Thermal Management of Industrial Processes
Lead Research Organisation:
Newcastle University
Department Name: Sir Joseph Swan Institute
Abstract
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Organisations
- Newcastle University (Lead Research Organisation)
- PepsiCo (Collaboration)
- Tata Steel Europe (Collaboration)
- Energy Data Management (Collaboration)
- Wylam Brewery (Collaboration)
- Belhaven Group (Collaboration)
- BP (United Kingdom) (Project Partner)
- E ON Engineering Ltd (Project Partner)
- Veolia (United Kingdom) (Project Partner)
- KBR (United Kingdom) (Project Partner)
- Vertellus Specialties (United Kingdom) (Project Partner)
- Tata Steel (United Kingdom) (Project Partner)
- Pfizer (United Kingdom) (Project Partner)
- North East of England Process Industry Cluster (United Kingdom) (Project Partner)
- Alstom (United Kingdom) (Project Partner)
Publications
Roddy D
(2012)
Development of a CO2 network for industrial emissions
in Applied Energy
Ammar Y
(2012)
Low grade thermal energy sources and uses from the process industry in the UK
in Applied Energy
Sturm B
(2013)
Opportunities and barriers for efficient energy use in a medium-sized brewery
in Applied Thermal Engineering
Ammar Y
(2013)
Evaluation of low grade heat transport in the process industry using absorption processes
in Applied Thermal Engineering
Ammar Y
(2012)
Desalination using low grade heat in the process industry: Challenges and perspectives
in Applied Thermal Engineering
Sturm B
(2012)
The feasibility of the sustainable energy supply from bio wastes for a small scale brewery - A case study
in Applied Thermal Engineering
| 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 | Public |
| 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 |