Professor Tony Roskilly

Sir Joseph Swan Institute for Energy Research

Process Industries Thermal Energy Management Process Industries Thermal Energy Management Pro-TEM NetworkPro-TEM Network

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

Network Objectives Network Objectives

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.

Importance of thermal energy management 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.

Importance of thermal energy management 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.

Importance of thermal energy management 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..

Importance of thermal energy management Importance of thermal energy management

Importance of thermal energy management 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.

Process Synthesis & Retrofit (Design)

Design Toolbox

Trade-off Analysis

Process & Energy

systems Integration (Control)

Process Operability

Analysis

• Low, medium and high grade heat demand

• Location and quantification of streams

• Modelling discrete decision

• CHP

• Interactions of design and control

• Stable, flexible and multi-parametric programming

• Energy-Cost-Environmental Impact

• Life Cycle Analysis

• Sustainability

• Process Intensification

• Heat Integration

• Controllability

Design Toolbox for Energy Efficiency in the Process IndustryDesign Toolbox for Energy Efficiency in the Process Industry

Imperial College, UCL (£644.7K)Imperial College, UCL (£644.7K)

Measure accurately the energy used at each stage in melting and casting processes

Calculate the energy losses from oxidation and scarp

Measure the energy input for CRIMSON (Constrained Rapid Induction Melting Single Shot Method) and up-casting processes

Assess energy requirements in traditional foundry industry

Develop a model that will help foundries achieve 30% energy savings

Energy Saving in the Foundry IndustryEnergy Saving in the Foundry IndustryBirmingham University; Aeromet, Cast Metals Federation, Ford Motor Co., Birmingham University; Aeromet, Cast Metals Federation, Ford Motor Co.,

Grainger and Worral, KTN for Resource Efficiency, N-Tec Ltd.Grainger and Worral, KTN for Resource Efficiency, N-Tec Ltd. (£514K) (£514K)

1. Audit energy use and benchmark current performance

2. Energy flows on site

3. Generation of Process gases

1. Characterise the process gasses

2. Determine the likely performance and the suitability of gas turbines

3. Review electricity generation options

1. Audit and model energy use across 12 business units

2. Identify metering deficiencies

1. Examine options for heat use on site

2. Apply model to business units and test

3. Optimise process operation

4. Recommend improvements

Stage 1 Stage 2 Stage 3 Stage 4

Evaluation of a Large Energy Intensive SiteEvaluation of a Large Energy Intensive SiteCardiff University; Corus Strip Products (£639.7K)Cardiff University; Corus Strip Products (£639.7K)

Based on oil refinery crude oil preheat exchanger train:

1. Analyse heat transfer on exchangers

2. Increase heat recovery through the mitigation of fouling

3. Enhance heat recovery through intensified heat

exchanger networks

4. Develop an automated design methodology for intensified

heat exchanger networks

Intensified Heat Transfer for Energy Saving in Process IndustriesIntensified Heat Transfer for Energy Saving in Process IndustriesBath & Manchester Universities; Bath & Manchester Universities;

CAL Gavin Ltd., EM Baffle BV (£560K)CAL Gavin Ltd., EM Baffle BV (£560K)

Energy Flows in Crisp Frying Process

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

Optimising Thermal Energy Recovery, Utilisation and Optimising Thermal Energy Recovery, Utilisation and Management in the Process IndustriesManagement in the Process Industries

Brunel, Newcastle & Northumbria Universities; Beedes Ltd., Flo-Mech Ltd., Brunel, Newcastle & Northumbria Universities; Beedes Ltd., Flo-Mech Ltd.,

Sustainable Energy Systems Ltd., United Biscuits Ltd. (£493K)Sustainable Energy Systems Ltd., United Biscuits Ltd. (£493K)

•

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

Reduction of Energy Demand in Paper MakingReduction of Energy Demand in Paper MakingManchester & Cambridge Universities; Arjo Wiggins Fine Papers Ltd., Manchester & Cambridge Universities; Arjo Wiggins Fine Papers Ltd.,

Aylesford Newsprint Services Ltd., Siemens plc, Smurfit Kappa SSK (£451.7K) Aylesford Newsprint Services Ltd., Siemens plc, Smurfit Kappa SSK (£451.7K)

Experimental Strand1.Energy Audit review existing energy reduction strategy and heat recovery technology; identify opportunities for energy reduction2.Flow Measurement Develop measuring instrumentation for air velocity, heat flux and humidity; map air movement and temperature profiles on baking plants

Theoretical Strand1.Computational Fluid Dynamics (CFD) build and validate CFD grids of prover, oven and cooler geometries2.Process OptimisationIdentify key design variables influencing energy efficiency and product quality; build Meta-model based on optimal parameters3.Industrial Software Tools Implement Meta-models within software tools

Thermal Management in Commercial Bread BakingThermal Management in Commercial Bread BakingLeeds University; Altair Engineering Ltd., Enviros Consulting Ltd., Leeds University; Altair Engineering Ltd., Enviros Consulting Ltd.,

Spooner Industries Ltd., Warburtons Ltd. (£466.6K)Spooner Industries Ltd., Warburtons Ltd. (£466.6K)

1. Develop and validate Energy Management Tool (EMT) to optimise energy efficiency, profitability and qualitygather 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

3. Online monitoring and controlDevelop inferential techniques to monitor melting stability and energy consumption develop an ‘expect system’ for feedback signals processing, system design testing or control

Thermal Management in Polymer ProcessingThermal Management in Polymer ProcessingQueen’s Belfast & Bradford Universities; All-Island Polymer & Plastic Network, Queen’s Belfast & Bradford Universities; All-Island Polymer & Plastic Network,

Brett Martin Ltd., Tangram Technology Ltd., TSM Control Systems (£640.6K)Brett Martin Ltd., Tangram Technology Ltd., TSM Control Systems (£640.6K)

• Identify national sources of low grade heat available from the process industry

• Identify potential use of the energy and their relative location

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

• System-wide modelling and optimisation with advanced process integration for low grade heat recovery

• Environmental and socio-economic issues

Tasks

Thermal Management of Industrial Process Thermal Management of Industrial Process Newcastle, Sheffield & Manchester Universities; Alstom Power UK Ltd., Newcastle, Sheffield & Manchester Universities; Alstom Power UK Ltd.,

BP Chemicals, Corus UK, E ON Engineering Ltd., M W Kellog, NEPIC, Pfizer, BP Chemicals, Corus UK, E ON Engineering Ltd., M W Kellog, NEPIC, Pfizer, Veolia Ltd., Vertellus Speicialities (£967.6K)Veolia Ltd., Vertellus Speicialities (£967.6K)

Professor Tony Roskilly

Sir Joseph Swan Institute for Energy Research

Process Industries Thermal Energy Management Process Industries Thermal Energy Management Pro-TEM NetworkPro-TEM Network