are covered by conventional thermal power generation. Based on Sharp calculation estimates.
*3 As of September 19, 2006. Based on Sharp research.
*4 Based on the estimated power generated by a typical residential photovoltaic power system of 4 kW (5,210 kW ÷ 4 kW = approx. 1,300 homes).

In addition to the 60-kW photovoltaic (PV) 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).

Via: (Sharp Corporation)

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