Periodic Reporting for period 1 - FLEXIndustries (Digitally-enabled FLEXible Industries for reliable energy grids under high penetration of Variable Renewable Energy Sources (VRES))
Période du rapport: 2022-06-01 au 2023-11-30
FLEXIndustries builds upon a holistic multi-disciplinary and multi-scale approach fostering its 7 multi-sector energy intensive industries design and deploy the most suitable Energy Efficiency Measures and Process Flexibility Methods for their industrial environments. FLEXIndustries develops and demonstrates a Dynamic Energy & Process Management Platform (DEPM) to monitor, analyse and optimize the most energy-intensive industrial processes. Demonstration will take place in 7 industrial facilities in 6 reference countries.
FLEXIndustries aims at:
• defining a comprehensive assessment methodology appliable to different sectors
• facilitating the convergence of IT/OT domains through digital twins
• combining novel energy storage, conversion systems and grid control technologies
• demonstrating at TRL7 the proposed holistic approach in 7 industrial relevant environments
• developing novel sustainable and financeable DR-led business models
• defining suitable paths-to-market, promoting replicability in additional sectors
The expected impacts of FLEXIndustries are:
• Contribution to Europe’s new EU Green Deal and Industry 4.0/5.0 targets.
• Achievement of at least one third of the EU process industries with Digital Twin by 2030.
• Creation of safe places for people, by considering Health & Safety as well as SSH issues
• Enabling training and development programmes
• Contribution to average worldwide employment of about 14.5 jobs/M€
• Enabling cooperation with Innovation Hubs, including agile4.0 isZEB, AI4EU project.
• Spread of wide-scale rollout of large-scale H4C across Europe by 2025
• Contribution to decrease waste production up to 40% by 2030.
• Attainment of 313 TWh energy savings until 2030, 65 MtCO2eq savings by 2030 within the EIIs ecosystem, contributing to SPIRE targets of 80% reduction in CO2-eq emissions and zero landfilling of recyclable/recoverable waste by 2050.
FLEXIndustries aims at:
• defining a comprehensive assessment methodology appliable to different sectors
• facilitating the convergence of IT/OT domains through digital twins
• combining novel energy storage, conversion systems and grid control technologies
• demonstrating at TRL7 the proposed holistic approach in 7 industrial relevant environments
• developing novel sustainable and financeable DR-led business models
• defining suitable paths-to-market, promoting replicability in additional sectors
The expected impacts of FLEXIndustries are:
• Contribution to Europe’s new EU Green Deal and Industry 4.0/5.0 targets.
• Achievement of at least one third of the EU process industries with Digital Twin by 2030.
• Creation of safe places for people, by considering Health & Safety as well as SSH issues
• Enabling training and development programmes
• Contribution to average worldwide employment of about 14.5 jobs/M€
• Enabling cooperation with Innovation Hubs, including agile4.0 isZEB, AI4EU project.
• Spread of wide-scale rollout of large-scale H4C across Europe by 2025
• Contribution to decrease waste production up to 40% by 2030.
• Attainment of 313 TWh energy savings until 2030, 65 MtCO2eq savings by 2030 within the EIIs ecosystem, contributing to SPIRE targets of 80% reduction in CO2-eq emissions and zero landfilling of recyclable/recoverable waste by 2050.
RINA-C in close cooperation with CERTH, developed an effective administrative, financial, technical, and legal management to ensure the successful execution of the project. CIRCE with STAM, CAR, LINKS, developed a market analysis of flexibility potential in intensive industries and identified a comprehensive set or parameters and established the architecture of the overall FLEXIndustries platform. CERTH with CAR, THD, and CIRCE, develops integrated energy systems, waste energy solutions, and modifies processes for flexibility, adapting to demo sites with numerical tools. LINKS collaborates closely with SIM to implement the FLEXIndustries DEPM Platform infrastructure and integrate functional modules from WP4 and WP5 tasks. CERTH in close cooperation with, CAR, FBK, UoP, aims to conduct analysis and forecast of the processes, material and energy related data. CAR aims to assess the sustainability of Industrial Flexibility concepts.ICONS supported by RINA-C, identifies optimal flexibility services and market mechanisms for remunerating energy-flexible industrial processes, creating relevant business use cases.
In the long-term, the expected results of FLEXIndustries are:
• Increase local RES electricity production from 0.4 up to 1.5 GWh,
• Increase on-site storage capacity by 0.1-0.4 MWh for electricity and by 6.6 MWh for heat.
• RES and storage systems acceptance rate in the industrial sector higher than 90% among EIIs.
• Achievement of a faster response time of 5%-8%.
• Achievement of 3.8% average peak shaving decrease.
• Substitution of fossil fuels with RES-based thermal generation and waste heat recovery systems, saving up to 33,111 tCO2eq/y.
• Reduction of 0.9%-41.0% energy consumption reduction.
• Accumulation of primary Energy Savings of 156.69 GWh/yr in total (160.23 incl. own actions), resulting also in corresponding overall process energy efficiency increase of 1.1%-90%.
• Increase of flexibility offered to the grid between 5-11%.
• Replication of Digital Twin solution in 5 industrial facilities and 3 additional sectors
• Increase of overall user satisfaction by 90% among FLEXIndustries’s industrial workforce.
• Increase of waste heat recovery of 69.49 GWh/y by using HPs, heat storage, ORC solutions and thermoelectric systems.
• Increase utilization of waste material volumes from 7% up to 41%.
• Energy cost reduction from 1.7% to 45.6% (1.9%-45.6% incl. own actions).
• LCC reduction at plant level of at least 1.4%.
In the long-term, the expected results of FLEXIndustries are:
• Increase local RES electricity production from 0.4 up to 1.5 GWh,
• Increase on-site storage capacity by 0.1-0.4 MWh for electricity and by 6.6 MWh for heat.
• RES and storage systems acceptance rate in the industrial sector higher than 90% among EIIs.
• Achievement of a faster response time of 5%-8%.
• Achievement of 3.8% average peak shaving decrease.
• Substitution of fossil fuels with RES-based thermal generation and waste heat recovery systems, saving up to 33,111 tCO2eq/y.
• Reduction of 0.9%-41.0% energy consumption reduction.
• Accumulation of primary Energy Savings of 156.69 GWh/yr in total (160.23 incl. own actions), resulting also in corresponding overall process energy efficiency increase of 1.1%-90%.
• Increase of flexibility offered to the grid between 5-11%.
• Replication of Digital Twin solution in 5 industrial facilities and 3 additional sectors
• Increase of overall user satisfaction by 90% among FLEXIndustries’s industrial workforce.
• Increase of waste heat recovery of 69.49 GWh/y by using HPs, heat storage, ORC solutions and thermoelectric systems.
• Increase utilization of waste material volumes from 7% up to 41%.
• Energy cost reduction from 1.7% to 45.6% (1.9%-45.6% incl. own actions).
• LCC reduction at plant level of at least 1.4%.
Edge Layer innovations:FLEXIndustries builds on previous EU co-funded projects, surpassing adaptive middleware approaches.
Multi-agent systems for advanced industrial energy and process control: FLEXIndustries adopts intelligent agents as control loops, autonomous entities observing real-time data through sensors and effecting changes via actuators.
Novel industrial waste heat recovery systems: FLEXIndustries will provide a set of innovations based on (i) a low-GWP industrial heat pump, (ii) two different improved ORC units and (iii) a novel TEG system for a cement kiln. → (i) HIREF will engineer a HPbased solution able to simultaneously provide useful cold water at 10°C and useful hot water at 90°C. (ii) THD will develop a heat-to-power engine suitable for exploiting the heat rejected by the cooling system of IC engines in biogas plants. TUL will examine a non-conventional turbine design (Elektra turbine) (iii) Finally, TRAF will optimize and scale up to 0.5MW a thermoelectric heat capture module for high temperatures covering the surface of a rotary clinker kiln at TITAN demo site.Integrated Battery (BESS) and Thermal Energy Storage Systems for industrial applications:FLEXIndustries will develop the integration of 2 stationary BESS at FORD’s demo site and SUAN’s demo site. FLEXIndustries will as well develop the integration of a latent heat based thermal storage tank, as in the case of the PRO facility (20 MWth) storing steam produced from the nearby RDF-fired CHP plant. Integrated solar thermal systems for industrial applications: Under FLEXIndustries, TVP will engineer and commission a solar thermal system based on High Vacuum Flat Panel technology, to be installed in K-FLEX demo site and will demonstrate the smart control and integration of solar-based air heating technologies (solarwall) in the large warehouses of the automotive industries.
Multi-agent systems for advanced industrial energy and process control: FLEXIndustries adopts intelligent agents as control loops, autonomous entities observing real-time data through sensors and effecting changes via actuators.
Novel industrial waste heat recovery systems: FLEXIndustries will provide a set of innovations based on (i) a low-GWP industrial heat pump, (ii) two different improved ORC units and (iii) a novel TEG system for a cement kiln. → (i) HIREF will engineer a HPbased solution able to simultaneously provide useful cold water at 10°C and useful hot water at 90°C. (ii) THD will develop a heat-to-power engine suitable for exploiting the heat rejected by the cooling system of IC engines in biogas plants. TUL will examine a non-conventional turbine design (Elektra turbine) (iii) Finally, TRAF will optimize and scale up to 0.5MW a thermoelectric heat capture module for high temperatures covering the surface of a rotary clinker kiln at TITAN demo site.Integrated Battery (BESS) and Thermal Energy Storage Systems for industrial applications:FLEXIndustries will develop the integration of 2 stationary BESS at FORD’s demo site and SUAN’s demo site. FLEXIndustries will as well develop the integration of a latent heat based thermal storage tank, as in the case of the PRO facility (20 MWth) storing steam produced from the nearby RDF-fired CHP plant. Integrated solar thermal systems for industrial applications: Under FLEXIndustries, TVP will engineer and commission a solar thermal system based on High Vacuum Flat Panel technology, to be installed in K-FLEX demo site and will demonstrate the smart control and integration of solar-based air heating technologies (solarwall) in the large warehouses of the automotive industries.