Optimising Energy Management in Industry - 'OPTEMIN'

Lead Research Organisation: Brunel University
Department Name: Institute of Energy Futures

Abstract

The UK Government the EU and the international community in general have ambitious targets for reduction of Greenhouse Gas Emissions (GHG) and Global Warming. Even though emission reduction targets to 2020 are likely to be met by the UK, longer term targets to 2050 and 2100 are unlikely to be met without substantial changes to policy and technological approaches in the generation, distribution and utilisation of energy.
Globally, industrial energy use is responsible for 33% of greenhouse gas emissions. In the UK, industrial emissions have reduced in recent years and are now estimated to contribute between 20-25% of total emissions. Approximately 70% of the energy demand of the industrial sector is for heat. All heating processes result in significant quantities of waste heat, up to 50% in some cases, and is widely acknowledged that there is significant potential for heat recovery, estimated at between 18-40 TWh/yr or £0.18-0.4 billion per year at today's energy prices. As yet, most of this potential has remained unexploited due to technical, economic and organisational factors. Other opportunities for energy efficiency and decarbonisation include the optimisation of steam systems that are responsible for 35% of industrial energy use, the use of bioenergy, particularly from organic and other wastes generated on site, and whole industrial site energy integration and optimisation.
To exploit the potential offered by energy efficiency, heat recovery and conversion to electrical or thermal energy at a higher or lower temperature and utilise the opportunities offered by waste to energy conversion and energy integration a number of major challenges need to be addressed. These include: i) development and application of technologies for data acquisition at high enough granularity to enable detailed analysis of performance at component, process and system level, ii) methodologies for the optimal design of technologies to provide confidence in their performance at impementation stage, iii) tools for performance analysis and control optimisation in real time, iv) modelling of energy flows at site level to provide optimisation of energy management based on energy, environmental and economic considerations, and iv) investigation and development of business models that overcome barriers and encourage the adoption of new energy efficient and demand reduction technologies.
In the OPTEMIN project we aim to address these challenges by working very closely with our key industrial collaborators to: i) understand the major technical, operational and economic issues associated with the acquisition and analysis of large energy data, ii) use the data to gain insights into the complex energy networks, their interactions and impacts in large industrial manufacturing facilities, iii) critically evaluate the performance of new innovative energy demand reduction and energy conversion technologies using data from demonstration installations, iv) investigate drivers and business models that can facilitate their full development and commercialisation, v) develop methodologies and tools to optimise individual process design, whole site energy integration and management and evaluate their decarbonisation potential within the context of Government policies and decarbonisation roadmaps to 2050. The overall objective is to demonstrate through the research programme and fully documented case studies supported by comprehensive data sets, the potential to achieve energy demand and carbon emission reductions in excess of 15%.

Planned Impact

Industrial energy use in the UK represents 20-25% of total greenhouse gas emissions. It is acknowledged that these emissions can be reduced by improving further the energy efficiency of manufacturing processes, the maximisation of energy recovery from waste and waste heat streams and improved overall industrial site energy integration and management. These changes will be enabled by technological innovations, cost reductions, and innovations in business models and policies that encourage and incentivise the adoption of new technologies and energy demand reduction measures.
The proposed research will optimise energy management in industry through the investigation, development and demonstration in collaboration with industry partners a new generation of innovative energy recovery and conversion technologies from waste and waste heat streams and optimum integration and management of these technologies to achieve energy demand reduction and emissions of the order of 10-15%. This will be achieved by: i) understanding the interrelationships and interactions between energy consuming processes and the different energy carriers in industrial and manufacturing sites through large data capture, classification, storage and retrieval, ii) the development of tools for the design of innovative energy recovery and conversion technologies and their optimum integration within existing industrial sites, iii) evaluation of the economic and environmental performance of these technologies; iv) the development of business models and data that can be used by decision makers at company level and policy makers to encourage and incentivise the adoption of energy demand reduction measures and technologies.
The new technology design and energy management tools and control algorithms that will be developed and demonstrated will benefit technology manufacturers and large industrial energy users. In the initial stages principal beneficiaries will be the industrial partners which include very large energy users from the Iron and Steel and Food and Drink manufacturing sectors, TATA Steel and Faccenda Foods, and innovative technology manufacturers, Spirax Sarco, Enogia SAS and Eonotherm Ltd. These innovations will, however, not only be applicable to the Iron and Steel and F&D sectors but also all other energy intensive sectors such as the Petrochemical, Pharmaceutical, Cement and Pulp and Paper which offer significant potential for waste and waste heat to energy conversion. In industrial thermal processes 30-50% of energy input is wasted through different waste heat streams. Recovery and conversion or upgrading some of this heat through the innovative heat recovery and conversion systems is expected to reduce energy demand by 10-15%, assuming a conversion efficiency of 50% and result in return on investment of between 2-5 years.
The reduction of carbon emissions will enable the Government and industry to move closer to the decarbonisation targets set for 2050 and beyond and project outcomes will contribute to Government decarbonisation policies and action plans. At the same time, the energy intensive industries will benefit from lower energy costs and increased competitiveness which should lead to lower final product costs and improved employment opportunities from which the general public will benefit. Technology manufacturing companies will also benefit from the rapidly rising global heat recovery and power generation market which is expected to reach $53.12 billion by 2018.

Publications

10 25 50

 
Description Evaluation of the efficiency of new heat to power technologies.
Comparison of environmental impacts and cost effectiveness of energy efficiency approaches in the food and steel sectors
Exploitation Route The technologies being developed are implemented on industrial sites.
Information and data in publications can be used by academia and industry
Sectors Energy

 
Description Findings from the research are contributing to the development of new technologies and energy saving approaches by industry
First Year Of Impact 2018
Sector Energy
Impact Types Economic

 
Title The enhanced DBSCAN algorithm for clustering 
Description The statistical analysis on the collected data is conducted, including operating conditions and voltage unbalance rates of machines at different operational modes. With the value of MinPts, the optimal Eps value of an enhanced DBSCAN can be determined by the k-dist curve plot automatically. Then for every manufacturing sub-process, the machine status can be identified by the enhanced DBSCAN algorithm. 
Type Of Material Technology assay or reagent 
Year Produced 2019 
Provided To Others? Yes  
Impact The classical DBSCAN algorithm requires two parameters, Eps and MinPts, the accurate estimation of which is a critically important task for good performance. For the enhanced DBSCAN, the optimal Eps could be determined by the first sharp change on k-dist curve automatically 
 
Title The genetic algorithm for job shop scheduling 
Description The production schedule defines how and when machine and materials will be utilised to make each product. Quotas and order deadlines are dictated by customer demand, however varying degrees of flexibility always exist in how these demands are met. Research on multiple jobs processed by several machines while each job must be performed in a given order is one of the most important industrial activities job shop scheduling (JSS). Genetic algorithm (GA) is an evolutionary process inspired optimization approach, and has been widely adopted in job shop scheduling. Here we use GA to solve the JSS in bakery. 
Type Of Material Technology assay or reagent 
Year Produced 2019 
Provided To Others? Yes  
Impact The genetic algorithm is deployed to solve the job shop scheduling problem in bakery based upon the commercial electrical tariffs, and this reduces the electricity bill by £80 per day in the case study. In addation, Gantt chart presents the result of optimal scheduling. 
 
Description OPTEMIN Project 
Organisation TATA Steel
Country India 
Sector Private 
PI Contribution Analysis of data and advice on energy savings
Collaborator Contribution Staff time and data
Impact Project on-going.
Start Year 2017
 
Title point energy monitoring platform 
Description The point energy technology is developed for SMEs to improve the insight of the energy usage in the manufacturing processes and installed in a local bakery. 
Type Of Technology Webtool/Application 
Year Produced 2018 
Open Source License? Yes  
Impact Dashboard is available for industrial partner to visualize live electrical data for a whole production line, gas data for hot water and steam 
URL http://www.likang.org/
 
Description 2018 International Conference on Intelligent Manufacturing and Internet of Things & International Conference on Sustainable Energy Engineering 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact The 2018 International Conference on Intelligent Manufacturing and Internet of Things & International Conference on Sustainable Energy Engineering has launched on September 22, 2018 at Huxi Campus, Chongqing University. IMIOT & ICSEE 2018 is jointly organized by Chongqing University, Queen's University Belfast, University of Leeds and Chongqing Association for Science and Technology, with support of the government of Shapingba District and University Consortium on Engineering Education and Research. Nearly 300 delegates, including academicians, Changjiang Scholars and Outstanding Young Persons from home and abroad have attended the event. Experts and scholars different countries and regions presented in 16 sessions, sparkled a number of discussions and research collaborations. Three conference proceedings have been published in Springer's lecture notes.
Year(s) Of Engagement Activity 2018
URL https://www.springer.com/us/book/9789811323836
 
Description 2018 UK-China (Chongqing) Knowledge Exploitation and Standardization Forum 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The forum brought together leading figures from the government, academia and industry to discuss novel and cross-boundary approaches of collaborations and facilitation mechanism between UK and China to promote innovation and knowledge exploitation in the fields of intelligent manufacturing and revolutionary smart energy systems. In the meantime, the forum has launched the preparation event of the UK-China knowledge exploitation network, and showcases some of the latest progresses and projects in the two areas. The event was featured with distinguished guest speeches on the impact of policy, role of incubators and catapults, novel mechanisms to facilitate UK-China collaborations on knowledge transfer, sustainable innovation and knowledge transfer, and case studies of UK-China collaborations on knowledge transfer. Posters of existing and potential knowledge transfer projects from academic institutions were presented to attract further funding and investment, and a UK-China Knowledge Exploitation Network Preparation Ceremony was launched.
Year(s) Of Engagement Activity 2018
URL http://ukchinaconsortium.com/chongqing-conferenceworkshop
 
Description Invited presentation 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Attend EPSRC 6 sensor project meeting at University of Surrey on 4 March 2018 and made a presentation on point energy technology, which has sparkled discussions and questions among attendees from both academia and industrialists.
Year(s) Of Engagement Activity 2019
 
Description LoCITY 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact London auxTRU project introduction
Year(s) Of Engagement Activity 2017
 
Description Workshop on nexus of smart energy, intelligent manufacturing and transportation systems 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Schools
Results and Impact This workshop provides a platform to share some latest studies and thoughts on the nexus of smart energy, manufacturing and transportation systems in alignment with the global effort in achieving 100% clean and renewable transition for all sectors. In additional to invited speeches and panel discussion, an early career researchers workshop and a UCEER project scoping meeting will be organised, out of which task groups for networking and consortium projects will be formed for tackling key challenging problems across the smart energy, manufacturing and transportation systems.
Year(s) Of Engagement Activity 2019
URL http://ukchinaconsortium.com/leeds-workshop