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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
WP Title Type ofactivity
Objectives Startmonth
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
WP Title Type ofactivity
Objectives Startmonth
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
Work Packages with UNIMAN coordination/participation (Cont.)
WP Num
WP Title Type ofactivity
Objectives Startmonth
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
Work Packages with UNIMAN coordination/participation (Cont.)
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
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 3
0.5-1 person months each for feedback on research and keeping informed
Main activity:Research collaboration
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 4
0.5-1 person months each for feedback on research and keeping informed
Main activity:Research collaboration
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 5
Main activity: Demonstration
Interaction to implement demonstration
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 6
Main activity: Demonstration
Interaction to implement demonstration
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 7
Main activity: Demonstration
Interaction to implement demonstration
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 8
Main activity: Demonstration
Interaction to implement demonstration
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 9
Main activity: Dissemination, exploitation
Interaction to implement dissemination
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 10
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