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Material

Mass Production and Application of Vertically Aligned Carbon Nanotubes (VA-CNTs)

Carbon nanotubes (CNTs) are nanometer-sized materials in the form of graphene sheets rolled into cylinders. They show excellent properties and offer potential for various applications.
Hitachi Zosen is developing low-cost mass production technologies for VA-CNTs based on our elemental technologies. Specifically, our development efforts focus on the production of A4 size VA-CNT sheets, substrates composed of an alignment of A4 size VA-CNT sheets, and the continuous production of VA-CNTs using roll-to-roll techniques.
We expect various applications, e.g., conductive electrodes and products utilizing the excellent thermal conductivity, chemical stability, and unique fine tube structure of VA-CNTs. Through open innovation, we are pursuing product evaluation and joint development with makers and research institutes in related fields.

<Nano-material Development Project Department>


Properties and applications of VA-CNT

The Device for Nanocluster Formation using Pulsed Laser Beam


Fig.1 SEM image of Cu nanoclusters

A cluster is an aggregate of several to several thousand similar atoms or molecules, and is also known as a nanocluster due to its extremely small size and diameter in the order of nanometers (Fig. 1).

Substances with such small particles exhibit a different effect to their larger counterparts known as a quantum size effect, and this is expected to play an important part in next-generation material technologies within the energy, environment, display, IT and biotechnology fields.


Fig.2 The first device for nanocluster formation using pulsed laser beam

We have succeeded in commercializing a device capable of generating nanoclusters from various materials such as metal and ceramics (Fig. 2), and have delivered the first unit to a research institute with which we are jointly conducting verification tests.

This device is capable of forming high-quality composite material nanoclusters via irradiation of two types of materials with a high-powered laser. The resulting composite nanoclusters are used as photocatalysts, battery materials and hydrogen absorbing materials so we are focusing our marketing efforts on manufacturers with a need for such special materials.

<Fundamental Research Group>

Hitz Dehydration System (HDS®) by Zeolite Membrane Element

HDS is a dehydration system which utilizes Hitachi Zosen's new zeolite dehydration membrane element.
The system is capable of efficiently dehydrating and refining various organic solvents including bio-ethanol. The Hitz zeolite membrane element features outstanding durability resulting from its seal-less integrated structure, while the optimized membrane microstructure exercises superior dehydration capabilities over conventional dehydration membranes. In addition, the membrane assembly or module employs a highly reliable and easy-to-maintain modular structure.
As a result, HDS® is a compact and energy-efficient system which consumes by 20-30% less power than a adsorption dehydration which is generally called as Molecular Sieve system. Global demand for bio-ethanol, particularly from the United States and Brazil, is set to rise amidst efforts for reducing CO2 emissions and for the search for alternative energies to replace fossil fuels.

Hitachi Zosen has been engaged for developing and construction for the HDSR for use in the biomass ethanol production process as well as diversifying our membrane product lineup and developing new applications including highly-efficient chemical production systems.

<Membrane Project, Development Project Department>

Hitz Dehydration System

OLED Manufacturing Equipment


Organic layer deposition equipment
for G3 (600x700mm) substrates

Organic light emitting diodes (OLEDs) are composed of multiple organic layers several tens of nanometers thick interposed between an anode and a cathode. These organic layers emit light when a direct current is applied between the anode and cathode. Our OLED manufacturing equipment utilizes a proprietary ‘planar evaporation source’ in the organic layer deposition process to deliver a number of features such as:

(1)the ability to change the vapor deposition orientation to face up, down or sideways;
(2)the ability to achieve high material utilization of 20% or more on a G2 substrate and 30% or more on a G3 substrate;
(3)the ability to facilitate the supply of organic materials by providing a material heating component outside of the vacuum chamber;
(4)the ability to maintain a stable vapor deposition rate during film deposition by providing a valve control mechanism;
(5)minimal particle (waste) emission accompanying substrate or evaporation source movement through the use of a static film deposition method.

Hitachi Zosen Corporation has participated in the New Energy and Industrial Technology Development Organization (NEDO)’s "Development of Fundamental Technologies for Next-generation Large-screen OLED Displays" project (a "Green-IT Project") since July 2008, and is aiming to develop OLED film deposition equipment capable of being adapted to substrate sizes of G6 (1500x1850mm) and above.

<OLED Project, Development Project Department>

Organic light emitting diodes (OLEDs) are composed of multiple organic layers several tens of nanometers thick interposed between an anode and a cathode. These organic layers emit light when a direct current is applied between the anode and cathode. Our OLED manufacturing equipment utilizes a proprietary ‘planar evaporation source’ in the organic layer deposition process to deliver a number of features such as:

(1)the ability to change the vapor deposition orientation to face up, down or sideways;
(2)the ability to achieve high material utilization of 20% or more on a G2 substrate and 30% or more on a G3 substrate;
(3)the ability to facilitate the supply of organic materials by providing a material heating component outside of the vacuum chamber;
(4)the ability to maintain a stable vapor deposition rate during film deposition by providing a valve control mechanism;
(5)minimal particle (waste) emission accompanying substrate or evaporation source movement through the use of a static film deposition method.

Hitachi Zosen Corporation has participated in the New Energy and Industrial Technology Development Organization (NEDO)’s "Development of Fundamental Technologies for Next-generation Large-screen OLED Displays" project (a "Green-IT Project") since July 2008, and is aiming to develop OLED film deposition equipment capable of being adapted to substrate sizes of G6 (1500x1850mm) and above.

<OLED Project, Development Project Department>

Development of The High-Purity Type Electrostatic Separator

There are two main types of plastic recycling: material recycling and thermal recycling. Although various forms of sorting technologies have been successfully developed and commercialized, there is as yet no practical high-volume dry process for separating plastics with similar specific gravity.
Hitachi Zosen has developed the separation process designed for plastics with 99% + purity. Based on electrostatic separator technology, the process was awarded some academic prizes, and that Patent (No. 3746412) was awarded the 2010 Osaka Excellence in Invention Prize.
This electrostatic separator which enables high-purity separation utilizes the electrification characteristics generated by friction on different types of plastics, in combination with the centrifugal force acting on plastics charged by a rotating drum electrode.
The standard model ES-30F separator from Hitachi Zosen features a compact design (1.3m W x 1.0m D x 2.3m H) and power consumption of 1kW, with processing capacity of maximum 300 kg/h.

<Product Development Project Department>


Fig.1
Basic principle of the high purity electrostatic separator

Fig.2
Model ES-30F separator(Class 300kg/h)
· Size: 1.3m(W) x 1.0m(D) x 2.3m(H)
· Capacity: Max 300kg/h
· Power consumption: Approx. 1kW(AC 100V)

RESEARCH & DEVELOPMENT