Professor Tony Roskilly Sir Joseph Swan Institute for Energy Research

1. Process Industries Thermal Energy Management Pro-TEM Network Professor Tony Roskilly Sir Joseph Swan Institute for Energy Research

2. Network Objectives To provide a forum which incorporates stakeholder opinions in the area of process industries thermal energy management To stimulate knowledge transfer and mobility between academia, industry, NGOs and the government Disseminate research findings ~£5.4m EPSRC funding for 9 projects

3. Importance of thermal energy management • Industrial energy use in UK is about 400 TWh per year, which is 19% of total energy consumption. • For example: • 42 TWh by food and drinks industry • 64 TWh by chemicals industry • 34 TWh by the metals industry • Professor Tassou, Brunel University et. al.

4. Importance of thermal energy management In UK, the plastics processing sector consumes large amounts of electricity costing ~ £380 million p.a. Also large user of gas. The energy cost can be reduced by 10 – 20 % with simple no cost or low cost measures Professor Price Queen’s University Belfast et. al.

5. Importance of thermal energy management Approximately 2 billion loaves of bread are made within UK annually. The energy costs ~ £100 Million Typically energy losses between 55-80% Dr Thompson et al. Leeds University.

6. Importance of thermal energy management Energy utilisation for a whole refinery accounts for 6 – 7 % of oil throughput. Reduced thermal efficiency results in crude oil fouling and costs ~ $4.5 billion Thermal Energy Management could save 20 - 30% energy in energy recovery systems Professor Crittenden University of Bath et. al..

7. Importance of thermal energy management The energy used to melt 1 tonne of Aluminium is approximately 1 TJ. Possible to deliver 30% savings in energy Dr Jolly Birmingham University Approx. 23,000 GWh of energy consumed in paper making per year. With thermal energy management, 20% of energy (4,600 GWhr) can be saved Dr Austin Cambridge University et al.

8. Design Toolbox for Energy Efficiency in the Process Industry Imperial College, UCL (£644.7K) • Low, medium and high grade heat demand • Location and quantification of streams • Modelling discrete decision • CHP • Process Intensification • Heat Integration • Controllability Process & Energy systems Integration (Control) Process Synthesis & Retrofit (Design) Design Toolbox • Interactions of design and control • Stable, flexible and multi-parametric programming Process Operability Analysis Trade-off Analysis • Energy-Cost-Environmental Impact • Life Cycle Analysis • Sustainability

9. Energy Saving in the Foundry Industry Birmingham University; Aeromet, Cast Metals Federation, Ford Motor Co., Grainger and Worral, KTN for Resource Efficiency, N-Tec Ltd. (£514K) Calculate the energy losses from oxidation and scarp Assess energy requirements in traditional foundry industry Measure accurately the energy used at each stage in melting and casting processes Measure the energy input for CRIMSON (Constrained Rapid Induction Melting Single Shot Method) and up-casting processes Develop a model that will help foundries achieve 30% energy savings

10. Evaluation of a Large Energy Intensive Site Cardiff University; Corus Strip Products (£639.7K) Stage 3 Stage 4 Stage 1 Stage 2 Characterise the process gasses Determine the likely performance and the suitability of gas turbines Review electricity generation options Audit and model energy use across 12 business units Identify metering deficiencies Examine options for heat use on site Apply model to business units and test Optimise process operation Recommend improvements Audit energy use and benchmark current performance Energy flows on site Generation of Process gases

11. Intensified Heat Transfer for Energy Saving in Process Industries Bath & Manchester Universities; CAL Gavin Ltd., EM Baffle BV (£560K) Based on oil refinery crude oil preheat exchanger train: Analyse heat transfer on exchangers Increase heat recovery through the mitigation of fouling Enhance heat recovery through intensified heat exchanger networks Develop an automated design methodology for intensified heat exchanger networks

12. Optimising Thermal Energy Recovery, Utilisation and Management in the Process Industries Brunel, Newcastle & Northumbria Universities; Beedes Ltd., Flo-Mech Ltd., Sustainable Energy Systems Ltd., United Biscuits Ltd. (£493K) Preliminary analysis results of crisps frying process Validation of thermodynamic modelling and simulation tools Frying process characterisation using modelling Analysis and optimisation of heat recovery in process industries Control strategies and optimum energy recovery methods for frying processes Energy Flows in Crisp Frying Process

13. Reduction of Energy Demand in Paper Making Manchester & Cambridge Universities; Arjo Wiggins Fine Papers Ltd., Aylesford Newsprint Services Ltd., Siemens plc, Smurfit Kappa SSK (£451.7K) • Tackle the issue in existing processes • Consider to measure sheet solids mid-machine online • Exam data from the newsprint machine to establish energy use patterns (Energy auditing) • Test programme on the board machine to develop data for modelling • Examine generic possibilities for more energy efficient designs in the future • Use plant data to develop generic energy flow models • Use these models to examine possibilities for redesigning the processes with lower energy use as a design priority Develop a robust, effect approach to reducing thermal energy use in paper making

14. Thermal Management in Commercial Bread Baking Leeds University; Altair Engineering Ltd., Enviros Consulting Ltd., Spooner Industries Ltd., Warburtons Ltd. (£466.6K) • Theoretical Strand • Computational Fluid Dynamics (CFD) •  build and validate CFD grids of prover, oven and cooler geometries • Process Optimisation • Identify key design variables influencing energy efficiency and product quality; build Meta-model based on optimal parameters • Industrial Software Tools •  Implement Meta-models within software tools Experimental Strand Energy Audit  review existing energy reduction strategy and heat recovery technology; identify opportunities for energy reduction Flow Measurement  Develop measuring instrumentation for air velocity, heat flux and humidity; map air movement and temperature profiles on baking plants

15. Thermal Management in Polymer Processing Queen’s Belfast & Bradford Universities; All-Island Polymer & Plastic Network, Brett Martin Ltd., Tangram Technology Ltd., TSM Control Systems (£640.6K) 1. Develop and validate Energy Management Tool (EMT) to optimise energy efficiency, profitability and quality gather input information  develop database  develop system models  develop optimisation techniques  integrate elements  test and validate software 2. Apply process monitoring techniques and determine effect of processing/material on energy consumption in extrusion carry out experiments on extrusion lines  monitor melt temperature profiles and homogeneity  monitor and determine optimal energy consumption  investigate screw geometry / scale-up  consolidate data for modelling Online monitoring and control Develop inferential techniques to monitor melting stability and energy consumption  develop an ‘expect system’ for feedback signals processing, system design testing or control

16. Thermal Management of Industrial Process Newcastle, Sheffield & Manchester Universities; Alstom Power UK Ltd., BP Chemicals, Corus UK, E ON Engineering Ltd., M W Kellog, NEPIC, Pfizer, Veolia Ltd., Vertellus Speicialities (£967.6K) • Novel technologies • to increase the amount of low grade heat available from process industries • to increase the efficiency of using the low-grade thermal energy for district heating • to upgrade the heat and thus render it suitable for additional applications • Identify national sources of low grade heat available from the process industry • Identify potential use of the energy and their relative location Tasks • System-wide modelling and optimisation with advanced process integration for low grade heat recovery • Environmental and socio-economic issues

17. Process Industries Thermal Energy Management Pro-TEM Network Professor Tony Roskilly Sir Joseph Swan Institute for Energy Research