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Today it is more important than ever to pursue corporate management that contributes to the resolution of global environmental issues that are growing more serious. Hitachi Construction Machinery is working to reduce the environmental impacts of its business operations and contribute to the development of infrastructure that can cope with climate change and other issues through the provision of construction machinery.
The HCM Group’s environmental policy aims to help resolve global environmental issues by undertaking initiatives for longterm value creation in the three scopes of “manufacturing”, “using”, and “taking on challenges”.
In terms of “manufacturing”, we are building a production system for reducing the environmental impacts of not only our own plants, but the facilities of suppliers as well. In terms of “using”, we are helping to lower CO2 emissions using technologies to raise efficiencies such as hybrid designs and information-oriented construction and reduce waste through product recycling. In terms of “taking on challenges”, we aim to expand business opportunities through applications for global environmental issues, the creation of services, and use of open innovation with partners from within and outside the HCM Group.
In FY2016, we established ambitious goals for both 2020 and 2030. These targets ensure that we can contribute to the resolution of environmental issues, including global climate change which is a key element of the SDGs. The HCM Group is steadily implementing measures aimed at these long-term goals as part of its social mission as a manufacturer of construction machinery with global operations.
Under the 2030 CSV Goal, the entire HCM Group is working on various initiatives to reduce environmental impacts from its manufacturing process in order to achieve an improvement rate (compared to 2005) of 40% for the basic unit of energy, 40% for the basic unit of waste, and 50% for the basic unit of water, by the year 2030.
Meanwhile, our five plants in Ibaraki Prefecture (including the KCM Ryugasaki Works) had established a goal to improve the basic unit of energy usage 30% by FY2016 compared to FY2010, which has been achieved by each plant through steady independent activities.
Hitachi Construction Machinery established a three-year plan called the Energy Policy Project in FY2014 and is working on proactive energy conservation initiatives at its five plants in Ibaraki Prefecture (including the KCM Ryugasaki Works) in order to reduce its electricity usage during peak demand and total electricity usage.
In March 2017, we introduced a waste heat recovery system at Hitachinaka Works. The compact heat supply (micro cogeneration) system is expected to reduce electricity usage by 124.6 megawatt hours annually because it supplies electricity to the plant and it is used as a heat source for gas vaporization equipment. Tsuchiura Works has already introduced a system for using the waste heat produced from compressors for indoor heating and a system for using underground water for heating and cooling purposes that it uses for radiators that are a component of excavators. This effective use of unused energy is considered one of our important energy conservation measures and a pillar of our initiatives currently underway.
Also, a trial plan is under consideration in which the heat exchanger introduced at the Kasumigaura Works will be utilized to reuse waste heat from the burn off furnace for hardening processes to increase the strength of iron components that was normally released into the air as a source of heat for the electric heater used for oil distillation equipment.
Under the Energy Policy Project, we are working on initiatives to reduce standby power inside our plants. In FY2016, we introduced the EMilia energy management system, which is one of the core solutions of Hitachi’s Lumada IoT platform. EMilia visualizes the electricity data of each piece of equipment at multiple manufacturing bases in real time, making it possible to analyze and diagnose future operating methods and automatic control methods, which in turn can reduce standby power. In addition, EMilia makes it possible to achieve highly efficient operations because it streamlines energy usage.
Furthermore, our manufacturing subsidiaries in Japan are working to promote energy conservation efforts to cut electricity usage during times of peak demand. The Tsuchiura Works supplies electricity to its Convention Hall using solar power and electric automobile storage batteries recharged at night in order to reduce the amount of electricity used during times of peak demand. As a result, it was able to reduce the amount of electricity used during times of peak demand by upwards of 35%. This initiative forms part of its business continuity plan (BCP) to address electricity supply during emergency situations, such as power outages.
Unit for reusing the waste heat of Tsuchiura Works inside the plant’s air conditioning system
EMilia provides electricity data on each piece of equipment
The HCM Group’s manufacturing bases are promoting zero emission activities. The HCM Group defines zero emissions as a final disposal rate (amount of waste sent to landfills / amount of waste generated) of less than 0.5%. As of FY2016, eight of our manufacturing bases in Japan and three overseas fulfilled the definition of zero emissions.
In addition, we are promoting the use of IT in waste management in order to maintain a high level of compliance with requirements for proper disposal and achieve more efficient waste management operations. Therefore, we are also working on increasing the issuance rate of electronic manifests. Currently, nine of our manufacturing bases in Japan employ electronic manifests 100% of the time.
Constraints on water resources caused by climate change and growing populations worldwide have become a global issue. The HCM Group quantifies the water stress level for each of its manufacturing bases and is working to utilize water resources more efficiently and reduce its water usage.
For example, PT. Hitachi Construction Machinery Indonesia, which is located in an area of high risk in terms of water, introduced a reverse osmosis (RO) membrane water filtration system in FY2012. By removing minerals that can inhibit electro-deposition paints, PT. Hitachi Construction Machinery Indonesia is able to stabilize paint quality and reduce its water usage. Additionally, in FY2016 PT. Hitachi Construction Machinery Indonesia reduced its basic unit of water usage by about 22% compared to the previous year by reusing water that had already been used once with a water recycling system.
Construction machinery plays a critical role in the development of social infrastructure, including railways, water supply and sewage, and the power grid. At the same time, measures to address global warming, including reducing GHG emissions caused by the use of hydraulic excavators, are a pressing issue for construction work sites.
Hitachi Construction Machinery’s ZH200-5B hybrid hydraulic excavator is a new next-generation machine that offers the same performance as the standard ZX200-5B while consuming less fuel. The ZH200-5B regenerates rotational energy when the electric motor’s swing device decelerates. This energy is then Hitachi Construction Machinery is working to further advance its conventional hydraulic technologies as well as develop electricity-powered hydraulic excavators by expanding the use of electronic control technologies for which reliability has improved in recent years. Electricity-powered excavators do not have an engine and instead operate using a commercial power source. Therefore, they do not produce exhaust or CO2 emissions at construction sites, nor do they have used engine oil or oil filters, making them environmentally friendly. Furthermore, the CO2 emissions of a stored in a capacitor and used to assist the hydraulic motor during acceleration. The electric assist motor adjusts the electrical energy in the capacitor by connecting with the hydraulic pump to generate electricity or using the electricity as auxiliary energy. These mechanisms allow the ZH200-5B to reduce its fuel consumption by around 30% compared to the ZX200-3.
The energy-saving hydraulic system is another feature that greatly contributes to reduced fuel consumption. The addition of an electronic control to the three-pump and three-valve hydraulic system makes it possible to control power more smoothly, reducing loss from the hydraulic pressure in the process.
Earth Create Co., Ltd. (Oda District, Okayama Prefecture)
Earth Create engages in a wide range of businesses, including sales of pit sand and general sand, soil recycling, demolition work, and intermediate processing, among others. Every year the company replaces between four or five of its construction machines with new models. This time around, the company required improved fuel economy for the new models it purchased. Prior the the company selecting its next machines, we held a demonstration test using the standard ZX200-3 and ZX200-5B, which the company currently uses, along with Hitachi Construction Machinery’s hybrid ZH200-5B and a competitor’s hybrid excavator.
One day was dedicated to each machine when conducting the demonstrations. Actual data indicated that the ZH200-5B was the most fuel efficient, and that this model can carry out the same workload as previous machines while using around 30% less fuel. After witnessing this performance, Earth Create decided to purchase three units of ZH200-5B. Mr. Akitoshi Yokobatake, an operator that works for Earth Create, noted, “The ZH200-5B always re-starts in eco mode, regardless of which mode was used the previous time. This feature is very helpful in terms of reducing fuel consumption.”
During the demonstration, work was always carried out in eco mode. Nevertheless, operators shared feedback that included, “Eco mode was more than enough for the work load and it made fine work easier.”
Wujiang Municipal Water Construction Co., Ltd. (Wujiang City, Jiangsu Province)
Wujiang Municipal Water Construction Co., Ltd. was established in 2001 to engage in water gate and bridge construction work. Today, the company operates a fleet of six hydraulic excavators. When updating its equipment in 2016, the company decided to introduce one ZH200-5A, the latest version of our hybrid hydraulic excavator. After performing 500 hours of work over a three-month period, the company found that compared to its previous ZX200-3, the ZH200-5A used about 30% less fuel, greatly lowering work costs.
Wujiang Municipal Water Construction Co., Ltd. noted, “We have been using Hitachi Construction Machinery’s reliable machines for over a decade. The ZH200-5A is a very appealing machine as it offers excellence in operation and greater efficiency, in addition to the fact it consumes less fuel. The ergonomic design of the operator’s seat is also excellent as it has reduced operator fatigue.”
The company also applauds the ZH200-5A’s longer warranty compared to previous models and our range of after-sales services.
Hitachi Construction Machinery is working to further advance its conventional hydraulic technologies as well as develop electricity-powered hydraulic excavators by expanding the use of electronic control technologies for which reliability has improved in recent years.
Electricity-powered excavators do not have an engine and instead operate using a commercial power source. Therefore, they do not produce exhaust or CO2 emissions at construction sites, nor do they have used engine oil or oil filters, making them environmentally friendly. Furthermore, the CO2 emissions of a commercial power source are estimated to be around 10 to 25%* less than an engine-type model. At the same time, electricity-powered excavators also offer the benefits of improved work environment, lower running costs, and easier maintenance. In addition to hydraulic excavators, the HCM Group offers a wide variety of machines, trolley-type dump trucks, and recycling machines, among others.
* Calculated using the actual CO2 conversion coefficient for fiscal (0.559~0.500kg-CO2/kwh [Kanto]).
Suzuyu Co., Ltd. (Ishinomaki City, Miyagi Prefecture)
Suzuyu is a major regional metal recycling company that collects, sorts, and cuts metal scrap mainly in Miyagi Prefecture. Conventionally, the company used several 20-ton hydraulic excavators with grapple attachment to load, sort and break apart metal scrap. Until now, work had to stop temporarily whenever a truck arrived at the yard in order to move the hydraulic excavator to the truck. Only after this process was loading restarted. As a result, the company decided to introduce our electricity-powered fixed high post material handling excavator that can operate and rotate from high positions, in order to make operations more efficient and safer.
After introducing this machine, Suzuyu can now carry out scrap processing work with a single machine, which is powered by electricity, resulting in less noise and no exhaust. This has significantly improved the environment around the company’s yard. This machine also offers significant cost savings in terms of maintenance compared to excavators with an engine.
The electricity-powered material handling excavator in action. High expectations for significant reductions in exhaust and CO2 emissions