Efficient Energy Integrated Solutions for Manufacturing Industries Igor Bulatov
The University of Manchester, UK
LOCIMAP/EFENIS joint event, Leverkusen, Germany, 15-16 July 2014
Europe 2020 Strategy Priorities: – Smart growth – developing an economy based on knowledge and innovation – Sustainable growth – promoting a more resource efficient, greener and economy more competitive economy. – Inclusive growth – fostering a highemployment economy delivering economic, social and territorial cohesion COMMUNICATION FROM THE COMMISSION EUROPE 2020 A strategy for smart, sustainable and inclusive growth Brussels, 3.3.2010 COM(2010) 2020
Europe 2020 Strategy Priorities: – Smart growth – developing an economy based on knowledge and innovation – Sustainable growth – promoting a more resource efficient, greener and economy more competitive economy. – Inclusive growth – fostering a highemployment economy delivering economic, social and territorial cohesion COMMUNICATION FROM THE COMMISSION EUROPE 2020 A strategy for smart, sustainable and inclusive growth Brussels, 3.3.2010 COM(2010) 2020
Europe 2020 Strategy Targets: • 75 % of the population aged 20-64 should be employed. • 3% of the EU's GDP should be invested in R&D. • The "20/20/20" climate/energy targets should be met (including an increase to 30% of emissions reduction if the conditions are right). • The share of early school leavers should be under 10% and at least 40% of the younger generation should have a tertiary degree. • 20 million less people should be at risk of poverty. COMMUNICATION FROM THE COMMISSION EUROPE 2020 A strategy for smart, sustainable and inclusive growth Brussels, 3.3.2010 COM(2010) 2020
Europe 2020 Strategy Targets: • The "20/20/20" climate/energy targets should be met (including an increase to 30% of emissions reduction if the conditions are right). To reduce greenhouse gas emissions by at least 20 % compared to 1990 levels or by 30 %, if the conditions are right; increase the share of renewable energy sources in our final energy consumption to 20 %; and a 20 % increase in energy efficiency COMMUNICATION FROM THE COMMISSION EUROPE 2020 A strategy for smart, sustainable and inclusive growth Brussels, 3.3.2010 COM(2010) 2020
Seven Flagship Initiatives "Innovation Union"
"European platform against poverty"
"An agenda for new skills and jobs"
"An industrial policy for the globalisation era"
"Youth on the move"
"A digital agenda for Europe"
"Resource efficient Europe"
Seven Flagship Initiatives "Innovation Union"
"European platform against poverty"
"An agenda for new skills and jobs"
“An "An industrial policy for the globalisation era"
"Youth on the move"
"A digital agenda for Europe"
"Resource efficient Europe"
“20-20-20” current status: not on track So far the EU is not on track to meet its 20% energy saving target by 2020 1900
Primary energy consumption*, Mtoe
1850 1800
Projections from 2007 Projections from 2009 20% Energy saving objective
Business as usual
1750 1700
Current status
1650
Gap
1600 1550
20% objective
1500 1450 1400 2005
2010
* Gross inland consumption less non-energy uses
2015
2020
“20-20-20” current status: not on track With current status, dependence on energy imports is likely to grow « Business as usual » scenario based on 2009 figures 100%
Oil
80% 60%
Gas 40% 20%
2005 2008 2020
2030
If nothing changes, Europe’s dependence on fossil fuel imports will rise by 2030
“20-20-20” current status: not on track
Meeting all three “20-20-20 by 2020” goals becomes a matter of urgency
“20-20-20” current status: not on track
Despite all recent efforts within EU there are still considerable economic energy saving potentials to be tapped
EFENIS positioning within EC efforts Public sector
Indicative national EE targets
Sectoral measures
EC efforts
Monitoring and reporting
Households
Services
General measures promoting EE
Energy supply
Industry
EFENIS Project Overview • The EFENIS extended total site energy management including industrial and residential areas is beyond state-of-the art • The Project has a potential to increase industry competitiveness & deliver massive CO2 reduction before 2020 • Consortium beyond the EU - interesting for global outreach
• Budget: ca €3.9m of EU funding plus €3.2m of own resources • Started : 1 August 2012
• Duration: 36 months
Partners • 17 Partners • 11 Countries, including China, South Korea and Ukraine
10
Partners Industry
SMEs Academia and Research
• Bayer Technology Services • MOL Hungarian Oil and Gas Company • Vestas Aircoil • IPLOM - Industria Piemontese Lavorazione Oli Minerali – Piedmontese Mineral Oil Processing Factory • ENN Science and Technology Development Co. Ltd. • Spivdruzhnist-T • ESTIA Consulting and Engineering • The University of Manchester (Coordinator) • VTT Technical Research Centre of Finland • University of Pannonia • University of Paderborn • Aristotle University of Thessaloniki • Genoa University • University of Maribor • Hanyang University • Alexandra Instituttet A/S • Technical University Hamburg Harburg
Objectives The overall objective of EFENIS is to facilitate and accelerate the move to low carbon manufacturing processes and site management by deployment and demonstration of innovative energy management systems and enabling efficiency technologies
The Project Methodology State-of-the-Art Utility Boiler
Steam turbine
W PO W E R
Fu e l
Gas turbine Air W
Fu e l
C O ND
HI G H
(a) Total Site generic representation of a site utility system
P R ES S
M ED . P RE S S LO W
Process Boiler
PR ESS
Process Boiler Fu e l
Fu e l
PR O C ESS A
PR O C ESS B
PR O C ESS C C O OL IN G W ATER
R EFR IG ER ATIO N
T Site heat source profile
Q rec
Steam levels which can be generated/used
VHP HP
(b) Total Site Targeting
Site Pinch HP
MP IP
MP IP
LP Site heat
LP
sink profile
CW
Site profiles shifted together to provide the site utility requirement targets
H
Total Site heat and power consumption and generation targets
The Project Methodology (cont.) Replaced by fundamentally upgraded total site analysis
Waste heat recovery
Local energy integration • Operability • Controllability • Carbon footprint • Emission trading • Implementability • Acceptability • RAM • LCA • Societal values
A fundamentallyupgraded total site analysis and integration with clean carbon management
Total Site Integration
Heat transfer
Carbon capture
Work Contents Demonstration
Decision-supporting Methodology
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents – Total site integration • Total site targeting and process integration (new tools)
Work Contents – Total site integration • Total site targeting and process integration (new tools) • Novel boiler model
Work Contents – Total site integration • Total site targeting and process integration (new tools) • Novel boiler model
• Novel steam turbine model
Work Contents – Total site integration • Total site targeting and process integration (new tools) • Novel boiler model
• Novel steam turbine model
Specify Equipment Failure Information
Specify Operating Strategy
• Integration of reliability with the utility systems
Determine All System States
Steady State Optimisation
Markov Analysis
Obtain the probability of each state
Obji
Pi
Obtain the objective function of each state
Re-organise the System Objective Function
Reliability considered
Work Contents – Total site integration • Total site targeting and process integration (new tools) • Novel boiler model
• Novel steam turbine model
T
• Integration of reliability with the utility systems
HP MP
MP LP
• Low temperature waste heat CW
LP
Low Temperature Waste Heat Recovery
H
Work Contents – Total site integration • Total site targeting and process integration (new tools) • Novel boiler model
• Novel steam turbine model • Integration of reliability with the utility systems • Low temperature waste heat • Enhanced Total Site targeting with energy storage
Adding the storage option
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Energy Integration Manager tool In investment projects for structural modifications of individual process units, updating of those process models is obligatory as a very early planning step. An efficient and sustainable workflow for assuring a long term validity of total site analysis results has to be based on a generic interface between process models and the EFENIS optimisation framework.
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents – Carbon Management • Total Site modelling and optimisation of CO2 capture by absorption
Work Contents – Carbon Management • Total Site modelling and optimisation of CO2 capture by absorption • Modelling and optimisation of materials and processes for CO2 capture from flue gas by PSA-VSA adsorption
Work Contents – Carbon Management • Total Site modelling and optimisation of CO2 capture by absorption • Modelling and optimisation of materials and processes for CO2 capture from flue gas by PSA-VSA adsorption • System architecture and system integration
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents – Waste Heat Recovery Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents – Waste Heat Recovery T
• Identification of waste heat recovery potentials
HP MP
MP LP
CW
LP
Low Temperature Waste Heat Recovery
H
Work Contents – Waste Heat Recovery • Identification of waste heat recovery potentials
• Technology selections and design for waste heat recovery • Improving retrofitability and implementability
Absorption refrigeration cycle
Heat pump cycle
ORC with Regenerator
Work Contents – Waste Heat Recovery • Identification of waste heat recovery potentials
• Technology selections and design for waste heat recovery
Twisted-tape inserts
• Improving retrofitability and implementability Coiled wire inserts
• Selection of heat transfer enhancement techniques for total site integration • Advanced heat exchangers (modelling and optimisation)
hiTRAN®
Plate heat exchanger
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents – CHP & District Heating Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents – CHP & District Heating EFENIS beyond-plant-boundary concept Plant A
Plant B
Plant C
Total site
Individual plant interactions with the utility system Total site and its utility system
Interactions between the total site energy management and the local energy network
Work Contents Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents – Demonstration Demonstration
Decision-supporting Methodology WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
Work Contents – Demonstration • Analysis of the as-is state of the site • Perform the ‘EFENIS’ total site analysis • Comparison of results • Check transferability to other sites • Retrofit upgrade
Chemical Industry
Refinery
Coal-to-liquids
Bayer (DE)
MOL (HU)
ENN (PRC)
Refinery (District heating network) IPLOM (IT)
Work Contents Demonstration
Decision-supporting Methodology
WP1 Total site integration and optimisation
WP11 Energy Integration Manager tool
On-going
WP5: Chemicals
WP6: Oil Refinery
WP7: Coal-toChemicals
WP2 Total Site carbon management
WP4 Integration with CHP and distr.heating
WP3 Total Site waste heat recovery with intensified heat transfer
Enabling Technologies
WP9 Technology transfer
WP10 Project Management
WP8: CHP and Distr. Heating
On-going
Intermediate results • Graphical targeting tool and design procedures for total site energy management • Most of software modules (targeting tool, data reconciliation tool, etc) developed • Conceptual insights analysed and design guidelines produced for the management of site utility system considering operability and RAM • Improved process models for heat and mass balances developed and tested • Conceptual insights, model development and design procedures for integrated cooling water systems with other site utilities • Rigorous reactive absorption model developed and verified • Waste heat technologies selected • Current four total site studies carried out using conventional methodologies • Four total sites evaluated using the novel integration methodology
Intermediate results www.efenis.eu
EFENIS in Political Context According to the Commission: • The Project is timely and topical • EFENIS integrated approach is also relevant for EU Smart Cities and Communities Innovation Partnership
• EFENIS complements EU-Smart Cities network • EFENIS complements LOCIMAP EU project on industrial parks energy consumption optimisation
Acknowledgement
The financial support from FP7-ENERGY-2011-2 Grant Number 296003 “Efficient Energy Integrated Solutions for Manufacturing Industries - EFENIS” is gratefully acknowledged
Any suggestion on further collaboration is most welcome Contact details: Dr Igor Bulatov The University of Manchester, Manchester, UK Tel.: + 44 (0)161 306 4389 Fax: + 44 (0)161 236 7439 Email:
[email protected] www.efenis.eu
