%% Swiss%Competence%Center%for%Energy%Research% … · 2015. 4. 17. · Swiss$CompetenceCenter$for$Energy$Research$ $ ©$SCCER$EIP,$March$2015$ $ Page$2$/18$ Tableof%Contents$ 0 INTRODUCTION

Swiss Competence Center for Energy Research

© SCCER EIP, March 2015 Page 1 / 18

Swiss Competence Center for Energy Research Efficiency of Industrial Processes Innovation Roadmap Date: 31/03/15



Table of Contents

0 INTRODUCTION ..................................................................................................... 3

1 WP1 MONITORING AND IMPLEMENTATION .................................................... 4

2 WP2 ENERGY EFFICIENCY (DIRECT) ..................................................................... 8

3 WP3 PROCESS EFFICIENCY (INDIRECT) ............................................................. 11

4 WP4 PLANT-WIDE INTEGRATION ..................................................................... 15

5 APPENDIX ............................................................................................................. 18

Preface The innovation roadmap of the SCCER EIP is based on discussions during the roadmap workshop of research partners and industry partners of the SCCER on 1 December 2014, followed by numerous bilateral revisions and an Executive Committee meeting on 18 March 2015 to consolidate the contri-butions. Main contributions were made by:

• Research partners: ETH Zurich, EPF Lausanne, Hochschule Luzern, Interstaatliche Hochschule für Technik Buchs, Hochschule für Technik Rapperswil and University of Geneva

• Industry partners: ABB Schweiz AG, AIRLIGHT ENERGY Manufacturing SA, Celeroton AG, Energie-Agentur der Wirtschaft, Flumroc AG, INEOS AG, Lenum AG, Lonza AG, SusChem Switzerland and Zero-C SA



0 Introduction Switzerland is an example of a modern industrialised society characterized by an economic wealth mainly due to its innovation capacity. The country must however pay a price for the related agricultur-al, industrial and tertiary activities in the form of direct and indirect energy consumption estimated to 91’0000 TeraJoules (TJ) in 2010 according to the Swiss Federal Office of Energy, comprising 215’000 TJ of electricity (56.5% hydropower, 38% nuclear power) and 616’190 TJ of fossil fuels;; the share of renewables (excluding hydro-power) is only 2.4% (15’000 TJ) of the overall national energy demand to which 40'000 TJ due to wood energy must be added. The simultaneous implementation of the Swiss Federal Council’s “Energy Strategy 2050”, triggered in 2011 by the Fukushima-Daiichi nuclear accident and the next stage of the Swiss climate policy aiming at a drastic reduction of the country’s greenhouse gas emissions are key-challenges for the overall energy sector:

• The first one implies a phase-out of nuclear energy by 2035, currently generating one third of the national electricity demand, through stringent energy efficiency measures in the overall energy sector and the promotion of renewable energy;;

• The second one implies a 20-30% reduction of the country’s CO2 emissions from the 1990 level by the year 2020, according to the revised federal CO2 Act, and a possible 50-80% re-duction by 2050.

The industrial sector in Switzerland is responsible for around 20% of the energy consumption. The Swiss Federal Office of Energy reveals that there is a saving potential of 20-40% in absolute terms (PJ) until 2050. The vision of the Swiss Competence Center for Energy Research on Efficiency of Industrial Processes (SCCER-EIP) is to enhance the energy efficiency of the Swiss industry. Research and development capacities have to be increased to develop advanced concepts and innovations, enabling the industry sector to reach their energy efficiency targets according to the “Energy Strategy 2050” for Switzerland and to improve their competitiveness. The SCCER-EIP will offer the required increase of research capacities and will furthermore provide the framework to establish a national interdisciplinary competence center based on selected partners from the ETH-domain (ETHZ, EPFL), Universities (UNIGE), Universities of Applied Science (FHO, HSLU) as well as several industry partners. New concepts and processes, innovations and demonstration facilities are developed, tested and evaluated. R&D addresses systems at different scales, from individual process units to integrated processes up to integrated sites connected with their surroundings, with a focus on technological innovation but also addressing organizational and managerial aspects.



1 WP1 Monitoring and Implementation

1.1 Motivation / Relevance for the Energy Strategy 2050

In Switzerland, approximately 20% of the total energy is consumed by industry of which more than 50% is used for process heating. The Swiss Federal Office of Energy (SFOE) estimates that for sev-eral thousand industrial processes in Switzerland there is a saving potential of 20 to 40% through energy efficiency improvements. Despite this fact many companies are not aware of the potential for energy savings in their process, resulting in energy efficiency measures, which are in fact economical-ly viable, not being implemented. Therefore, the innovation challenges with respect to “Monitoring and Implementation” are to provide systematic data on energy utilization and management from ongoing and finalized projects and to develop targeted tools and databases to assess the technical, economic and market potential for energy conservation. A further innovation challenge is to develop, evaluate and disseminate strategies aimed at an accelerated and broad diffusion of energy efficiency solutions in the industry. This will include assessments and recommendations regarding business models and an analysis of changes in the boundary conditions needed for substantially improved industrial energy efficiency. The activities in WP1 are linked to the other work packages in SCCER-EIP and there is also a link to SCCER-FEEB&D due to the potential use of industrial waste heat for buildings.

1.2 First phase (2014-2016)

1.2.1 Goals

Task 1.1 Observatory of industrial energy utilization and management 1. Provide a general overview of the energy consumption and management of the Swiss indus-

try sector 2. Extract data from large ongoing and finalized projects (data mining)

Task 1.2 Mapping of opportunities and assessment of potential energy savings

1. Systematic collection of data on energy efficiency measures to build a database 2. Development of a tool to analyse the technical, economic and market potential of efficiency

measures in industry Task 1.3 Facilitating technology transfer and implementation

1. Assessments and recommendations regarding business models and other implementation strategies

2. Analysis of changes in the boundary conditions needed for substantially improved industrial energy efficiency

1.2.2 Key milestones

Task 1.1 Observatory of industrial energy utilization and management MS 1.1.1

a. Identification, characterization and validation of available data from different sources b. Finalise a structure for the Observatory based on the requirements c. Identify indicators – relevant from the perspective of benchmarking/ comparison with

EU industrial sectors MS 1.1.2

a. Perform a stakeholder analysis to identify the target audience for the Observatory and how they can profit from it



b. Obtain feedback from industry (stakeholders) for further development of Observatory tool

c. Develop prototype of Observatory MS 1.1.3

a. Gap analysis on further data needed b. Develop data-mining methods to close identified gaps


MS 1.2.1 a. Scoping of energy efficiency industry database including decisions about techno-

logical, sectoral, temporal scope etc. b. Preparation of data format

MS 1.2.2 a. Develop a database containing a set of energy efficient measures in industry to re-

duce thermal and electrical energy demand b. Establish technical and economic potentials by using standards (esp. for mass-

produced equipment such as motors) and best practice technologies and conduct classical techno-economic analysis

MS 1.2.3 a. E-Module tool to be extended by five new modules and one external fluid library to

allow the use of additional fluid components b. Develop first version of a framework to allow advanced application through coupling

of E-Modules MS 1.2.4

a. Develop a bottom-up model to simulate the current and potential future energy use of 2-3 industrial sectors in Switzerland

Task 1.3 Facilitating technology transfer and implementation

MS 1.3.1 a. Select representative firms from 2 identified industrial sub-sectors b. Identify instruments influencing decision processes – match with potentials of effi-

ciency measures MS 1.3.2

a. Identification and characterization of barriers’ taxonomy b. Develop “best practices” for effective implementation of Energy Management Systems c. Identify new energy market scenarios and players d. Identification of success factors for business models

MS 1.3.3 a. Evaluation of and comparison with programs (costs and effectiveness) running in other

areas (e.g. Efficiency in Buildings) and with the experience made outside Switzerland.

1.2.3 Gaps and barriers

The tasks within WP1 face the following barriers: 1. Confidentiality agreements regarding the further use and publication of industrial data and

information 2. Limited number of process-related data per industrial subsector may limit their use for Ob-

servatory’s purposes 3. Irregular/unknown frequency at which top-down data sources (SFOE, EnAW) supply new

industrial data 4. Comparison with EU industrial sub-sectors difficult due to un-comparable indicators



1.2.4 Action items

Task 1.1 Observatory of industrial energy utilization and management

1. Collect data available from the different sources (SFOE, EnAW, industrial partners, fairs, ect) 2. Create a prototypes of the Observatory 3. Get feedback from stakeholders identified 4. Creation of a shortlist of processes/thermal unit operations relevant for the selected industrial

sub-sectors to be implemented as E-Modules (WP 1.2)


1. Sign confidentiality agreement with ProKilowatt and obtain and analyze data on energy ef-ficiency programs

2. Try to initiate collaboration with EnAW/AEnEc and with at least four of their part-ners/consultancies (e.g. Weisskopf and groupe-e) and/or other partners

3. Visit industry fair, collect data and compare with data on measures implemented in CH 4. Create generic datasets based on the detailed information received from the sources for 2-3

industrial sectors 5. Develop a dedicated tool to conduct a comparative assessment of individual energy effi-

ciency measures, e.g. in terms of cost-effectiveness (i.e., GJ saved per CHF spent for indi-vidual measures or for packages of measures) or as cost-supply curves for packages of measures and larger systems

6. Identify key process parameters and working conditions for each process/thermal unit opera-tion listed in the shortlist

7. Create E-Modules for the identified processes/thermal unit operations

Task 1.3 Facilitating technology transfer and implementation

1. Selection of the most appropriate industrial partners within the 2 selected industrial sec-tors and start collaboration within MS-1.3.1 and MS-1.3.2

2. Selection of the most suitable EnergieSchweiz programs to be evaluated and start evalua-tion within MS-1.3.3

3. Development of appropriate questionnaires for industrial partner interviews and surveys within MS-1.3.1 and MS-1.3.3



1.2.5 Priorities and timelines

1.3 Outlook with goals second phase (2017-2020) and onwards

1. Expand the scope of the Observatory a. breadth (additional industrial sectors) and b. depth (additional processes through E-Modules)

2. Development of sectoral Pinch Analyses 3. Develop extensive industrial sector-specific technical know-how for the sectors under con-

sideration (handbooks, case studies) 4. Intensify the co-operation between the SCCERs FEEB&D and EIP through possible projects

involving the use of industrial waste heat and district heating 5. Intensify the co-operation between SCCER-CREST and EIP through joint contribution to a da-

tabase and bottom-up modelling 6. Expand the database and bottom-up model to the most important industrial sectors in CH 7. Development of Facilitator and risk assessment tools which:

a. allow firms in identifying and overcoming barriers b. guide firms in the decision-making process c. suggest the suitable energy efficiency programs and incentives d. help filtering the appropriate business Models for the specific business e. provide the possibility for interlinking the E-Modules and the observatory (e.g. internet

based public access)

a,b

b

Jun 16 Dez 16

MS 1.1.1

start 6 months 12 months 18 months 24 months 30 months

a

a

Dez 14 Jun 15 Dez 15

WP1.3

WP1.2

WP1.1

MS 1.1.2

MS 1.1.3

MS 1.2.1

MS 1.2.2

MS 1.2.4

cb

a

MS 1.2.3

b

a

a, b

a, b

a, b

MS 1.3.1 a, b

MS 1.3.2

MS 1.3.3

a,b,ca,b,d



2 WP2 Energy Efficiency (direct)


The goal with respect to the energy strategy 2050 is to tackle processes used in many different indus-trial sectors that show a high energy consumption. The aim is to substitute current energy intensive systems with new plug and play solutions that reduce energy usage significantly. Topics covered in the first phase of the SCCER are heating and cooling applications, process heat and steam genera-tion, heat recovery as well as cogeneration. Follow up topics will be in the area of compressed air, energy storage in industry (collaboration with SCCER HaE), high temperature heat pumps (based on IEA Heap Pump Annex 35), and the pre-commercialization of the multi temperature heat pumps. Be-sides feasibility in new plants, solutions for retrofitting and reuse of old equipment need to be consid-ered in order to reduce payback time and investment cost, which are huge hurdles in the implementa-tion of renewables and efficient technologies in industry. The reduction of energy consumption will be achieved by a widespread usage of new energy efficient and scalable technology applicable to many different industrial sectors. Goals By 2035

• Market ready technology which reduces CO2 emissions for heating/cooling/drying/pressurized air by 30%

• System solutions including storage technology to improve energy efficiency and reduce peak loads

By 2050 • Reduction of the total fossil energy demand of industrial processes of 30% • Energy efficient systems and usage of renewables at similar investment costs as systems

based on fossil fuels

2.2 First phase (2014-2016)

2.2.1 Goals

• Development of energy efficient technologies for heating (80-200°C), cooling and storage in industrial processes, which can be used widely and scaled over a large range.

• Create and test a prototype of a multi temperature heat pump system with micro turbo ma-chinery, which shows performance (COP) improvements of 10% compared to existing solu-tions.

• Comparison of system solutions for process heat and steam generation including storage thereof, which reduce primary energy consumption by up to 30% using renewable energies and waste heat

• Development of improved waste heat recovery systems for example by designing and testing prototypes of oil-free micro turbomachinery


• Prototype of heating/cooling system for multiple temperature levels built and tested by end of 2016

• Overview of research and market status in different areas of process heat generation estab-lished along with metrics for easy comparison by 2016.

• Pilot project on process heat / steam generation using renewables realized by 2019 • Case studies of at least two industrial partners needing process heat finished by 2017




• Efficient, reliable and cost effective micro turbomachinery not available • Implementation of renewable energies and heat recovery suffer from high investment cost

(but low operating cost) compared to conventional systems. • No standardized solutions available for efficient energy supply in industry leading to specially

designed solutions and therefore high cost • Industry needs technology for retrofit and reuse of existing equipment whenever energy effi-

ciency methods are applied to reduce cost of implementation. • Industrial processes are often very sensitive to changes of parameters which reduces the

chances of accommodating energy efficient solutions

2.2.4 Action items

• Develop standardized and scalable solutions for heating/cooling/storage/regeneration • Develop guidelines for usage / comparison of systems / recommendations • Demonstrate usage of renewables / efficiency / waste heat recovery in industry • Target different areas of energy saving in industry based on the outcomes of WP1 • Develop integrated design and optimization methodologies and tools for small-scale, oil-free

turbomachinery • Develop scenarios for implementation of new technology and reuse/rededication of existing,

functional installations


The timeline within SCCER EIP for WP2 is quite well defined in the existing documents and was ad-justed slightly at the beginning of 2015 to deepen the research and reduce the broadness. The following figure shows research priorities in a wider context for the following years.

TRL: Technology Readiness Level, cf. for example http://en.wikipedia.org/wiki/Technology_readiness_level.




The outlook for the second phase of WP2 in the SCCER EIP builds on the first phase and extends its depth and width. Early research stages (i.e. small scale turbomachinery) will be moved closer to mar-ket applications while new topics will be added which had to be neglected in the first stage in order to keep a clear focus within the given budget. High temperature, low charge heat pumps (component and systems level)

• Investigation of natural refrigerants such as H2O, R290, CO2, R600a for high temperature heat pumps (150°C)

• Multi stage turbo compressors over a wide capacity range for heat pumps and ORC • Reduction of refrigerant charge (flammables)

Pressurized air and drying processes

• Plug and play solutions for industrial drying processes (Solar, waste heat, heat recovery, etc.) • Pressurized air and steam expanders instead of valves for energy recovery

Systems Integration

• Two Pilot projects on integration of energy efficient solutions for process heat/vapour genera-tion/drying processes

• High temperature storage materials (for industrial heat) • Integration of high temperature solar thermal systems

Retrofitting and Reuse

• Investigation of maximizing the possibility to retrofit existing processes • Establishing new approaches to reuse old equipment when retrofitting a plant in order to re-

duce investment cost • Pilot project as showcase of retrofit and guidelines for easy implementation



3 WP3 Process Efficiency (indirect)


The industrial sector accounts for about 20% of Switzerland’s energy consumption;; more than half is used for heating/cooling during process production. Beside the direct measures towards energy efficiency in industrial processes addressed in WP2, WP3 deals with indirect measures, which can inherently enhance the process efficiency and thus yield to a remarkable decrease of the overall energy consumption. There are a number of possible measures that can be taken, which have the potential to enhance process efficiency and thus energy efficiency: all these diverse applications have common key elements that have to be reconsidered in order to improve energy efficiency. The selected areas where the WP3 of the SCCER-EIP will have an impact and produce innovations of interest for the Swiss process industry are:

a) Advanced approaches to continuous manufacturing: to enable transition from batch to continuous manufacturing in the pharmaceutical industry. This is aimed to minimization of waste, energy consumption and raw material usage during production;;

b) New materials and processes for low-thermal energy separations: to develop of novel materials, tailor-made at the molecular scale, and advanced separation processes, integrated and optimized, to significantly enhance the efficiency of the industrial processes;;

c) Advanced concepts towards highly efficient heat transfer: to achieve high thermal and energy efficiency in the removal and reuse of heat with potential benefits to many processes, e.g. efficient data centers and supercomputers.

Tackling the energy efficiency from a process point of view can lead to remarkable energy savings that may go beyond the 20-40% goal of the Swiss Federal Office of Energy. On the other hand, the implementation of indirect measures that require new processes design, espe-cially for high valuable products, needs a long learning time. Therefore, results of WP3 are expected in some years from the start of the SCCER-EIP.

3.2 First phase (2014-2016)

3.2.1 Goals

a) Advanced approaches to continuous manufacturing (Prof. Mazzotti, Prof. Rudolf von Rohr) • Determination of a feasible continuous membrane crystallization process based on antisol-

vent addition-removal for a given industrial case study. Possible set-ups: from single to a cas-cade of membranes modules.

• Temperature cycles integration. • Polymeric materials applications in continuous manufacturing for antisolvent removal. • Consolidated predictive model for continuous membrane crystallization processes. • Reactors for continuous processing (gas, liquid, liquid-liquid) • Models to predict transport phenomena (computational fluid dynamics)

b) New processes and materials for low energy separations (Prof. Mazzotti, Prof. Rudolf von Rohr)

• Identification of the case studies for separation in industrial processes. • Implementation and improvement of models to simulate membrane- and adsorption-based

processes.



• Consolidated predictive model for continuous gas separation processes. • Development and optimization of new membrane and adsorption-based separation cycles. • Implementation of molecular scale simulations for tailor-made materials. • Synthesis and testing of the designed materials.

c) Advanced concepts towards highly efficient heat transfer (Prof. Rudolf von Rohr, Prof. Poulikakos)

• Optimization of convective dropwise condensation for heat exchangers • Fundamental study of surface engineering towards improved condensation


a) Advanced approaches to continuous manufacturing (Prof. Mazzotti, Prof. Rudolf von Rohr) • Developing of a predictive model for membrane crystallization • Determination of experimental case study • Experimental set-up (single/cascade membrane modules) built and running • Experimental set-p for hydrogenation reactions with new reactors • Case study with new reactor (hydrogenation)


• Development and validation of computational models for membrane modules performance determination

• Model optimization for adsorption-based membrane gas separations • Evaluation of novel gas separation processes (membrane, adsorption) in terms of energy

consumptions • New materials tested and molecular scale simulations carried out (Berend Smit, EPFL)


• Implementation of novel methods and materials for condensation enhancement • Realization towards industrial oriented applications


a) Advanced approaches to continuous manufacturing (Prof. Mazzotti, Prof. Rudolf von Rohr) • Investment budget. • Membrane technology (availability of specific membrane modules). • Commitment of industry (for the definition of a proper/applied case study).


• Identification of industrial case studied of interest. • Industry commitment. • New material synthesis. • Budget requirements.


• Identification of potential industrial partners for the materialization of the study findings • Limitations in scaling up.



3.2.4 Action items

a) Advanced approaches to continuous manufacturing (Prof. Mazzotti, Prof. Rudolf von Rohr) • Collaboration with membrane technology experts in order to meet technical requirements on

membrane crystallization. • Set up of direct collaboration with specific industries from the advisory board list. • Fund raising.


• Set up of direct collaboration with specific industries from the advisory board list. • Fund raising.


• Collaboration with commercial partners for accommodating cutting-edge surface engineering. • Fund raising through CTI for optimization of fabrication process


a) Advanced approaches to continuous manufacturing (Prof. Mazzotti, Prof. Rudolf von Rohr) • Membrane modules/chemical compounds, auxiliary equipment selection and purchasing. • Building of the experimental apparatus. • Developing and improvement of a predictive model for membrane crystallization processes. • Improve the collaboration with membrane technology experts for applications involving tailor-

made membranes. • Efficient and reliable catalytic coating of novel reactor.


• Development and validation of membrane computational models. • Definition of case studies and required material features for membrane-based processes. • Improve the collaboration with Berend Smit, EPFL.


• Validation of the novel strategy adopted • Optimization of the heat exchange performance • Scaling in up and industrialization


The technology development and optimization performed during the current phase of the SCCER project will produce a selection of technologies/processes indirectly capable of enhancing the energy efficiency in process industry. In the second phase of the SCCER-EIP, further development and comprehensive laboratory testing of the above mentioned technologies will be carried out with the aim of bridging the gap between simula-tions/preliminary experimental campaign and real applications. Hybrid gas separation technologies for biogas upgrading: The long-term vision of the Swiss “Energy Strategy 2050” is the phase-out of nuclear power plants along with a reduction in the greenhouse-emissions. The main strategies to achieve this vision are a



stabilization of electricity demand thanks to improved efficiency, particularly in buildings, and the in-crease in new renewable power supply (solar, wind, geothermal). At the same time cost competitive-ness and system reliability need to be maintained. Alongside these mid-to-long term measures, and in order to cope with the mentioned issues, power production will have to rely also on the use of natural gas, both in centralized and decentralized systems. Nevertheless, this would lead to a significant in-crease in greenhouse-gas emissions, losing part of the renewables benefits. The progressive substi-tution of fossil fuel-based natural gas with biogas is a promising solution to this issue. Biogas produc-tion in Europe and Switzerland has steadily increased over the last years. Depending on the end user and on the production route, biogas requires different treatments before the utilization. Notably, bio-gas sweetening and upgrading represent two of the most important steps. In particular, biogas has to be desulphurized, i.e. removing H2S, and enriched in its CH4 content, i.e. removing part of the CO2. Therefore, it is of paramount importance to develop and optimize a cost/energy effective upgrading process. Several techniques exist for both the acid gas and the CO2 removal and are based on: (i) chemical absorption, (ii) pressure swing adsorption, and (iii) membranes. All these technologies are currently under investigation in WP3. On the grounds of the experience acquired in the first phase of the SCCER in developing new separation processes and materials, the application and optimization to the biogas treatment will be pursued in the second SCCER phase. Continuous crystallization for CO2 capture and utilization Continuous crystallization is of paramount importance to reduce the energy consumption and maxim-ize the yield of several industrial processes. Notably, CO2 is a required (or undesired) product in dif-ferent industrial processes: chemical commodities production (urea, methanol), food preparation, biogas upgrading are among the most common examples. Nowadays, chemical and physical scrub-bing is regarded as the state-of-the-art technology for CO2 separation: indeed the number of existing plants for acid gas removal makes this technology mature and ready for commercialization. On the other hand, the needs to limit the energy consumption for the solution regeneration and the issues linked to degradation, corrosion and vapour formation, have prompt the research to develop 2nd and 3rd generation technologies for CO2 capture. Among the different solution proposed, the chilled am-monia process (CAP), which makes use of NH3-H2O in solution to capture CO2, is a promising pro-cess on the verge of commercialization. Particularly, in order to limit the energy consumption of the CAP, solid formation can be exploited in the process. Using the background acquired in the first phase of the SCCER and in a linked CTI project, in the second phase of the SCCER we plan to carry out experimental testing and model validations of the continuous crystallizer system required to make use of solids formation in the CAP process. Enhancement of heat transfer on interfacial phase change phenomena

• Development of appropriate derivations to predict the performance of heat exchangers. • Utilization of prediction models for improving the interfacial phase change heat transfer • Broadening the range of potential materials suitable for industrial use (ceramics, Titanium,

Tantalum, Zirconium) Investigating case studies to replace inefficient heat transfer systems.



4 WP4 Plant-wide Integration


The energy saving potential in the field of process integration is very high in different sectors. Exam-ples in the food industry show a saving potential of up to 75% and a reduction of the total energy cost by 60% when one considers the integration of energy conversion technologies like heat pumps and cogeneration1,2,3,4. In addition, in most of the cases the combined energy and resources efficiency approach shows benefits in terms of water consumption (factor 4) and waste streams productions, since these can be converted into additional energy resources. By rescheduling the operation and integrating thermal storage systems, the batch system integration will allow (i) to realize heat recovery options and (ii) the batch processes to become actors on the electrical grids. By reusing waste heat for other processes in industrial clusters or sharing energy conversion or waste management facilities, the large-scale integration presents a huge energy saving potential. One could imagine considering cities as being the best way to evacuate waste heat from the industry. Extrapolat-ing data from the International Energy Agency (IEA) to Switzerland shows a potential of energy sav-ings of 5% of the heating demand in buildings and 25% of the energy usage in industry. This, howev-er, needs a comprehensive approach to identify the real waste heat of industrial processes and to realize in a practical way the system wide integration using the appropriate district-heating network.

4.2 First phase (2014-2016)

4.2.1 Goals

• Demonstrate and validate methods and tools by developing test cases in collaboration with industry (sites selected in collaboration with WP1)

o 10 Swiss sites to be studied by 2020: § 3-5 sites by end 2016 § 1-2 industrial sites (EPFL), 2-3 SMEs (HSLU)

• Document and prioritise energy optimisation solutions in industry and SME cases o 15% savings target, cf. Swiss EnergyScope

§ reached via 5% expected savings per sector (industry, transport & buildings) o 5% savings in industry realised by 2020 o 15% identified savings in industry & SMEs by 2016

• Identify cross-cutting technologies for reaching energy savings in industry and SME cases (in collaboration with WP2 & WP3)

o 3 technologies with high readiness level identified by 2016 § 2 conversion techs (WP2) and 1 process tech (WP3) § 1 realised cross-cutting technology in industry/SME by 2020

• Launch energy expert networks, clustering experts from academia, industry and SME with technological as well as engineering expertise

1 B. Laulan, Intégration énergétique d’un procédé agroalimentaire à l’aide de la plateforme internet PinchLight. Master thesis report (Prof F. Marechal), Mechanical Engineering, EPFL 2010. 2 Francois Marechal, Anurag Kumar Sachan, and Leandro Salgueiro. “5.3 Application of Process Integration Techniques in the Brewing Industry.” In Handbook on Process Integration, edited by J. Klemes. Woodhead Pub-lishing Ltd, 2013. 3 Becker, Helen Carla. “Methodology and Thermo-Economic Optimization for Integration of Industrial Heat Pumps.” EPFL, 2012. doi:10.5075/epfl-thesis-5341. 4 M. Bendig, Integration of Organic Rankine Cycles for Waste Heat Recovery in Industrial Processes. Thèse EPFL, n° 6536 (2015)




• 2015 o Q1: application filed for 1 EU project on large scale energy efficiency

§ CH partners from 3 different process industrial sectors o Q2: longlist of Swiss industrial sites and SMEs for energy studies drawn o Q3: energy optimisation studies launched

§ 1 batch process, 1 industrial site o Q4: 1-3 large scale process integration studies for industrial symbiosis purposes iden-

tified • 2016

o Q1: 3-5 case studies started o Q2: longlist of cross-cutting technologies drawn

§ advanced integration technologies, including renewables and storage integra-tion

o Q3: batch software developed, retrofit and cluster methodologies & strategy defined o Q4: 3-5 case studies realised demonstrating energy efficiency roadmaps in different

sectors § at least 1 process integration study and 1 batch process integration § 1 large scale integration study initiated

o Q4: 3 cross-cutting technologies identified


• Awareness and acceptance of energy saving potential • Need for training and education on methods & tools (diploma level as well as lifelong learning) • Lack of integration in engineering practice and policy recommendation (e.g. energy efficiency

directive) • Pan-European economic climate, low Industrial competitiveness • Technology readiness level, incl. industrial perception & commitment • Flexible and resilient solutions vs integrated solutions - success stories • Risk funding, investment & support mechanisms • Cross-border understanding and wish to collaborate in industrial symbiosis

4.2.4 Action items

• Training & education: a. Continuing education and training programs

i. Creation of a master of advanced studies (ETH level) for training of engineers and policy makers, to be developed as a continuing education program

ii. Creation of an additional/linked program (e.g. CAS) for practicing engineers, planners and energy managers

iii. Creation of a training program (UAS) iv. Creation of a short course / summer school

b. Integration of case studies within study programs of academic partners c. Development of accreditation by SFOE: initiation of experts network.

• Method development & validation: a. Development of new algorithms and software platforms b. Stress testing of new methods c. Validation and demonstration via test cases

• Energy auditing and planning: a. Financing mechanisms, funds raising, incentives, projects, energy service companies’

business models b. Methods and tools licensing program for software developed in the WP4. c. Realisation of pilot projects for tech demonstration, e.g. ORC, advanced heat ex-

changers, heat pumps d. Development of energy efficiency implementation roadmap (e.g. recommendation of

ISO 50001) • Publications and dissemination actions:



a. Integration in policy and industry recommendations b. International collaboration via participation in Industrial Energy-Related Technologies

and Systems (IETS) program of International Energy Agency


The main goal of WP4 will be to develop comprehensive methods for improving and disseminating the methods developed during the first phase into industry. The focus will be on the incorporation of prac-tical constraints like system operation, flexibility and reliability and on the development of suitable business models. The integration with multi-energy grids and the integration of advanced energy con-version technologies (fuel cells, industrial heat pumps), process technologies (e.g. advanced heat) and power to gas systems (e.g. CO2 capture storage and recycling) will also be studied further. The development of methods will focus on the systematic generation of process development roadmaps that integrate emerging technologies. The three research axes will remain unchanged: (i) process integration with an emphasis on advanced process units and energy conversion technologies inte-grated in intensified processes, (ii) batch processes with a focus on the role of batch processes for the management of the electrical grids, and (iii) large scale integration with a focus on the practical devel-opment of industrial clusters integrated in an urban environment and on the integration of renewable energy resources. A method for assessing the potential of energy savings for the energy transition resulting from the large-scale integration will be developed. A database of advanced technologies integration models will be developed and strengthened in order to offer an expert basis for the dissemination of the technologies developed within WP2 and WP3 while at the same time offering a stronger basis to quantify the impact of process integration and ad-vanced technology integration in the Swiss energy transition policy. The dissemination of the energy and resource efficiency practice will be further developed by strengthening and further developing the continuing education programs and by offering specific train-ing programs to engineers in industry. It is also expected to develop Massive Open Online Courses (MOOCs) on energy and resources efficiency in industrial processes and to integrate them into a dis-tance-learning program.



5 Appendix

Figure 1: Graphical representation (balanced scorecard) of the WP1 innovation roadmap

Goals 2050

Goals 2020

Goals 2016

Milestones in 1st phase (2014-2016)

Action items

Barriers/drivers

Competition on resources (money,

time,..)

Investment horizon

Lack of standards / benchmarks

Lack of information

Provide open data (Observatory)

Data analysisEnergy utilization

EE measures

Raise Awareness Facilitation

Energy savings until 2050: 5 TWh compared to trend (reference scenario)

Increase number of implemented energy efficiency measures by 30% in the period 2040-2050 (compared to period 2000-2010)

Observatory established in 2 sectors

Identifying indicators (consumption, efficiency)

Procedure to overcome gap: tech. requirements / industry level of details

Stakeholder analysis

Requirements for obs.

Gap analysis & systematic data mining

EE industry databases

Database structure

Bottom-up model developed E-module

Bottom-up model running

Investment decision process characterized

Effectiveness EE programs

Recommend. future programs

Success factors business models / financial schemes

Bottom-up model / E-module running in 2 sectors

Success factors identified for business models / financial

schemes/ EE programs

New solutions for business model / financial schemes

implemented (3 pilot cases)

Marketing

Confidentiality

Resistance to changes

Methods for data treatment

(confidentiality pb)

Success stories

Industry survey to calibrate observatory detail level

Benchmarking with EU

Web 3.0 (semantic web)

Energy saving identificator developed

Energy saving facilitator developed

Diffusion of energy saving identificator & facilitator

Energy utilization tracking / analyzing in 2 sectors for 3 years

Task 1.1 Task 1.2 Task 1.3

Documents

%% Swiss%Competence%Center%for%Energy%Research% … · 2015. 4. 17. · Swiss$CompetenceCenter$for$Energy$Research$ $ ©$SCCER$EIP,$March$2015$ $ Page$2$/18$ Tableof%Contents$ 0 INTRODUCTION