Energy efficiency demonstration in manufacturing industry The University of Manchester (UNIMAN) Manchester, 3 August 2012 Energy–2011-8-1

Energy efficiency demonstration in manufacturing industry

The University of Manchester (UNIMAN)

Manchester, 3 August 2012

Energy–2011-8-1

Who are we?

1824 Created by industrialists as the Manchester Mechanics Institution

1846 Owens College founded

1880 Owens College became The Victoria University of Manchester

1905 Faculty of Technology, University of Manchester

1956 Royal Charter granted to Manchester College of Science and Technology

1965 University of Manchester Institute of Science and Technology

2004 The merger of Victoria University and UMIST resulted in establishment of The University of Manchester

The University of Manchester

Staff: 10,712 (4500 academic & research)

Students: ca 40,000

2008 Research Assessment Exercise (RAE): The UoM has smashed the 'Golden Triangle' of research universities traditionally dominated by Oxford, Cambridge and London

65% of research activity is judged to be 'world-leading' or 'internationally excellent'

Centre for Process Integration (CPI)

Birthplace of

• Energy pinch technology

• Water pinch technology

• Hydrogen pinch technology

Activities

• Research

• Software development

• Professional training

• Innovative technology transfer

• Consulting

• Teaching

Staff

• 5 academic staff

• 25 PhD students

• 160 MSc students (CEAS)

What do we do?

Research & technology

The clean and efficient use of materials, energy and capital

Efficient Use of Raw Materials•Design and optimisation of chemical reactors

•Reaction-separation systems

•Hydrogen integration in refining

•Molecular modelling of refinery processes

•Integrated refinery heavy-end processes

Energy Efficiency•Design of heat recovery systems

•Fouling in heat recovery systems

•Cogeneration and site utility systems

•Distributed energy systems•Distillation system design•Absorption sytems•Sub-ambient systems and low temperature separation

Emissions Reduction•Water and wastewater minimisation

•Decarbonised energy production

•Biofuels production•Flue gas emissions

Process Operations•Refinery optimisation•Refinery scheduling•Reliability and maintenance

• EU collaborative projects

• National funding

• Industry (international)

Software

• Software packages:

STAR - site utility and cogeneration systems designWORK - low temperature (sub-ambient) processes designSPRINT - energy systems design for individual processes on a site

Star

• Energy targeting• Total site analysis• Cogeneration• Utility system optimization• Fuel gas emissions

Training and Consultancy

•Software•Workshops ("Hands on" training)•Annual conference•Quality assurance

Process Integration Research Consortium

• Created in 1984

• Currently 15 major organisations representing different process and utility industries (ca 60-70 in total during its existence)

• Providing a focal point for research and development oftechnologies

• Rapid technology transfer through software and training

UNIMAN’s role in EFENIS?

1. Project Co-ordinator

2. RTD Partner

UNIMAN’s Interest in EFENIS

• The Project will enhance CPI UNIMAN’s expertise in - In-depth understanding of site-wide heat and power management

- conceptual guidelines for site utility systems design and operation

- energy demand calculation with uncertainty data

- a systematic framework for min site energy consumption of multi-criteria and multi- objective optimisation under uncertainty

- waste heat sources identification for total site integration

- technology extension for heat recovery for total site integration

- introduction of CHP into the total site context

- integration of energy efficiency and emissions technology

- better integration of waste heat and cooling technologies

• To link research with demonstration activities in major industrial sites

UNIMAN’s Role in EFENIS

UNIMAN will contribute principally to

• Total site integration and optimisation technology

• Total site waste heat recovery with intensified heat transfer

Participant number

Participant short name

Estimated eligible costs (whole duration of the project)Total receipts

Requested EC contribution

RTD/Innovation

Demonstration

Management Other Total

( A ) ( B ) ( C ) ( D ) ( A ) + ( B ) + ( C ) + ( D )

1 UNIMAN 163.080 277.760 276.755 47.174 764.769 0 585.119

UNIMAN budget

UNIMANRTD WP1 6WP2 0WP3 6WP4 2DEMO WP5 8WP6 8WP7 6WP8 6WP9 5Total 47MANAGEMENT WP10 24

TOTAL per PARTICIPANT 71

UNIMAN person-months

WP10ProjectManagement

WP9Technology transfer

WP1Total site integration and optimisation

WP5: Chemicals

Decision-supporting Methodology

Enabling Technologies

Demonstration

WP6: Oil Refinery

WP7: Coal-to-Chemicals

WP8: CHP and Distr. Heating

WP2Total Site carbon management

WP3Total Site waste heat recovery with intensified heat transfer

WP4Integration with CHP and distr.heating

Work Packages with UNIMAN coordination/participation

WP Num

WP Title Type ofactivity

Objectives Startmonth

Endmonth

WP 1 Total site integration and optimisation technology (UNIMAN)

RTD Task 1.1: Total site targeting and process integration (UNIMAN)Task 1.2: Improving operability of site utility systems, subject to demand

fluctuation (UNIPAN)Task 1.3: RAM (Reliability, Availability, Maintainability) analysis for

site utility systems (UNIMAN)Task 1.4 Systematic framework for efficient and reliable modelling in

site energy management (UNIMAN)Task 1.5 Integrated cooling water system design (UNIMAN)Task 1.6 Total Site multi-criteria and multi-objective optimisation

((UNIMAN)Task 1.7 Total Site Process Operability for Energy Efficiency (AUTH)Task 1.8 Total Site Optimization of Energy, Cost and Environmental Impact

(AUTH)

1 30

WP 3 Total site waste heat recovery with intensified heat transfer (UNIMAN)

RTD Task 3.1 Identification of waste heat recovery potentials (UNIMAN)Task 3.2 Technology selections and design for waste heat recovery

(UNIMAN)Task 3.3. Combined heat & power (VTT)Task 3.4 Improving retrofitability and implementability (UNIMAN)Task 3.5: Selection of heat transfer enhancement techniques for total site

integration (UNIPAN)Task 3.6: Advanced heat exchangers (CFD-modelling and optimisation)

(UPB)

6 24

Work Packages and Tasks with UNIMAN coordination/participation

WP Num



Endmonth

WP 4 Integration with local CHP and district heating energy systems (UNIGOA)

RTD Task 4.1: Identification of local energy sources, the potential industrial, commercial and residential energy demands and outlining the boundaries of the integrated energy sectors (UNIMAN)

Task 4.2: District heating and cooling (UNIGOA)Task 4.3: Selection and modelling of energy technologies for local-energy

integration (UNIGOA)Task 4.4: Optimisation of localised and distributed energy systems

(UNIGOA)

6 30

WP 5 Demonstration - Putting into practice total site energy management for the chemical industry (BAYER)

DEMO Task 5.1: Analysis of the as-is state of the site (BAY, support by UNIMAN, UPB and UNIPAN) Year 1

Task 5.2: Perform “fundamentally-improved” Total Site Analysis (BAY supported by UNIMAN, UPB and UNIPAN)

Task 5.3: Detailed planning and implementation of identified improvement measures (BAY, UNIMAN, UNIPAN, UPB)

Task 5.4.: Check transferability to other sites (BAY, UNIMAN, UNIPAN, UPB)

1 36

WP 6 Demonstration - Putting into practice total site energy management for oil refineries (MOL)

DEMO Task 6.1: Analysis of the as-is state of the site (MOL, support by UNIPAN, UNIMAN) Task 6.2: Perform “fundamentally-improved” Total Site Analysis (UNIPAN, UNIMAN, SODRU support by MOL)Task 6.3: Comparison of results of 6.1 and 6.2 (MOL, UNIPAN, UNIMAN, SODRU)Task 6.4.: Check transferability to other sites (MOL, UNIPAN, UNIMAN)Task 6.5: Retrofit Upgrade (MOL)

1 36

Work Packages with UNIMAN coordination/participation (Cont.)

WP Num



Endmonth

WP 7 Demonstration - Putting into practice total site energy management for coal-to-chemicals (ENN)

DEMO Task 7.1: Analysis of the as-is state of the site (ENN, support by UNIMAN, UNIPAN, VA)

Task 7.2 Integration of cooling water systems with other site utilities (VA, supported by UNIMAN)

Task 7.3: Perform “fundamentally-improved” Total Site Analysis Task 7.4: Comparison of results of 7.1 and 7.2 (ENN, UNIMAN,

UNIPAN, VA)Task 7.5.: Check transferability to other sites (ENN, UNIMAN, UNIPAN,

VA)Task 7.6: Retrofit Upgrade (ENN)

1 36

WP 8 Demonstration - Putting into practice total site energy management for CHP and district heating (IPLOM)

DEMO Task 8.5: Retrofit Upgrade (IPLOM)Task 8.4: Check transferability to other sites (IPLOM, UNIGOA, AUTH,

VTT)Task 8.3: Comparison of results of 8.1 and 8.2 (IPLOM, UNIGOA, AUTH,

UNIPAN, VTT)Task 8.2: Perform “fundamentally-improved” Total Site Analysis (UNIGOA,

AUTH, VTT, support by IPLOM)Task 8.1: Analysis of the as-is state of the site (IPLOM, support by

UNIGOA, UNIPAN, AUTH)

1 36

WP9 Technology Transfer (BAYER)

OTHER Task 9.1 – Protection of project resultsTask 9.2 – Development of exploitation strategyTask 9.3 – Knowledge DisseminationTask 9.4 – Training ActivitiesTask 9.5. Energy Service Centre activities

6 36


WP Num



Endmonth

WP 10 Project management(UNIMAN)

MGT Task 10.1 – Periodic reports after each reporting period (12 months), final report, financial distribution report (UNIMAN)

Task 10.2 – Submission and organisation of the cost statements and consortium agreements (UNIMAN)

Task 10..3 – Report on gender, societal and ethical issues of exploitation (UNIMAN)

1 36


WP Num

WP Title Deliverables

Num TitleDissemLevel

DateMon

WP1 Total site integration and optimisation technology

D1.1 Report on conceptual design methodology for the total site energy analysis

PU 12

D1.3 Report on system modelling and analysis for RAM study of site utility systems

RE 15

D1.4 Report on application of novel conceptual design method from energy-intensive process units

PU 15

D1.5 Systematic framework for efficient and reliable energy demand calculation

RE 20

D1.6 Report on design framework for integrating cooling water systems with other site utilities

RE 24

WP3 Total site waste heat recovery with intensified heat transfer

D3.1 Report on identification of waste heat recovery potentials to be integrated within a total site

PU 12

D3.2 Report on technology selection and extension for waste heat recovery

PU 20

WP9 Technology transfer

D9.5 Training session among Industrial and Academic partners PU 24

WP10 Project management

D10.1 Periodic reports after each reporting period (12 months), final report, financial distribution report

PU 24

D10.2 Submission and organisation of the cost statements and consortium agreements

PU 36

D10.3 Report on gender, societal and ethical issues of exploitation

PU 36

List of Deliverables

PU: PublicRE: Restricted to a group specified by the consortium (including the Commission Services)

Participant no. Participant organisation name1 (Coordinator) The University of Manchester (UNIMAN)2 Bayer (BAY)3 MOL Hungarian Oil and Gas Company (MOL)4 Vestas Aircoil (VA)5 IPLOM (Industria Piemontese Lavorazione Oli Minerali -

Piedmontese Mineral Oil Processing Factory) (IPLOM)

6 ENN Science and Technology Development Co. Ltd. (ENN)7 VTT Technical Research Centre of Finland (VTT)8 Sodrugestvo-T (SODRU)9 ESTIA Consulting and Engineering (ESTIA)10 University of Pannonia (UNIPAN)11 University of Paderborn (UPB)12 Aristotle University of Thessaloniki (AUTH)13 Genoa University (UNIGOA)14 University of Maribor (UNIMAR)15 Hanyang University (HU)16 Alexandra Instituttet A/S (AI)

Collaboration with Partners within Work Package 1

0.5-1 person months each for feedback on research and keeping informed

Main activity:Research collaboration














Piedmontese Mineral Oil Processing Factory) (IPLOM)6 ENN Science and Technology Development Co. Ltd. (ENN)7 VTT Technical Research Centre of Finland (VTT)8 Sodrugestvo-T (SODRU)9 ESTIA Consulting and Engineering (ESTIA)10 University of Pannonia (UNIPAN)11 University of Paderborn (UPB)12 Aristotle University of Thessaloniki (AUTH)13 Genoa University (UNIGOA)14 University of Maribor (UNIMAR)15 Hanyang University (HU)16 Alexandra Instituttet A/S (AI)


Main activity: Demonstration

Interaction to implement demonstration





















Main activity: Dissemination, exploitation

Interaction to implement dissemination





Collaboration with all Partners

Efficient Use of Raw Materials•Design and optimisation of chemical reactors

•Reaction-separation systems

•Hydrogen integration in refining

•Molecular modelling of refinery processes

•Integrated refinery heavy-end processes

Energy Efficiency•Design of heat recovery systems

•Fouling in heat recovery systems

•Cogeneration and site utility systems

•Distributed energy systems•Distillation system design•Absorption sytems•Sub-ambient systems and low temperature separation

Emissions Reduction•Water and wastewater minimisation

•Decarbonised energy production

•Biofuels production•Flue gas emissions

Process Operations•Refinery optimisation•Refinery scheduling•Reliability and maintenance

Research & Technology to be applied

Research & Technology to be applied (Cont.)

Targeting and Design

• Simulation

• Graphical method - Charts like grand composite curve, site composite curve provide

relationship between processes energy demand and utility system

• Mathematical programming - widely used to determine the optimum topology - some linearization simplifications reformulate MINLP into MILP

Documents

Energy efficiency demonstration in manufacturing industry The University of Manchester (UNIMAN) Manchester, 3 August 2012 Energy–2011-8-1