Energy efficiency demonstration in manufacturing industry The University of Manchester (UNIMAN) Manchester, 3 August 2012 Energy–

Who are we?

1824 Created by industrialists as the Manchester Mechanics Institution 1846 Owens College founded 1880 Owens College became The Victoria University of Manchester 1905 Faculty of Technology, University of Manchester 1956 Royal Charter granted to Manchester College of Science and Technology 1965 University of Manchester Institute of Science and Technology 2004 The merger of Victoria University and UMIST resulted in establishment of The University of Manchester The University of Manchester Staff: 10,712 (4500 academic & research) Students: ca 40, Research Assessment Exercise (RAE): The UoM has smashed the 'Golden Triangle' of research universities traditionally dominated by Oxford, Cambridge and London 65% of research activity is judged to be 'world-leading' or 'internationally excellent'

Centre for Process Integration (CPI) Birthplace of Energy pinch technology Water pinch technology Hydrogen pinch technology Activities Research Software development Professional training Innovative technology transfer Consulting Teaching Staff 5 academic staff 25 PhD students 160 MSc students (CEAS)

What do we do?

Research & technology The clean and efficient use of materials, energy and capital Efficient Use of Raw Materials Design and optimisation of chemical reactors Reaction-separation systems Hydrogen integration in refining Molecular modelling of refinery processes Integrated refinery heavy-end processes Energy Efficiency Design of heat recovery systems Fouling in heat recovery systems Cogeneration and site utility systems Distributed energy systems Distillation system design Absorption sytems Sub-ambient systems and low temperature separation Emissions Reduction Water and wastewater minimisation Decarbonised energy production Biofuels production Flue gas emissions Process Operations Refinery optimisation Refinery scheduling Reliability and maintenance EU collaborative projects National funding Industry (international)

Software Software packages: STARSTAR - site utility and cogeneration systems design WORKWORK - low temperature (sub-ambient) processes design SPRINTSPRINT - energy systems design for individual processes on a site Star Energy targeting Total site analysis Cogeneration Utility system optimization Fuel gas emissions

Training and Consultancy Software Workshops ("Hands on" training) Annual conference Quality assurance

Process Integration Research Consortium Created in 1984 Currently 15 major organisations representing different process and utility industries (ca in total during its existence) Providing a focal point for research and development of technologies Rapid technology transfer through software and training

UNIMAN’s role in EFENIS?

1.Project Co-ordinator 2.RTD Partner

UNIMAN’s Interest in EFENIS The Project will enhance CPI UNIMAN’s expertise in - In-depth understanding of site-wide heat and power management - conceptual guidelines for site utility systems design and operation - energy demand calculation with uncertainty data - a systematic framework for min site energy consumption of multi-criteria and multi- objective optimisation under uncertainty - waste heat sources identification for total site integration - technology extension for heat recovery for total site integration - introduction of CHP into the total site context - integration of energy efficiency and emissions technology - better integration of waste heat and cooling technologies To link research with demonstration activities in major industrial sites

UNIMAN’s Role in EFENIS UNIMAN will contribute principally to Total site integration and optimisation technology Total site waste heat recovery with intensified heat transfer

Participant number Participant short name Estimated eligible costs (whole duration of the project) Total receipts Requested EC contribution RTD/ Innovation Demons tration ManagementOtherTotal ( A )( B )( C )( D ) ( A ) + ( B ) + ( C ) + ( D ) 1UNIMAN UNIMAN budget UNIMAN RTD WP16 WP20 WP36 WP42 DEMO WP58 WP68 WP76 WP86 WP95 Total47 MANAGEMENT WP1024 TOTAL per PARTICIPANT71 UNIMAN person-months

WP10 Project Management WP9 Technology transfer WP1 Total site integration and optimisation WP5: Chemicals Decision-supporting Methodology Enabling Technologies Demonstration WP6: Oil Refinery WP7: Coal-to- Chemicals WP8: CHP and Distr. Heating WP2 Total Site carbon management WP3 Total Site waste heat recovery with intensified heat transfer WP4 Integration with CHP and distr.heating Work Packages with UNIMAN coordination/participation

WP Num WP Title Type of activity Objectives Start month End month WP 1 Total site integration and optimisation technology (UNIMAN) RTD Task 1.1: Total site targeting and process integration (UNIMAN) Task 1.2: Improving operability of site utility systems, subject to demand fluctuation (UNIPAN) Task 1.3: RAM (Reliability, Availability, Maintainability) analysis for site utility systems (UNIMAN) Task 1.4 Systematic framework for efficient and reliable modelling in site energy management (UNIMAN) Task 1.5 Integrated cooling water system design (UNIMAN) Task 1.6 Total Site multi-criteria and multi-objective optimisation ((UNIMAN) Task 1.7 Total Site Process Operability for Energy Efficiency (AUTH) Task 1.8 Total Site Optimization of Energy, Cost and Environmental Impact (AUTH) 130 WP 3Total site waste heat recovery with intensified heat transfer (UNIMAN) RTDTask 3.1 Identification of waste heat recovery potentials (UNIMAN) Task 3.2 Technology selections and design for waste heat recovery (UNIMAN) Task 3.3. Combined heat & power (VTT) Task 3.4 Improving retrofitability and implementability (UNIMAN) Task 3.5: Selection of heat transfer enhancement techniques for total site integration (UNIPAN) Task 3.6: Advanced heat exchangers (CFD-modelling and optimisation) (UPB) 624 Work Packages and Tasks with UNIMAN coordination/participation

WP Num WP Title Type of activity Objectives Start month End month WP 4 Integration with local CHP and district heating energy systems (UNIGOA) RTD Task 4.1: Identification of local energy sources, the potential industrial, commercial and residential energy demands and outlining the boundaries of the integrated energy sectors (UNIMAN) Task 4.2: District heating and cooling (UNIGOA) Task 4.3: Selection and modelling of energy technologies for local-energy integration (UNIGOA) Task 4.4: Optimisation of localised and distributed energy systems (UNIGOA) 630 WP 5 Demonstration - Putting into practice total site energy management for the chemical industry (BAYER) DEMO Task 5.1: Analysis of the as-is state of the site (BAY, support by UNIMAN, UPB and UNIPAN) Year 1 Task 5.2: Perform “fundamentally-improved” Total Site Analysis (BAY supported by UNIMAN, UPB and UNIPAN) Task 5.3: Detailed planning and implementation of identified improvement measures (BAY, UNIMAN, UNIPAN, UPB) Task 5.4.: Check transferability to other sites (BAY, UNIMAN, UNIPAN, UPB) 136 WP 6 Demonstration - Putting into practice total site energy management for oil refineries (MOL) DEMOTask 6.1: Analysis of the as-is state of the site (MOL, support by UNIPAN, UNIMAN) Task 6.2: Perform “fundamentally-improved” Total Site Analysis (UNIPAN, UNIMAN, SODRU support by MOL) Task 6.3: Comparison of results of 6.1 and 6.2 (MOL, UNIPAN, UNIMAN, SODRU) Task 6.4.: Check transferability to other sites (MOL, UNIPAN, UNIMAN) Task 6.5: Retrofit Upgrade (MOL) 136 Work Packages with UNIMAN coordination/participation (Cont.)

WP Num WP Title Type of activity Objectives Start month End month WP 7 Demonstration - Putting into practice total site energy management for coal-to-chemicals (ENN) DEMO Task 7.1: Analysis of the as-is state of the site (ENN, support by UNIMAN, UNIPAN, VA) Task 7.2 Integration of cooling water systems with other site utilities (VA, supported by UNIMAN) Task 7.3: Perform “fundamentally-improved” Total Site Analysis Task 7.4: Comparison of results of 7.1 and 7.2 (ENN, UNIMAN, UNIPAN, VA) Task 7.5.: Check transferability to other sites (ENN, UNIMAN, UNIPAN, VA) Task 7.6: Retrofit Upgrade (ENN) 136 WP 8 Demonstration - Putting into practice total site energy management for CHP and district heating (IPLOM) DEMO Task 8.5: Retrofit Upgrade (IPLOM) Task 8.4: Check transferability to other sites (IPLOM, UNIGOA, AUTH, VTT) Task 8.3: Comparison of results of 8.1 and 8.2 (IPLOM, UNIGOA, AUTH, UNIPAN, VTT) Task 8.2: Perform “fundamentally-improved” Total Site Analysis (UNIGOA, AUTH, VTT, support by IPLOM) Task 8.1: Analysis of the as-is state of the site (IPLOM, support by UNIGOA, UNIPAN, AUTH) 136 WP9 Technology Transfer (BAYER) OTHERTask 9.1 – Protection of project results Task 9.2 – Development of exploitation strategy Task 9.3 – Knowledge Dissemination Task 9.4 – Training Activities Task 9.5. Energy Service Centre activities 636 Work Packages with UNIMAN coordination/participation (Cont.)

WP Num WP Title Type of activity Objectives Start month End month WP 10 Project management (UNIMAN) MGTTask 10.1 – Periodic reports after each reporting period (12 months), final report, financial distribution report (UNIMAN) Task 10.2 – Submission and organisation of the cost statements and consortium agreements (UNIMAN) Task – Report on gender, societal and ethical issues of exploitation (UNIMAN) 136 Work Packages with UNIMAN coordination/participation (Cont.)

WP Num WP TitleDeliverables NumTitle Dissem Level Date Mon WP1 Total site integration and optimisation technology D1.1 Report on conceptual design methodology for the total site energy analysis PU12 D1.3 Report on system modelling and analysis for RAM study of site utility systems RE15 D1.4 Report on application of novel conceptual design method from energy-intensive process units PU15 D1.5 Systematic framework for efficient and reliable energy demand calculation RE20 D1.6 Report on design framework for integrating cooling water systems with other site utilities RE24 WP3 Total site waste heat recovery with intensified heat transfer D3.1 Report on identification of waste heat recovery potentials to be integrated within a total site PU12 D3.2 Report on technology selection and extension for waste heat recovery PU20 WP9 Technology transfer D9.5Training session among Industrial and Academic partnersPU24 WP10 Project management D10.1 Periodic reports after each reporting period (12 months), final report, financial distribution report PU24 D10.2 Submission and organisation of the cost statements and consortium agreements PU36 D10.3Report on gender, societal and ethical issues of exploitation PU36 List of Deliverables PU: Public RE: Restricted to a group specified by the consortium (including the Commission Services)

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package person months each for feedback on research and keeping informed Main activity: Research collaboration

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package person months each for feedback on research and keeping informed Main activity: Research collaboration

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package person months each for feedback on research and keeping informed Main activity: Research collaboration

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package 5 Main activity: Demonstration Interaction to implement demonstration

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package 6 Main activity: Demonstration Interaction to implement demonstration

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package 7 Main activity: Demonstration Interaction to implement demonstration

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package 8 Main activity: Demonstration Interaction to implement demonstration

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package 9 Main activity: Dissemination, exploitation Interaction to implement dissemination

Participant no.Participant organisation name 1 (Coordinator)The University of Manchester (UNIMAN) 2Bayer (BAY) 3MOL Hungarian Oil and Gas Company (MOL) 4Vestas Aircoil (VA) 5IPLOM (Industria Piemontese Lavorazione Oli Minerali - Piedmontese Mineral Oil Processing Factory) (IPLOM) 6ENN Science and Technology Development Co. Ltd. (ENN) 7VTT Technical Research Centre of Finland (VTT) 8Sodrugestvo-T (SODRU) 9ESTIA Consulting and Engineering (ESTIA) 10University of Pannonia (UNIPAN) 11University of Paderborn (UPB) 12Aristotle University of Thessaloniki (AUTH) 13Genoa University (UNIGOA) 14University of Maribor (UNIMAR) 15Hanyang University (HU) 16Alexandra Instituttet A/S (AI) Collaboration with Partners within Work Package 10 Collaboration with all Partners

Efficient Use of Raw Materials Design and optimisation of chemical reactors Reaction-separation systems Hydrogen integration in refining Molecular modelling of refinery processes Integrated refinery heavy-end processes Energy Efficiency Design of heat recovery systems Fouling in heat recovery systems Cogeneration and site utility systems Distributed energy systems Distillation system design Absorption sytems Sub-ambient systems and low temperature separation Emissions Reduction Water and wastewater minimisation Decarbonised energy production Biofuels production Flue gas emissions Process Operations Refinery optimisation Refinery scheduling Reliability and maintenance Research & Technology to be applied

Research & Technology to be applied (Cont.) Targeting and Design Simulation Graphical method - Charts like grand composite curve, site composite curve provide relationship between processes energy demand and utility system Mathematical programming - widely used to determine the optimum topology - some linearization simplifications reformulate MINLP into MILP 31