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[Image] Electric Energy Losses are Reduced by up to 40% Every Day. *1 Operation with Less Environmental Impact.

Amorphous core transformers reduce the impact on the global environment. The transformers use an amorphous alloy in their iron core which improves electrical characteristics and significantly reduces energy loss. The savings are equivalent to the amount of CO2 absorbed annually by about 370 cedar trees *2. This high level of energy conservation contributes to reducing CO2 emissions.

Based on a comparison between the Super Amorphous Zero P Series (three-phase, 1,000 kVA 50 Hz, equivalent load factor of 50%) and Hitachi “Top Runner transformers 2014”.
The amount of CO2 that one cedar tree can absorb each year is about 14 kg. CO2 emission coefficient is based on the coefficient(0.497kg-CO2/kWh) of Japan in 2011 released from International Energy Agency.

What is an amorphous core transformer?

[Image] - High Efficiency & Low Energy Loss  - Adoption of Amorphous Alloy!

The role of a transformer is to convert high-voltage electricity supplied from a power station into lower-voltage electricity for safe use. Transformers operate 24 hours a day, seven days a week during which time they undergo constant losses of 2 to 4% of the electricity that passes through them. This loss is divided into two different categories: load losses caused by the load on the transformer during the use of electricity and no-load losses (standby electricity) caused regardless of whether a load is present. Amorphous core transformers significantly reduce no-load losses by using an amorphous alloy *3 for the iron core, which the transformer windings that carry the electricity are coiled.
Hitachi Industrial Equipment Systems Co., Ltd. is a manufacturer of amorphous core transformers in Japan with an integrated production line that extends from iron core processing through to assembly that requires advanced processing techniques.

[Image] from left, Super Amorphous Zero P Series,Super Amorphous Zero MS Series,Super Amorphous Zero S Series,Super Amorphous Zero C Series,Super Amorphous Zero MC Series.

[Image] Comparison of Transformer Characteristics (for three-phase, 500 kVA, 50 kHz transformers, in comparison with existing Hitachi products)

Load loss may vary depending on the extent of the load, while no-load loss is constant. For example, when a factory begins production, load loss depends on the variable load, whereas no-load losses are constant regardless of the load. The key to reducing energy loss lies in how to reduce the no-load losses.

What is an amorphous alloy?
Metals have a crystalline structure with an orderly arrangement of atoms. A metal in a liquid state at a high temperature can retain its liquid structure upon solidifying if it is cooled rapidly. The resulting non-crystalline alloy has a random arrangement of crystals and is called an amorphous alloy. Amorphous alloys have excellent electrical characteristics, but require advanced techniques for machining.

[Image] Amorphous Alloy conception diagram

World-Class Level of Energy Conservation!

Image: -At a load factor of 50%- Approximately 40% reduction in total losses. Annual reduction of approximately 5.1 tons in CO2 emissions

Transformers are used for a long period of time, with an average life span of 25 to 30 years. Therefore, it is important to minimize the no-load losses that are incurred for as long as the transformer is operating. The Super Amorphous X SP Series have reduced no-load loss to about a half of the losses in conventional transformers*1. As a result, up to about 40% of total losses are eliminated in comparison to the Top Runner standards*4 specified under the Energy Conservation Act*1 Amorphous transformers will contribute to an annual reduction of about 5.1 tons of CO2 emissions. This is equivalent to the annual CO2 absorption by up to about 370 cedar trees*2.

The world's first Clean Development Mechanism (CDM)*5 for power transmission and distribution networks, based on amorphous core transformers, has been approved by the United Nations. This is a world-class level of energy Conservation. Hitachi will continue contributing to [counter] measures preventing global warming.

What are the Top Runner standards?
Transformers are designated pieces of equipment under the Energy Conservation Act (law concerning the rational use of energy) which stipulate reference values (Top Runner standards) for evaluating energy efficiency (total losses) and also the date of application.
What is the Clean Development Mechanism (CDM)?
The Clean Development Mechanism (CDM) is an arrangement allowing industrialized countries to provide financial or technical support to developing countries in projects that reduce greenhouse gases, as an alternative to more expensive methods in their own homeland.

Image: Comparison of Hitachi Top-Runner Products Expressed in Terms of Number of Cedar Trees (One cedar tree can absorb about 14 kg of CO2 per year)

Image: Significant Reduction in CO2 Emissions

Manufacturing to Reduce CO2 Emissions

Image: Nakajo Works, Hitachi Industrial Equipment Systems Co., Ltd.
Nakajo Works, Hitachi Industrial Equipment Systems Co., Ltd.

Image:  Reviewing the use of energy, Promote energy conservation in the field

The transformers used for receiving and distributing high-voltage power produced at Hitachi Industrial Equipment Systems Co., Ltd.'s Nakajo Works. The site, which is located in a rich natural environment, surrounded by pine groves facing the sea (in Tainai City, Niigata Prefecture), also produces switches, air cleaners and other equipment.

This factory was an early adopter of energy-conservation equipment and systems, and works aggressively to reduce CO2 emissions. The site makes continuous improvements and efforts to rationalize energy use, by designating the keywords "End", "Repair" and "Change" for improvement and identification of waste. In recognition of its performance, Nakajo Works is a model factory for energy conservation and has twice received governmental commendations (in 1979 and 2005) for outstanding energy management.

[Image] Energy Conservation Based on Keywords for Improvement and Identifying Waste

For example, electric power losses were minimized by the introduction of Super Amorphous Transformers. The number of transformers was successfully decreased from 48 to 33 by rearranging the layout based on the realization of actual energy use. These reductions produced energy conservation benefits totaling 503 MWh. Real-time power usage examination facilitated a number of changes including improvements to production and air conditioning equipment, a switch to clean energy (gas) and a lighting upgrade. Nakajo Works is achieving its goal of manufacturing in a way that reduces the impact on the environment with measures that include the introduction of test equipment for energy conservation and replacing or improving the efficiency of its plant with a target of 60% by 2010 (relative to the level in 1990).

Image: Energy Conservation Achieved by Upgrade to Super Amorphous Transformers (a case of use in Nakajo Works in 1999 leading in the industry)

Record of Awards

Amorphous transformer have reduced stand-by power, and will contribute to reduction of CO2 emissions and preventing global warming. Hitachi super energy-saving transformer, "Super Amorphous XSH series" won the several prizes.

  • 59st Electrical Construction Equipment and Materials Fair (2011)"Award of Minister of Land, Infrastructure and Transport".
  • Eco-Products Awards (2011)"The Grand Prize for Energy Saving Product".
  • Energy Conservation Grand Prize for excellent energy conservation equipment (2012)"Director General Prize of Agency of Natural Resources and Energy".
The awards and standards referred to in the text apply to Japan.

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