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2012 Vol.44 No.2

IHI ENGINEERING REVIEW

2012 Vol.44 No.2

1. Products

Products1Completion of the World's Largest LPG PlantOvercoming many obstacles during the construction boom, IHI successfully completed the last phase expansion of liquefied petroleum gas (LPG) plant for SONATRACH, thereby deserving client's trust for building the world's largest LPG plant.

IHI Corporation

The LPG plant was constructed during a span of thirty years in the industrial zone of Arzew in western Algeria. In 1984 IHI completed the Phase I of the project with an annual production of 4 million tons. Phase II of the project was completed in 1998 with an additional annual production of 2 million tons. On 3rd August 2010, IHI delivered the final phase, Phase III, with an annual production of 3 million tons and achieved completion of the world's largest LPG plant with a total annual production capacity of 9 million tons.

Products2Delivering Clean Energy to People around the WorldIHI's liquefied natural gas (LNG) terminals are hubs connecting global supply and demand of clean energy

IHI Corporation

LNG is a clean energy that plays an important role in city gas supplies and power generation. LNG is delivered from LNG-producing countries to importing countries' LNG terminals, which require specialized technologies to safely handle liquids at cryogenic temperatures. The LNG technologies of the IHI Group support global demands for clean energy.

Products3Slicing Tomatoes Extremely Thinly by Using an Aircraft Engine TechnologyIntroducing SAKON+, the stainless steel kitchen knife that cuts extremely well and features longlasting self-reproducing cutting quality

IHI Corporation

By applying a coating technology used for aircraft engine turbine blades, we have developed a kitchen knife that keeps its cutting quality. This technology uses electric discharge energy to fuse super-hard particles with the stainless steel metal structure so that extremely fine saw teeth (on the order of micrometers) are reproduced on the blade edge when the knife is used.

Products4In-Line Heat Treatment!?Next-generation heat treatment equipment

IHI Machinery and Furnace Co., Ltd.

Conventionally, heat treatment in components manufacturing has been carried out in areas separate from the processing lines. Overturning this common practice, IHI Corporation (IHI) and IHI Machinery and Furnace Co., Ltd. (IMS) have used our unique mist cooling technology to develop in-line heat treatment equipment which can be integrated into processing lines.

Products5Challenging the Global Market with Centrifugal Separation TechnologiesWire Saw Slurry Recycling System, which has a 90% share in the Japanese market, realizes solar cell cost reductions.

IHI Compressor and Machinery Co., Ltd.

While power generation technologies using natural energy have recently been attracting attention, in reality their power generation costs remain high. Our Wire Saw Slurry Recycling System (WSRS) is playing a role in reducing solar cell manufacturing costs as well as the environmental burden of solar technologies.

2. Technologies

Technologies1Turn a Ship on the Spot without Using the Rudder!Z-Peller, a special turnable ship propulsion unit that can turn its propelling force toward any horizontal direction

Niigata Power Systems Co., Ltd.
MINAMI Shunichi

Since we delivered our first unit in 1969, for more than 40 years we have been selling Z-Peller not only in Japan but also overseas. With total production exceeding 3 200 units, this is one of our hit products. This report introduces the Z-Peller and our recent activities.

3. Reports

Reports1The 2011 off the Pacific Coast of Tohoku Earthquake Restoration Could Be the Dawn of a New Phase at Soma Aero-Engine Works : On-Site Capabilities and Innovative Manufacturing Technology Are Key to a Fast Recovery

MATSUMOTO Naoshi

The Soma Site of Aero-Engine & Space Operations (Soma Works 1&2, IHI Castings Co., Ltd., and IHI Jet Service Co., Ltd.) is located in the northern part of Soma City, Fukushima Prefecture. During the 2011 off the Pacific Coast of Tohoku Earthquake, a violent tremor registering six on the Japanese seismic scale occurred and the site suffered the most serious damage among all the sites of the IHI Group. Nevertheless, as a result of the joint restoration efforts of the IHI Group companies, we were able to declare full restoration of the Soma Site in the middle of May 2011. This paper reports on the extent of damage, the process toward restoration, the lessons learned from the earthquake, and our vision for recovery efforts going forward.

4. Technical Papers

Technical Papers1Development of VGS Unit (STEP4) for RHV4 Turbocharger

INOUE Tomohiro, KOBAYASHI Yuuji, MATSUYAMA Yoshimitsu, SAKAI Yasutaka

As emission regulations are increasingly tightened worldwide, the development of fuel-efficient diesel engines that are less burdensome on the environment is progressing. When coupled with engine downsizing, VGS (Variable Geometry System) turbochargers are very effective in reducing diesel engines' fuel consumption and emissions. As further engine downsizing is a major trend, there are strong demands to increase the power density of VGS turbochargers while improving their performance and reliability. To meet such demands, a new VGS turbocharger with improved turbine performance and reliability has been developed. This paper introduces key technologies adopted for the new VGS turbocharger, such as clearance flow control, improved VGS structure, MIM (Metal Injection Molding ; a new technique), and new materials.

Technical Papers2Advanced Development of Pulverized Coal Firing Technologies

TAMURA Masato, WATANABE Shinji, OONO Emi, ITOKAZU Ryuunosuke, KOZAKI Takahiro

IHI has been developing combustion technologies which give very low environmental impact. Various equipment and numerical tools support the development process at each stage. Small- and large-scale test furnaces are used for evaluating actual combustion behaviour. Numerical simulation is also used to assist theoretical understanding. An example of recent development is the realization of very low Air/Coal ratio burners for dried lignite coal firing. Another commercialized burner made it possible to reduce slagging when burning coals which have a low ash melting temperature, such as sub-bituminous coals. The dynamic and static performance of pulverizers, which play a very important role in fuel burning process as pulverized fuel size dominates burnout behaviour, has been improved. This paper gives an outline of recent development of combustion technologies. A large-scale coal combustion test facility which is newly installed is also described.

Technical Papers3Development of Numerical Prediction of Liquid Film Flows on Packing Elements in Absorbers

ISO Yoshiyuki, CHEN Xi

Gas-liquid interfacial flows, such as liquid film flows, are encountered in many industrial processes including absorption and distillation. The present study focuses on the characteristics of the transition between film flow and rivulet flow as the liquid flow rate and the wall surface texture treatments are varied. A threedimensional gas-liquid interfacial flow simulation based on the Volume of Fluid (VOF) model has been developed. A hysteresis of the transition between the film flow and rivulet flow as the liquid flow rate changes has been discovered, which implies that the transition phenomenon depends primarily on the history of the change of the interfacial surface shape. Further study on the texture geometry shows that surface texture treatments can impede liquid channeling and increase the wetted area.

Technical Papers4Remote Monitoring and Maintenance Technology Providing "Anytime, Anywhere" Equipment Support- Development of a Common Remote Monitoring and Maintenance Platform -

HASEGAWA Fumio, HOSOYA Masashi, MIZOUCHI Kentaro

It is necessary for the providers of equipment to give their customers full support, and to provide them with security and safety once the customers start operating the equipment. As doing the above is becoming more important than ever before, a framework is needed that monitors equipment status and maintains it over its entire life cycle. Therefore, a common platform for the construction of remote maintenance systems has been developed, and is the subject of this report.

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