REEMAIN Newsletter, Issue #2

n.2, OCTOBER 2014

At the conclusion of its first year of activity, the REEMAIN project is ramping up and we can be confident that Year 2 will mark a leap forward in our technical progress. Lot of interesting things have happened in the last six months. We managed to advance on several fronts, from a deeper identification of potential places for improvement at our demo production sites to the identification of relevant technology options, from the formulation of the performance indicators to the first wave of input to the rough cut modelling for our factories’ simulations. Thanks to an impressive collective effort, guided by our partners Jakob Energy RES and EURAC, we have produced an exhaustive Technology Roadmap for RES, storage and waste heat recovery in industrial production. The roadmap is addressed more extensively in the “spotlight” section of the newsletter. Given the range of our demonstration activities throughout the foundry, textile and food sectors, we have analysed combinations or clusters of technological solutions applied to those different productive contexts. A summarised version of our deliverable will soon made available to the FoF community and to those interested, via our website. Important progress has been done in selecting some of the KPIs (Key Performance Indicators). While we paid attention to review the most important ones from the REEMAIN perspective, we also based our approach on previous activities carried out in the framework of the KAP project. We expect to complete the definitive list probably by the end of October. On the outreach front, we have participated in a workshop on energy efficiency in industrial processes at SCM in Rimini at the end of September, in connection with the LET’s conference that took place in Bologna. This happens also at the time when we are connecting to the colleagues of other projects addressing similar issues, like Daphne, Factory Ecomation and FoundEnergy in what promises to become an interesting cluster of innovation in energy efficiency for manufacturing.

Efficiently yours, Anibal Reñones

REEMAIN Project Coordinator, Fundación CARTIF

Inside

Welcome to the 2nd REEMAIN Newsletter

4 REEMAIN Interviews

News from REEMAIN 5

In the spotlight: SCM Foundry

2

Recommended events

10

Anibal Reñones, Project Coordinator, Fundación CARTIF

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dr. jakob energy research (JER) is an international consultancy for RES research and product development as well as marketing, dissemination, education and training, established in 2009.

Area of expertise are solar process heat, solar cooling, thermal cooling, poly-generation, façade integrated solar systems as well as building physics, energy-efficient buildings and industrial processes. JER is also involved in other European funded FP7 demonstration and R&D projects like InSun (Industrial Process Heat by Solar Collectors) and FRESH NRG (Fresnel for Solar Heat with New Receiver and Geometry).

Website www.drjakobenergyresearch.de

Contacts for REEMAIN project: Dr. Uli Jakob, Managing director

About JER Pushing innovation through technology roadmaps. Interview to Dr. Uli Jakob

In the spotlight: JER

From his office nested among the historical buildings of Weinstadt’s city centre in Baden-Württemberg, Germany, Dr. Uli Jakob enjoys an especially warm day. “I look in the sun – he says with a great smile – that’s where we find life, energy and energy solutions”. With his small and specialised team at JER (dr. jakob energy research), Uli is busy identifying, studying, profiling and matching factories, their processes and possible solutions originating from a wide range of innovative technologies.

Together with partners EURAC, Solera, CARTIF, DMU, R2M, Ikerlan and CRIT, JER

has produced a robust Technology Roadmap for RES, Storage and Waste Recovery for Efficient Manufacturing listing and ranking different types of technologies that can be applied in industrial processes. “We have made efforts – clarifies Uli – to extrapolate detailed information and data for each technology under exam, designing a SWOT (Strengths and Weaknesses, Opportunities and Threats) matrix for each case, so that we can suggest sufficiently detailed approaches for different cases”. The idea was to build upon a first deliverable from the REEMAIN project, the Analysis of Factory Typologies, which already provided indications in terms of sectors for which technologies would be broadly suitable. “It goes without saying – continues Uli - that not all technologies can apply to all sectors. For instance, foundries have specific requirements at much higher temperatures than other processes. To run our exercise EURAC and JER have developed our own version of a ranking methodology based on MCDA (Multi Criteria Decision Analysis). It has been our starting point, to assign values to the different angles by which we can look at technologies, like technical, economic, marketing or environmental aspects and adapt them to the needs of industrial production. What we are trying to do with the Technology Roadmap is to go deeper in the level of detail, so that we can deliver what we can consider a building block for the REEMAIN simulation tool, which will have to be designed by our colleagues of IES, as something that plant managers can use to make their decisions”.

Technology roadmaps tend to be dynamic documents, especially in areas characterised by fast innovation, which may make updates necessary soon. “We are aware of that and one of the issues we’d like to address is the shift from

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(Continued)

treating technologies individually, to evaluating combination of different technologies. That’s something at which we will work in the future, hoping to make at least part of the Technology Roadmap public, when we get closer to the completion of our project”.

According to Dr. Jakob, there is still much to be done in energy efficiency for industries: “For some reason the agenda until now has been dominated by the residential context. I believe the work being done in REEMAIN is the first one, at least of this scale, to address the challenges of energy efficiency in industrial environment. That’s also why we pay huge attention to standardisation, through the involvement of a standardisation body, AENOR from Spain. Standardisation is in a way a pre-condition to achieve impact also on the level of policy making, which in our case will come in the long run”.

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Launched as a Capacity project in the SMEs associations scheme, the project has gone deep in studying efficiency problems and bottlenecks within the foundry and metal industry. “All in all – explains Ane Irazustabarrena Murgiondo, coordinator of the project – we are quite satisfied with the results we have achieved. We are reaching what can be defined now according to the new H2020 terminology, a TRL 6 for the demonstrator we will run within our facilities demonstrating the whole system with a shell and tube heat exchanger, able to recover gases up to 350ºC, combined with an ORC to generate electricity. The foundry environment is actually very complex and full measurements were not feasible in the framework of our project. So as an alternative we developed realistic simulation, in particular on temperatures and gas particles, checking corrosion, wear resistance and overall performance of the heat exchanger, which we believe can be perfectly extrapolated”. The FOUNDENERGY project actually tried different approaches to adapt to the needs of distinct foundries. “In the UK, at Saint Gobain, where we can work in a real industrial environment, we use a heat pipe to test what efficiency gains we could generate. We are also proposing an ORC in the range of 200-250° though there is a bit of uncertainty whether we will be able to demonstrate electricity production in the whole system, due to technical characteristics of the demonstration factory. Finally, we are also organising a demonstration by our Croatian partners, with a serpentine bundle, which is going to be shown at the industry days in Cimos”. FOUNDENERGY has natural links with REEMAIN and several commonalities in its approach to optimise energy efficiency, also by looking at a partial recovery of the heat, which is of course one of the areas where the potential for optimisation is higher. “The innovation we have brought about - continues Ane - is among others that we did very analytical testing on coating solutions and have been quite good at adapting solutions to the specific needs of industrial environments that, needless to say, change from case to case. On the other hand, we have also encountered scalability issues and with the technologies we deploy, we definitely need large scale plants and processes to generate relevant gains”. A challenge that Tecnalia will soon take up with a new project, called TASIO, focusing on mature technologies for continuous process industries like cement. “This will be much closer to the market – says Ane – and will hopefully present partners with clear exploitation opportunities at the end of the work”. Three years from January 2015, enough to establish a fruitful exchange of information and experience with the REEMAIN group.

Roughly one month before its formal completion, the FOUNDENERGY project led by Tecnalia in Spain, is finalising the validation phase with three demonstrators.

REEMAIN interviews

Insight into the foundries processes: the FOUNDENERGY project comes to its conclusion

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REEMAIN is developing a tool to assess a dataset of technology solutions

In a nutshell, this is the innovative tool that the REEMAIN technical partners are planning to deliver as one of the main outcome of the project. It will be based on the existing IES-THERM “State of the Art” (SOTA) modelling tool to virtually assess a dataset of technology solutions and identify an optimal configuration which can then be installed and tested within the factories. The tool will facilitate the identification of appropriate solutions in the context of both the building level elements and manufacturing elements within the entire facility.

The REEMAIN tool is now in its requirements specification phase, which is the crucial step before starting the real software coding phase. IES together with the other partners involved in developing the technical solutions and tools for efficient manufacturing, have already defined the overall approach to modelling and simulations to be followed by the tool: how the tool will work, which renewables technologies will be modelled and included (solar cooling systems, PVs, solar thermal collectors and solar concentrators, ORC and CHPC systems, hot water thermal storage and Li-ion batteries), how simulations will be done and the overall time schedule for that.

It is very important to have a common vision and agreement on how this will be done in the software as

Developing a support tool to allow factory managers to evaluate energy consumption and materials use and thus make informed decisions with respect to where best invest their limited resources.

modelling manufacturing sites is very complex, every process being different from each other even in factories of the same sector.

Requirements specifications for the rough cut methodology implementation are also under preparation, and it is expected to be a web based tool linked to the REEMAIN tool.

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REEMAIN closer to definition of simulation models following workshop at DMU

A further step has been taken towards the definition of the renewable energy models to be used in the REEMAIN demo sites at a meeting held last June in Leicester at De Montfort University.

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KPIs (Key Performance Indicators)

Given the complexity of industrial production in general, and of the specificities to be taken into account in the REEMAIN demonstration fields, this is a specially complex task, with clear implications on all successive project phases.

Coordinated by EURAC, work in the definition of KPIs has moved from the KAP project work summarised in its “Standardisation proposal and dissemination activities” report. While the main structure of the KPI description proposed by KAP was maintained, the REEMAIN group involved in the activity soon realized the importance of adding a field concerning, among other things, the time scale of the KPI acquisition/update.

sector.

KPIs (Key Performance Indicators) are of fundamental importance in order to evaluate the effectiveness of measures deployed.

Further specifications will have to be proposed for the actual deployment of activities at the REEMAIN demo sites (Gullón biscuit factory, SCM foundry, Bossa textile factory). This work is currently going on and in the next few weeks, a definitive KPI list will be prepared, including both general KPIs (suitable for application to different sectors) and specific KPIs (specialized for the different factories).

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Preliminary report on efficiency measures

A “Preliminary report on selection of efficiency measures “ was issued at the end of the first assessment of the efficiency improvements needed in the three demo sites. This extensive report concludes provides an initial identification of problems, opportunities and corresponding measures proposed to reduce inefficiencies and optimise processes. In this first phase, the three factories have been analysed in detail in terms of processes, auxiliary services, layouts, production schedules, and a first list of possible efficiency measures has been identified for each of them following a traditional analysis of the manufacturing sites.

These preliminary solutions will be further studied, ranked and evaluated in the second phase of the task to obtain a roll-out plan for the full deployment of optimisation arrangements. In parallel to the traditional analysis, IES have applied its existing (non-commercial) analysis tool for manufacturing environment to create models of the three factories and to analyse SCM factory (the foundry case in REEMAIN) in detail, starting from the already

Problems mapping and first efficiency measures planned

extensive amount of metered data available for this site. The final proposal for efficiency measures is due by the end of this year.

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The SCM Workshop

A workshop gathering a little more than 40 participants took place in Rimini (Italy) at the SCM headquarters at the end of September, focussing

on “Improved efficiency and resources management in Factories”, in connection with the LET’s 2014 Conference held in Bologna.

“As a side event to the LET’s Conference – says Giuseppe Lucisano of SCM foundry, one of REEMAIN’s industrial partners – our workshop proved an excellent opportunity to do work together with colleagues from the Daphne, Factory Ecomation and Foundenergy projects. We share several common issues and an efficient exchange of information and experiences is fundamental to enhance the uptake of innovative solutions for our production processes”.

The workshop followed a visit to the SCM foundry and touched upon both technical and economic issues, looking also at management practices. “In our

The importance of technology foresight and patent trends: some conclusions from the REEMAIN workshop within the LET’s 2014 Conference

view - says Lucisano – it is also very useful to invest on technology foresight to detect innovation trends, to know for instance what has been patented, what kind of knowledge has emerged and what will come next”.

According to Franco Cavadini of Synesis, scientific and technical coordinator of the Factory Ecomation project, “Events like these must be seen as an occasion to bridge the gap between research and industry. Work done in our projects can potentially benefit control optimisation approaches in several industrial settings, and it is very important for us to be challenged also with requirements and needs from different contexts”.

The workshop has also been the occasion to formally start the clustering activity among the four EU research projects (REEMAIN, Daphne, Factory Ecomation and Foundenergy), focussing on energy efficiency topics in energy intensive industrial sectors.

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Interesting upcoming events selected by the REEMAIN team

Recommended Events

Industrial Technologies Athens, 9 – 11 April

REEMAIN webinar on the WP3 Technology Roadmap 3 December 2014 14.30 CET

The webinar is intended to present and discuss the unique and robust REEMAIN "Technology Roadmap for RES, Storage and Waste Recovery for Efficient Manufacturing". It contains a listing inlcuding detailed SWOT analysis and ranking different types of innovative energy technologies that can be applied in industrial processes. The webinar is a previous step before face-to-face workshops where the current ranking and scores of the technologies will be reviewed by international specialists. Info: http://www.reemain.eu/News/Events/REEMAIN_webinar_on_the_WP3_Technology_Roadmap.kl

Industrial Technologies Athens, 9 – 11 April

Future of European Manufacturing Enabling the Next Industrial Renaissance London - UK, 27 November

After five years of the Eurozone crisis and with the first preliminary signs of recovery in sight, businesses, labour and policy makers are intensely seeking new avenues to strengthen manufacturing and re-energise this vital sector for the European economy. The Financial Times will bring together senior business leaders and policy makers for a unique, high level discussion on the particular opportunities and challenges facing industry in Europe. The debate will be centered on the fundamental adjustments that policy makers and business leaders need to make in order to revitalise European industry and strengthen long-term European competitiveness. Info: http://event.ft-live.com/ehome/index.php?eventid=94960

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ICIT 2015 Seville - Spain, 17 - 19 March 2015

IEEE ICIT is one of the flagship yearly conferences of the IEEE Industrial Electronics Society, devoted to the dissemination of new ideas, research and works in progress within the fields of intelligent and computer control systems, robotics, factory communications and automation, flexible manufacturing, data acquisition and signal processing, vision systems, and power electronics. IEEE ICIT 2015 will be held in Seville, Spain, from March 17th to 19th, 2015. Seville is well connected to the world by an international airport, a high speed train, four motorways, and a river port, and contains the longest bycicle track system in Europe. Touristic attractions include historic district with the gothic Cathedral and the Arabic Palace Alcazar, Baroque churches, a theme park, river cruises, and nearby National Parks and beaches. Seville combines a rich historical past, when it was the main gate to Europe from the Americas, with a vibrant present as a technological center and meeting point. Info: http://www.icit2015.org/

SET PLAN Conference 2014 Rome - Italy, 10 - 11 December

The move towards a low-carbon Europe with secure energy at affordable prices, with the achievement of the EU 2020 and 2030 energy targets, requires a profound transformation of the entire energy system, from the supply to the demand side. The SET Plan aims at increasing and focusing the efforts in research and innovation while enhancing the market uptake of new solutions as well as strengthening EU leadership in the development of low-carbon energy technologies.

The Conference will represent a unique forum for all stakeholders (experts, energy companies, universities, research institutes etc.), and representatives of national and EU institutions to have in-depth discussions on the new developments of the SET Plan in view of the Integrated Roadmap, and the actions needed to respond to the grand energy challenges ahead of us.

Info: http://www.setplan2014.it/

Energy Storage World Forum Rome - Italy, 27 – 30 April 2015

The Energy Storage Conference With 7 Past Successful Events And A Community Of Over 5700 Professionals Worldwide. In 2015 our 8th Energy Storage World Forum will take place in Rome and it will feature new value to our followers and newcomers! There will be 2 training courses and 5 conference days. In the meantime see below what our speakers covered in London in April 2014. Info: http://www.energystorageforum.com/

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More information on this Newsletter and related dissemination and communication activities of the project available at: REEMAIN D&C Secretariat e-mail: [email protected] Project Coordinator Centro Tecnológico CARTIF Parque Tecnológico de Boecillo 205. C.P. 47151 Boecillo, Valladolid - España Tel. 0034 983 54 65 04 Fax 0034 983 54 65 21 Coordinator Anibal Reñones Industrial Diagnosis Area Fundación CARTIF Register on www.reemain.eu or get access with your LinkedIn, Facebook, Google or Twitter accounts to receive the REEMAIN newsletter via e-mail. For the purposes of media law, editorial responsibility rests with the REEMAIN Communication Secretariat.

About REEMAIN

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 608977