Smart Integration of Waste and Renewable Energy for Sustainable Heat Upgrade in the Industry

Project Information

SUSHEAT

Grant agreement ID: 101103552

DOI

10.3030/101103552

EC signature date 4 April 2023

Start date 1 May 2023

End date 30 April 2027

Funded under

• Climate, Energy and Mobility

Total cost

€ 4 673 743,75

EU contribution

€ 4 673 743,75

Coordinated by

UNIVERSIDAD NACIONAL DE EDUCACION A DISTANCIA
Spain

Periodic Reporting for period 1 - SUSHEAT (Smart Integration of Waste and Renewable Energy for Sustainable Heat Upgrade in the Industry)

Reporting period: 2023-05-01 to 2024-10-31

Summary of the context and overall objectives of the project

Europe aims to cut greenhouse gas emissions by 55% by 2030 and achieve net-zero CO2 emissions by 2050. The industrial sector, heavily reliant on fossil fuels for high-temperature processes, accounts for 81% of total energy consumption and produces 552 Mt/a of CO2 emissions. Only 14% of process heat demand is met by biomass and electricity, highlighting the sector's dependence on fossil fuels and the urgent need for sustainable solutions.
This project focuses on decarbonizing industrial heat demand by developing technologies for efficient, low-carbon heat production. It integrates high-temperature heat pumps, bio-inspired thermal energy storage, solar heat, and AI-based control systems to meet high-temperature energy needs. The goal is to reduce energy consumption and CO2 emissions in industrial processes, supporting the transition to cleaner energy.
The project aims to validate three novel technologies at TRL 5:
1. Stirling-based High-Temperature Heat Pumps (HT-HP): COP up to 2.8 for 150–250 °C heat.
2. Bio-Inspired Thermal Energy Storage (TES): PCM-based systems for flexible energy use during low availability periods.
3. AI-Driven Control & Integration Twin (CIT): Optimizing energy management.
A 200 kWth pilot will emulate the needs of two industries (dairy and fish oil) and extend findings to other sectors. Self-assessment tools will help industries evaluate energy efficiency and decarbonization pathways. Flexible technologies address intermittent energy sources, upgrading waste and solar heat to ensure reliable industrial energy provision.
The expected impacts are:
1. Annual savings of 100 TWh and a reduction of 20 million tons of CO2.
2. Increase energy efficiency.
3. Lower carbon credit dependence.
4. Positioning Europe as a leader in sustainable industrial technologies.
Long-term outcomes include system flexibility, clean energy solutions, and circular economic models for industrial decarbonization.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Activities Undertaken:
1. Analyzed industrial heat demand and tailored layout proposals to end-user needs, optimizing configurations based on the SUSHEAT concept.
2. Advanced the adaptation of High-Temperature Heat Pump (HTHP), Thermal Energy Storage (TES), and Control and Integration Twin (CIT) technologies for laboratory testing.
3. Completed basic and detailed designs and identified suppliers for test rig
Key Achievements:
1. Industrial heat demand and system scenarios:
o Identified industrial heat demand and the CO2 emission reduction potential of SUSHEAT (Marcos et al., 2024, DOI: 10.3390/app14198994).
o Developed preliminary scenarios for heat sources and system configurations tailored to end-user needs for testing.
2. Technology developments:
o HTHP component design:
Validated seals for 200 °C delivery temperatures and specified piston ring configurations.
Conducted ongoing COP optimization with performance mapping under SUSHEAT-relevant conditions.
o TES development:
Initiated testing of bio-inspired TES designs and characterized phase change materials (PCMs).
Developed an initial evolutionary algorithm based on bio-inspired design rules.
o AI-Based control system:
Developed a conceptual framework for simulating SUSHEAT systems.
Designed data structures, APIs, and animations to manage real-time simulations.
Identified hardware requirements for input/output operations.
3. Test rig design:
o Created process flow diagrams for industrial layouts and pilot plants.
o Established a testing plan for SUSHEAT validation and finalized the Piping and Instrumentation Diagram (P&ID).
o Secured suppliers with multiple sourcing options for components.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The project aims to improve the performance and operational capabilities of three core technologies, both as part of the integrated SUSHEAT system and as individual components. The following activities have been completed, marking advancements beyond the state of the art or representing significant progress for these technologies:
• Heat pump development:
o Sealing Solutions: Validated seals capable of 200 ºC operation, progressing toward the target of 250 ºC.
o Piston Rings: Specified configurations to minimize wear at high temperatures, supporting cost-effective maintenance.
o COP Optimization: Ongoing optimization for temperature ratios of 1.2–1.3 with initial performance mapping under project-relevant conditions.
• TES tank development:
o Bio-Inspired Design: Laboratory testing of TES tanks revealed PCMs with properties differing from literature, critical for material selection (Martínez et al., 2024, DOI: 10.10459.1/46694).
o Performance Gains: The first bio-inspired TES tank demonstrated comparable charging rates but 52% faster discharging compared to conventional designs (Cabeza et al., 2024, DOI: 10.3390/app14072940).
• CIT development:
o Generated a robust conceptual framework for simulating SUSHEAT-based systems was established (Butean et al., 2024, DOI: 10.1016/j.procs.2024.05.087).
o Created the base of a digital twin for virtual lifecycle simulations, including data structures, APIs, and enhanced visualizations for real-time management.
o Designed a framework for detailed system analysis and AI-supported micro-management, supported by hardware requirements for I/O operations.

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