Topic title: SPIRE 1 - 2014: Integrated Process Control
Full title: Cross-sectorial real-time sensing, advanced control and optimisation of batch processes saving energy and raw materials
Aim: The objective of the project is to maximise efficiency of batch processes regarding quality, energy, raw materials, costs.
Concept: Ten cooperation partners will make use of an online, model predictive control of complex batch processes for the production of emulsion polymers, steel, and silicon metal through the application of new sensor technologies, process models and automation tools. The consortium will focus on three different material systems to demonstrate the cross-sectorial applicability of developed sensors, optimization and control methods, with the goal of optimizing product quality, energy consumption, raw materials utilization and production costs of the considered processes.
Full title: Integrated Process Control based on Distributed In-Situ Sensors into Raw Material and Energy Feedstock
Aim: The objective of the DISIRE project is to evolve the existing industrial processes by advancing the Sustainable Process Industry through an overall Resource and Energy efficiency by the technological breakthroughs and concepts of the DISIRE technological platform in the field of Industrial Process Control (IPC).
Concept: With the DISIRE project the properties of the raw materials or product flows will be fully integrated in a unique inline measuring system that will extend the level of knowledge and awareness of the internal dynamics of the undergoing processes taking place during transformation or integration of raw materials in the next levels of production.
Full title: Robust and affordable process control technologies for improving standards and optimising industrial operations
Aim: ProPAT aims to develop novel sensors and analysers for providing measurements on composition, particle size and local bulk properties, as well as more traditional but smart sensors for measuring other process parameters, such as temperature, flowrate, pressure, etc., and integrate them into a versatile global control platform for data acquisition, data processing & mining and User Interface in order to measure properties of process streams and products, accurately and in real-time.
Concept: The PAT initiative focuses on building quality into the product and processes, as well as continuous process improvement. Essentially, integrating on-line measurement and/or modelling of critical quality attributes with automated feedback control of the process parameters impacting these attributes can ensure more efficient control of processes, reducing product variability, which will subsequently reduce the risk of releasing off-spec product into downstream discreet manufacturing, and increase customers’ satisfaction, thereby preventing products being rejected (and discarded) further down the supply chain.
Full title: Integrated Control and Sensing for Sustainable Operation of Flexible Intensified Processes
Aim : The main goal of the CONSENS project is to advance the continuous production of high-value products that meet high quality demands in flexible intensified continuous plants by introducing novel online sensing equipment and closed-loop control of the key product parameters.
Concept: CONSENS will focus on flexible continuous plants, but the results in the areas of sensing, control, and performance monitoring will be transferable to large-scale processes. The research and development is driven by industrial case studies from three different important areas of chemical production: complex organic synthesis, speciality polymers, and formulation of complex liquids.
Full title: in-line Cascade laser spectrometer for process control
Aim: Develop gas analysers beyond the state-of-the-art for fast in-line multi-component monitoring of gas compositions in a process stream and to replace currently employed analysers as gas chromatographs or Fourier-Transform-Infrared spectrometers.
Concept: Extend the established laser-based in-line gas sensing to the mid-infrared “chemical finger print” spectral range for multi-species detection and thus develop wide wavelength range Mid-IR laser gas analysers for fast inline multi-component monitoring of gas compositions. For this, novel semiconductor Mid-IR laser sources will be developed and integrated into in-line gas analysing measurement schemes suported by the advancements of spectroscopic and chemometric data evaluation.
Full title: Flexible Superheated Steam Torrefaction and Grinding of Indigenous Biomass from Remote Rural Sources to Produce Stable Densified Feedstocks for Chemical and Energy Applications
Aim: SteamBio will demonstrate in fields and forests an innovative mobile superheated steam process. This process will convert agro-forestry residues into stable feedstock for biochemical and bioenergy uses.
Concept: The overall SteamBio concept is to create a commercially viable platform that can stabilise biomass materials close to source for subsequent biochemical and bioenergy uses. The platform will be scalable enabling both mobile deployment according to seasonal demands and fixed location for high volume throughputs.
Full title: MefCO2 (Methanol fuel from CO2) - Synthesis of methanol from captured carbon dioxide using surplus electricity.
Aim: To develop an innovative green chemical production technology which contributes significantly to the European objectives of decreasing CO2 emissions and increasing renewable energy usage, thereby improving Europe’s competitiveness in the field.
Concept: The overall concept underpinning the project lies in the utilisation of ordinarily emitted greenhouse gas carbon dioxide and hydrogen, produced from redundant electrical energy into a widely-useable platform chemical, methanol. The technology is being designed in a modular intermediate-scale, with the aim of being able to adapt it to varying plant sizes and gas composition.
Full title: Mobile and Flexible Industrial Processing of Biomass
Aim: MOBILE FLIP aims at developing and demonstrating mobile processes for the treatment of underexploited agro- and forest based biomass resources into products and intermediates. The processes will be evaluated in terms of raw material flexibility, as the biomass resources are typically scattered and seasonal.
Concept: Process concepts have been designed around the key technologies pelletizing, torrefaction, slow pyrolysis, hydrothermal pretreatment and carbonisation.
Topic title: SPIRE – 3-2014: Improved downstream processing of mixtures in process industries
Full title: PROcessing Diluted Aqueous Systems
Aim: Key players of the European process industry from the areas of biotechnology, renewable resources, chemistry, process engineering, equipment supply as well as research organizations collaborate to meet major challenges in white biotechnology and renewables processing via realizing a substantial improvement in downstream processing.
Concept: A re-thinking of downstream process development, the optimization of separation technologies and suitable methodologies for fast-track development of tailored downstream processes are needed to boost the competitiveness of renewable based processes. These challenges are addressed in PRODIAS in order to unlock the potential of the renewable-based product market for the European process industry via significantly decreased production cost, increased productivity and efficiency, faster process development and significantly lower energy consumption.
Full title: Sustainability Toolkit for easY Life-cycle Evaluation
Aim: Project STYLE ultimately seeks to identify and deliver a practical ‘toolkit’ that can be used by future EU projects and industry to assess the value (in sustainability terms) of new technologies and process modifications that seek to make resource and energy efficiency improvements.
1. To identify best practice in sustainability evaluation, across multiple sectors in the process industries and through value chains, via inventory and classification of established approaches.
2. To test and deliver a practical ‘toolkit’ for sustainability evaluation of processes and products, spanning multiple sectors that is easily usable by non-practitioners of sustainability assessments.
3. To determine gaps, through critical assessment and validation, and identify future research needs to improve the ‘toolkit’ and ensure broad applicability across sectors.
Full title: Sustainability assessment methods and tools to support decision-making in the process industries
Aim: The aim of the SAMT project is to review and make recommendations about the most potential methods for evaluating sustainability in the process industry, focusing especially on energy and resource efficiency. SAMT will collect, evaluate and communicate the experiences of leading industrial actors from cement, oil, metal, water, waste and chemical industry, and review the latest scientific developments within the field of sustainability assessment. A central outcome of the project is a strategy for implementing best practices across different sectors of the process industry.
Concept: SAMT is a coordination and support action that promotes cross-sectorial learning and uptake of the most promising tools by conducting case studies, organizing workshops and identifying needs for future R&D and standardization.
Full title: Metrics for Sustainability Assessment in European Process Industries
Aim: The European project MEASURE stands for harmonised cross-sectorial sustainability assessment in the European process industries. The project team will focus on the following main topics:
The outcome will be a roadmap providing recommendations for standards as well as best-practice methods and tools for life cycle based evaluation approaches in process industries and sustainable process design.
Full title: MEthane activation via integrated MEmbrane REactors
Aim: The key objective of the MEMERE project is the design, scale-up and validation of a novel membrane reactor for the direct conversion of methane into C2H4 with integrated air separation.
Concept: The focus of the project is on the air separation through novel MIEC membranes integrated within a reactor operated at high temperature for OCM allowing integration of different process steps in a single multifunctional unit and achieving much higher yields compared with conventional reactor.
Full title: Tandem Electrocatalytic Reactor for Energy Resource Efficiency and Process Intensification
Aim: TERRA aims to develop, from TRL 3 to 5, a tandem electrocatalytic reactor (TER) coupling an oxidation reaction to a reduction one, with thus the great potential advantage of i) saving resources and energy (needed to produce the oxidant and reductants for the two separate reactions), and ii) intensify the process (reduce the nr. of steps, coupling two synthesis processes and especially eliminating those to prepare the oxidation and reduction agents).
Concept: The TER unit may be used in a large field of applications, but will be developed for a specific relevant case: the synthesis of PEF (PolyEthylene Furanoate), a next generation plastic.
Full title: Reactor Optimisation by Membrane enhanced Operation
Aim: Industry and academia have teamed up around a new reactor concept using membranes to carry out chemical synthesis and downstream processing in a single step. A new level of process intensification for catalytic driven and eco-friendly reaction systems is at hand: ROMEO’s aim is to reduce energy consumption by up to 80% and emissions by up to 90% in industrial catalytic gas-phase reactions.
Concept: The new technology concept will be proven by two prominent large volume reactions: a demo plant for hydroformylation will be built while another demo will show the feasibility of the concept for the water-gas shift reaction, in which carbon monoxide and water react to form hydrogen. These processes for bulk chemicals and bio-energy applications have been chosen to demonstrate the high impact of the ROMEO technology in a near industrial environment.
Full title: Process Intensification through Adaptable Catalytic Reactors made by 3D Printing
Aim: The concept of PRINTCR3DIT is to employ 3D printing to boost process intensification in the chemical industries by adapting reactors and structured catalysts to the requirements of the reaction. This manufacturing technique is particularly useful in reactions where diffusion, mixing and/or heat transfer are limitations against reaching higher performance. The utilization of the concept of 3D printing will also reduce the resource utilization of reactor and catalyst manufacture, energy consumed (< 15%) and transportation.
Concept: The methodology will be applied to three markets of fine chemicals, specialty chemicals and fertilizers, ranging from few tons to millions of tons of production per year. This demonstrates the enormous versatility of 3D printing for reactor and catalyst designs that cannot be improved with traditional building and design tools. For all these processes, the challenges to be solved are thermal management, innovative reactor design and flow distribution.
Full title: Enhanced energy and resource Efficiency and Performance in process industry Operations via onsite and cross-sectorial Symbiosis
Aim: The EPOS project brings together 6 global process industries from 6 key relevant sectors: steel, cement, minerals, chemicals, bio-based/life science products and engineering. EPOS's main objective is to enable cross-sectorial Industrial Symbiosis (IS) and provide a wide range of technological and organisational options for making business and operations more efficient, more cost-effective, more competitive and more sustainable across process sectors.
Full title: Human-mimetic approach to the integrated monitoring, management and optimization of a symbiotic cluster of smart production units
Aim: SYMBIOPTIMA will improve European process industry efficiency levels by: (a) developing a crosssectorial energy & resource management platform for intra- and inter-cluster streams, characterized by a holistic model for the definition, life-cycle assessment and business management of a human-mimetic symbiotic cluster. The platform multi-layer architecture integrates process optimization and demand response strategies for the synergetic optimization of energy and resources within the sectors and across value chains. (b) Developing extensive, multi-disciplinary, modular and “plug&play” monitoring and elaboration of all relevant information flows of the symbiotic cluster. (c) Integrating all thermal energy sources, flows and sinks of the cluster into a systemic unified vision, as nodes of smart thermal energy grid. (d) Taking into account disruptive increase of cross-sectorial re-use for particularly impacting waste streams, proposing advanced WASTE2RESOURCE initiatives for PET.
Full title: REE4EU - Integrated high temperature electrolysis (HTE) and Ion Liquid Extraction (ILE) for a strong and independent European Rare Earth Elements Supply Chain.
Aim: The REE4EU project will realize a breakthrough in securing the availability of rare earth elements in Europe, providing for the first time, a cost effective and efficient method of extraction and direct Rare Earth Alloys production from abundantly available in-process and end-of-life rare earth-containing waste streams. REE4EU will also develop urgently required market data on end-of-life rare earth availability and a triple value-chain business case for a new European secondary rare earth alloys production sector.
Full title: New Recovery Processes to produce Rare Earth -Magnesium Alloys of High Performance and Low Cost
Aim: REMAGHIC is focused on contributing to Europe’s rare earth recovery and magnesium recycling technologies, improving the efficiencies of these processes and advancing the technology readiness levels for a new generation of industrial processes that will produce new low cost competitive alloys for a wide variety of sectors across Europe’s manufacturing value chain.
The project motivation lies on the fact that magnesium alloys can offer a significant weight reduction when compared to aluminium alloys. weight reduction is a cross sectorial key design driver, if a superior energy absorption and vibratory behaviour is added, magnesium is promising candidate for future application if some of its drawbacks are overcome, such as its cost, manufacturability problems, corrosion and creep behaviour and low allowable service temperature. Addition of Rare Earth Elements (REE) improves the performance of Mg alloys significantly, though a price increase has to be taken into account. REMAGHIC believes that by investing in recovery and recycling technologies, a new alloying process can be developed to yield low cost Mg+REE alloys. In order to do this, REE that are usually stockpiled (Ce, La) in favour of the most demanded ones (Nd, Dy) will be considered as attractive candidates to lower the price. This list of REE will be completed by other promising candidates found in the literature (Y, Gd, Sm). The project will contribute to reducing the dependency of the supply of critical elements (REE and Mg) on sources exterior to the EU and to solving the REE Balance Problem.
Concept: REMAGHIC will contribute to the penetration of magnesium alloys in important sectors for the European industry (Transport, Energy, Biomedicine); it will foster the work done by Tier1s, and promote the interest of different OEMs on future generations of light structural components of competitive performance (that of primary Mg+REE alloys), low cost (that of primary Mg) and weight reduction (30%).
Full title: Waste Heat Recovery for Power Valorisation with Organic Rankine Cycle Technology in Energy Intensive Industries
Aim: The main objective of the project is to develop solutions to recover the waste heat produced in energetic intensive processes of industrial sectors such as cement, glass, steelmaking and petrochemical and transform it into useful energy. These solutions will be designed after an evaluation of the energetic situation of these four industries and will deal with the development of Waste Heat Recovery Systems (WHRS) based on the Organic Rankine Cycle (ORC) technology. This technology is able to recover and transform the thermal energy of the flue gases of EII into electric power for internal or external use. Furthermore, a WHRS will be developed and tested to recover and transform the thermal energy of the flue gases of EII into mechanical energy for internal use (compressors).
Concept: In order to reach this objective several challenging innovative aspects will have to be approached by the consortium. It is planned to design and develop a multisectorial direct heat exchanger to transfer heat directly from the flue gases to the organic fluid of the ORC system and to develop new heat conductor and anticorrosive materials to be used in parts of the heat exchanger in contact with the flue gases. These aspects will be completed by the design and modelling of a new integrated monitoring and control system for the addressed sectors. The consortium consists of 8 partners from 4 European countries. They cover several relevant sectors of the energy intensive industry, namely cement, steel, glass and petrochemical sectors. The industrial involvement in the project is significant and the project addresses the implementation of a full demonstration of the WHRS for electrical energy generation in one of the industrial partners (HOLCIM) and a semi-validation of the WHRS for air compressors energy supply system at pilot scale.
Full title: Industrial Energy and Environment Efficiency
Aim: Indus3Es project focuses on the development and demonstration in real environment of heat recovery in large industrial systems. The Indus3Es project will develop an innovative Absorption Heat Transformer to recover the low temperature waste heat, nowadays rejected from industries, due to the low quality of heat and the currently used technologies. A single effect heat transformer can increase the temperature of approximately 50% of the waste heat by approximately 50K (depending on available heat sink).”
Full title: Sustainable Production of Industrial Recovered Energy using energy dissipative and storage technologies
Aim: SusPIRE project assimilates in its conception the sustainable energy use challenge described in the European SETPLAN and in SPIRE road map. It addresses its efforts to energy intensive industries and within this segment market to energy recovery from residual heat streams. To achieve this goal a two clearly differentiated working areas will be key aspects of this project. Technology area will include the development of materials and equipment. New Heat Transfer Fluids (HTF) and Phase Change Materials (PCM) will be the base for manufacture high efficiency heat exchangers in terms of energy capture and storage. Two Borehole Thermal Energy Storage (BTE) areas(low temperature range (30-50ºC) and medium (50-80ºC) will support a energy cascading concept where energy will be sequentially used and finally stored for further use or commercialized to third parties. The methodology aspects of this project want to establish a framework to foster the energy commercialization of surplus energy. Living areas, symbiosis with other companies in industrial parks, sports centers will beneficiate from cheaper energy, environmental impact reduction and social acceptance of energy intensive industrial activities. The coordination of the manufacturing and the energy recovery processes will be carried out by means of a smart methodology. A protocol definition software will deploy actions to create best practices in terms of process adjustment and operating instructions. Management concepts based on energy recovery rate as Key Process Indicator (KPI), will be integrated into the decision making mechanism of the company assuring permanent advances in this field of activity in forthcoming years.
Topic title: Waste-1-2014: Moving towards a circular economy through industrial symbiosis.
Full title: Turning waste from steel industry into a valuable low cost feedstock for energy intensive industry
Aim: The main aim of RESLAG is to prove that there are industrial sectors able to make an effective use of the 2.9 Mt/y of landfilled slag, if properly supported by the right technologies. In making this prof, the RESLAG project will also prove that there are other very important environmental benefits coming from an “active” use of the slag in industrial processes, as CO2 saving (up to 970 kt/y from CSP applications, at least 71 kg/ton of produced steel from heat recovery applications), and elimination of negative impacts associated with mining (from the recovery of valuable metals and from the production of ceramic materials).
Concept: To achieve this ambitious goal four large-scale demonstrations to recycle steel slag are considered: Extraction of non-ferrous high added metals; TES for heat recovery applications; TES to increase dispatchability of the CSP plant electricity; Production of innovative refractory ceramic compounds. Overall, the RESLAG project aims at an innovative organizational steel by-products management model able to reach high levels of resource and energy efficiency, which considers a cascade of upgrading processes and a life cycle perspective.
Full title: Implementation of a CirculAr economy Based on Recycled, reused and recovered Indium, Silicon and Silver materials for photovoltaic and other applications
Aim: The main vision of CABRISS project is to develop a circular economy mainly for the photovoltaic, but also for electronic and glass industry. It will consist in the implementation of: (i) recycling technologies to recover In, Ag and Si for the sustainable PV technology and other applications; (ii) a solar cell processing roadmap, which will use Si waste for the high throughput, cost-effective manufacturing of hybrid Si based solar cells and will demonstrate the possibility for the re-usability and recyclability at the end of life of key PV materials. The developed Si solar cells will have the specificity to have a low environmental impact by the implementation of low carbon footprint technologies and as a consequence, the technology will present a low energy payback (about 1 year).
Concept: The originality of the project relates to the cross-sectorial approach associating together different sectors like the Powder Metallurgy (fabrication of Si powder based low cost substrate), the PV industry (innovative PV Cells) and the industry of recycling (hydrometallurgy and pyrometallurgy) with a common aim : make use of recycled waste materials (Si, In and Ag). CABRISS focuses mainly on a photovoltaic production value chain, thus demonstrating the cross-sectorial industrial symbiosis with closed-loop processes.
Full title: Fostering industrial symbiosis for a sustainable resource intensive industry across the extended construction value chain
Aim: The overall objective of FISSAC project is to develop and demonstrate a new paradigm built on an innovative industrial symbiosis model towards a zero waste approach in the resource intensive industries of the construction value chain, tackling harmonized technological and non-technological requirements, leading to material closed-loop processes and moving to a circular economy.
Concept: A methodology and a software platform will be developed in order to implement the innovative industrial symbiosis model in a feasible scenario of industrial symbiosis synergies between industries (steel, aluminium, natural stone, chemical and demolition and construction sectors) and stakeholders in the extended construction value chain. It will guide how to overcome technical barriers and non-technical barriers, as well as standardisation concerns to implement and replicate industrial symbiosis in a local/regional dimension. The ambition of the model will be to be replicated in other regions and other value chains symbiosis scenarios. The model will be applied based on the three sustainability pillars.
Full title: Buildings as Material Banks: Integrating Materials Passports with Reversible Building Design to Optimise Circular Industrial Value Chains
Aim: The aims of BAMB (Buildings as Material Banks) are the prevention of construction and demolition waste, the reduction of virgin resource consumption and the development towards a circular economy through industrial symbiosis, addressing the challenges mentioned in the Work Programme on Climate action, environment, resource efficiency and raw materials. The focus of the project is on building construction and process industries (from architects to raw material suppliers).
Concept: The BAMB-project implements the principles of the waste hierarchy: the prevention of waste, its reuse and recycling. Key is to improve the value of materials used in buildings for recovery. This is achieved by developing and integrating two complementary value adding frameworks, (1) materials passports and (2) reversible building design. These frameworks will be able to change conventional (cradle-to-grave) building design, so that buildings can be transformed to new functions (extending their life span) or disassembled to building components or material feedstock that can be upcycled in new constructions (using materials passports). This way, continuous loops of materials are created while large amounts of waste will be prevented.
Full title: A new circular economy concept: from textile waste towards chemical and textile industries feedstock
Aim: The objective of RESYNTEX is to create a new circular economy concept for the textile and chemical industries. Through industrial symbiosis, it aims to produce secondary raw materials from textile waste.
Concept: The project models a complete value chain from textile waste collection through to new marketable feedstock for the chemical and textile industries. It will focus on the reprocessing of blends and pure components of unwearable textile waste. Moreover, it will improve collection approaches and increase public awareness of and social involvement with the issue of textile waste, enable traceability of waste processing using data aggregation, develop innovative business models for the chemical and textile industries, and demonstrate a complete reprocessing line for basic textile components, including liquid and solid waste treatment.