Thermal Management of Industrial Processes

Lead Research Organisation: Newcastle University
Department Name: Sir Joseph Swan Institute

Abstract

This research project addresses the process industry contribution to the UK government goals of tackling climate change and reducing dependence on imported fuel. This programme fills these nationally important objectives by investigating the short, medium and long-term provision of energy for the UK, based on thermal technologies that exploit low grade process heat that is currently not recovered by this industry. The results of this 'Whole Systems Analysis research will improve plant efficiency and displace a significant fraction of fossil fuel use, thus reducing UK carbon dioxide emissions, by using techniques that are secure, clean, affordable and socially welcome. This research involves collaboration between several highly relevant industrial partners (e.g. Corus Ltd, North East Process Industry Cluster (NEPIC) Ltd, EON UK, Veolia (Sheffield Heat & Power Ltd), Pfizer Ltd, etc) and four internationally leading academic centres of excellence (Universities of Sheffield, Newcastle, Manchester & Tyndall Centre). The research programme targets a national problem by exploiting their complementary expertise through Whole Systems Analysis . Thus the objective of this research proposal is to investigate new and appropriate technologies and strategies needed for industry to exploit the large amount of unused low grade heat available. This will be achieved by providing a systematic procedure based on a comprehensive analysis of all aspects of process viability that will enable industry to optimise the management and exploitation of their thermal energy. This detailed procedure will be backed up by a sustained channel of communication between the relevant industrial and academic parties. This multidisciplinary work is thus applicable both to existing plants and the design of future plants. Please note that the establishment of an associated but separately funded EPSRC Network (e.g. PRO-TEM) is considered to be an integral part of this project, in order to satisfy the implicit role of technology transfer in both directions, between the process industry and the wider academic community. It will also provide access to industrial players who will provide essential case studies for the technical and socio-economic work. The case for an associated PRO-TEM Network is briefly discussed herein and the case is presented in detail in a separate proposal by Newcastle University.

Publications

10 25 50
 
Description The project successfully completed the research work described in the case for support. An extensive review of national sources of low grade heat available for the process industry was undertaken. Different sources of low grade heat were identified across a range of industrial sectors. Potential uses of this low grade heat were extensively investigated along with technological assessments of the potential to integrate with complementary technologies.



A case study, based on a real life industrial plant, was completed for the different sectors investigated including iron and steel, food processing, breweries and paper/pulp. Substantial engagement with a significant number of companies took place as described in the outcomes including analysis of operational processing sites, seminars for industry, journal papers, conference papers and poster presentations. The PRO-TEM Network was a crucial mechanism used to disseminate the results to both academia and industry particularly through the SusTEM 1st and 2nd Conference and the Applied Energy Special Issue.
Exploitation Route The project outcomes are highly relevant to a number of crucial UK industrial sectors and the project team have engaged extensively with industry. The project findings are being actively used and implemented in non-academic environments. A wide array of dissemination strategies have been used to maximise dissemination to all interested non academic parties. There was substantial collaboration with industrial partners resulting in the project results being utilised by companies in order to improve their thermal energy management. This has allowed a number of companies to utilise the project outcomes Work is also ongoing with a number of companies, particularly those in the food processing industry, to expand upon the work in the project. The results of the project have been fed into new FP7 project proposals and the results have been disseminated to partners in the European Energy Research Alliance (EERA). Finally the project involved collaboration with other UK universities and this project has resulted in strong links between these partners through joint publications and conferences.
Sectors Energy

URL http://research.ncl.ac.uk/pro-tem/
 
Description Potential low grade sources of heat identified, reviewed and technologically assessed. Case studies for a number of sectors were undertaken. Project results implemented by stakeholders to improve thermal energy management of their processes and reduced energy usage resulting in financial and environmental improvements. Beneficiaries: Process industry stakeholders
Sector Energy
Impact Types Cultural

 
Description GLOBAL-SECURE
Amount £485,000 (GBP)
Funding ID EP/K004689/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Academic/University
Country United Kingdom
Start 04/2012 
End 03/2013
 
Description Case Study: Food and Drink 1 
Organisation Belhaven Group
Country United Kingdom 
Sector Private 
PI Contribution Case Study in a medium sized brewery to undertake an energy audit to establish data and recommend long term sustainable opportunities within their plant and operations. This collaboration was extremely useful in the research work and resulted in 1 journal paper and 3 conference papers as a study of opportunities and barrieres to energy efficiency in medium sized breweries was based on this case study.
Start Year 2010
 
Description Case Study: Food and Drink 2 
Organisation Wylam Brewery
Country United Kingdom 
Sector Private 
PI Contribution Case study based on a micro brewery to analyse energy usage and potential opportunities for improvements to the thermal energy management of the plant. Techno-economic evaluations were undertaken on the plant's thermal energy management including an analysis on the implementation of an AD system.
Start Year 2010
 
Description Case Study: Iron and Steel 
Organisation Tata Steel Europe
Country United Kingdom 
Sector Private 
PI Contribution This report identifies opportunities for low grade heat recovery in the UK process industry. It then goes on to present a case study of an integrated iron and steel plant. The report gives an overview of the process and identifies the low grade waste heat streams at each step. The major sources are investigated in detail with temperature, flow rate and the total waste heat in both energy content and exergy.
Start Year 2010
 
Description Case Study: Pulp and Paper 
Organisation Energy Data Management
Country United Kingdom 
Sector Private 
PI Contribution This case study is of an integrated pulp and board mill producing over 150,000 tonnes of product per annum from virgin timber. The report gives an overview of the process and identifies the low grade waste heat streams at each step. The major sources of energy were investigated in detail with temperature, flow rate and the total waste heat in both energy content and exergy.
Start Year 2010
 
Description Collaboration with PepsiCo Limited 
Organisation PepsiCo
Country United States 
Sector Private 
PI Contribution Worked with PepsiCo Ltd to develop thermal energy management opportunities within their process capability. Worked with PepsiCo International to investigate heat exchanger technology and potential improvements to thermal management efficiency improvements. Also investigated the possibility of using wastes from processes to generate biogas in order to supply energy.
Start Year 2009
 
Description Biomass Heating and CHP Technology Seminar 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? Yes
Primary Audience Professional Practitioners
Results and Impact Technology seminar focusing on biomass heating and CHP. Attended by local SMEs.

Technology seminar attended by 27 SME companies. Presentation given by Northwoods Limited.
Year(s) Of Engagement Activity 2010
 
Description Energy Based Production Management in Greenhouses 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? Yes
Primary Audience
Results and Impact Public seminar presented to Energy Institute.

Seminar held to present work and discuss concept of using greenhouses as a heat sink for low grade heat. 30 attendees
Year(s) Of Engagement Activity 2012
 
Description Gasification Technology Seminar 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? Yes
Primary Audience Professional Practitioners
Results and Impact Technology seminar held to discuss gasification of biomass. Contribution to the seminar by Hybrid Gasification.

Technology seminar held for local SME companies. A local company contributed to seminar (Hybrid Gasification Limited). 40 attendees.
Year(s) Of Engagement Activity 2010
 
Description Lecture Tour to Australia 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? Yes
Geographic Reach International
Primary Audience Participants in your research or patient groups
Results and Impact Invited to give lecture tour to Australian universities including Monash, Melbourne and Queensland to present results of EPSRC project.

Presentation of project outcomes including identification of potential collaborations, sustainability of food production, opportunities and limitations of optimisation for thermal management in the processing industry.
Year(s) Of Engagement Activity 2011
 
Description Poster and Presentation: Effective Use of recycled heat via an integrated cascade system 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? Yes
Geographic Reach International
Primary Audience
Results and Impact Poster and presentation: displayed and presented at a conference, workshop and seminar.

Energy Institute/ABB Event on variable speed drives.

ERDF/Energy Institute Workshop on CHP/Trigeneration and waste heat recovery
Year(s) Of Engagement Activity 2011
 
Description Poster and Presentation: Energy Based Production Management in a Pot Plant Nursery 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience
Results and Impact Poster and presentation: displayed and presented at a conference, workshop and seminar.

Energy Institute/ABB Event on variable speed drives.

ERDF/Energy Institute Workshop on CHP/Trigeneration and waste heat recovery
Year(s) Of Engagement Activity 2011
 
Description Poster and Presentation: Thermal Management on Farms 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? Yes
Geographic Reach International
Primary Audience
Results and Impact Poster and presentation: displayed and presented at a conference, workshop and seminar.

Energy Institute/ABB Event on variable speed drives.

ERDF/Energy Institute Workshop on CHP/Trigeneration and waste heat recovery
Year(s) Of Engagement Activity 2011
 
Description Visits to European universities and companies 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience
Results and Impact Presentation of work with the food sector, dissemination of project results and discussions about potential cooperation.

Presenation of work undertaken in the project given with particular focus on the food sector.
Year(s) Of Engagement Activity 2011
 
Description Waste Heat Recovery: A Reality Check 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? Yes
Primary Audience
Results and Impact Presentation given at Energy Institute event.

Presenatation at event attended by 30 members of Energy Institute. Local company, Pipe Dream Limited, contributed to event.
Year(s) Of Engagement Activity 2011