Periodic Reporting for period 3 - CIRMET (Innovative and efficient solution, based on modular, versatile, smart process units for energy and resource flexibility in highly energy intensive processes)
Berichtszeitraum: 2021-10-01 bis 2022-12-31
The process industry contributes to over half of European industrial production and is responsible for huge energy consumption, GHG emissions and waste generation. An increase in energy and resource efficiency of these processes is critical for the competitiveness of this industry, but also for environmental sustainability.
CIRMET project aimed to develop a solution to provide energy and resource flexibility to EIIs. After the development and validation of the CIRMET concept at TRL7, it was concluded that the modular approach of the solution could provide flexibility to different sectors such as steelmaking, cement, non-ferrous metals and wastewater treatment, contributing to increasing their energy and resource efficiency and reducing their environmental footprint.
CIRMET project aimed to develop a solution to provide energy and resource flexibility to EIIs. After the development and validation of the CIRMET concept at TRL7, it was concluded that the modular approach of the solution could provide flexibility to different sectors such as steelmaking, cement, non-ferrous metals and wastewater treatment, contributing to increasing their energy and resource efficiency and reducing their environmental footprint.
The work started with the definition of the main requirements for the CIRMET demonstrator and the individual demonstrators according to the specifications of the validation plant (WP2). It was decided to develop the global solution following a modular approach that could permit to better answer to the different needs of the industrial sectors.
The first of the modules (EFFIMELT) was designed, manufactured and tested at WP3. It is a furnace that can treat different kind of metal-containing wastes thanks to its flexible design. It is powered by a highly efficient thermal plasma system and allows the complete valorisation of the wastes. The possible substitution of coke with biochar as reducing agent was tested. And the use of syngas from the torrefaction unit to substitute N2 in the plasma torch was also tested.
The furnace is the core, but the global EFFIMELT unit is composed of different auxiliary equipment. The briquetting area was designed to prepare the briquettes by mixing waste, reducing agent (either coke or biochar) and binder and compacting them. The heating area was refurbished with new melting furnaces and a new captation system was built.
The second of the modules (RECUWASTE) was designed, manufactured and tested in WP4. This WHRS transforms thermal energy into mechanical energy through an ORC unit to produce compressed air. The CVT is able to self-balance depending on the compressed air demand and the available heat. An energy storage system was integrated. Different systems were built: a system to store energy in batteries transforming the excess energy to be stored in batteries and a flywheel that is a mechanical storage system. The ORC unit included innovations looking at increasing process efficiency, sustainability and safety.
The third of the modules (AFF4.0) is a platform composed of physical and digital tools with a data fusion layer to transfer data from the physical to the digital side. The platform was designed and developed in WP5. Firstly, a soft sensor, a process optimization tool and a M&C tool were developed. Then, a software tool to monitor process data and provide descriptive analytic functionalities was developed and all the components were integrated.
Once individually validated, the modules were transferred to the plant where commissioning works were carried out. WP6 started earlier to perform the conditioning works needed to implement a new module as CIRMET. When ready, the different components of the demonstrators were commissioned and assembled according to the layout. For safety reasons, EFFIMELT and RECUWASTE were separately validated.
EFFIMELT validation trials consisted of operating the furnace in 2 scenarios: 1) only coke used as reducing agent and 2) 50% of coke substituted by biochar. Good metallurgical behaviour was observed in both with similar recovery rates of value elements. The lower environmental impact when using biochar contrasted with the higher processing cost.
RECUWASTE validation trials consisted of testing the system working in 3 different scenarios: 1) heat directly transferred to the air compressor, 2) reduced compressed air demand deriving the excess energy to the batteries and 3) lack of heat releasing the stored energy to the air compressor. The 3 scenarios were successfully tested.
AFF4.0 platform was tested in both RECUWASTE and EFFIMELT and, thanks to the online connection, data was transferred to the descriptive tool. The platform was also tested with the briquetting machine and with the slag produced at the EAF to optimize both processes.
Replicability studies were also done (WP7) for CIRMET and the individual modules for several sectors (steel, cement, glass and wastewater).
The results were disseminated through different channels. Technical webinars and a final workshop were organised. The partners took part in different events (conferences, fairs,..) to reach different stakeholders. Aiming at disseminating the knowledge built in CIRMET, learning resources were also developed, divided in 6 modules and classified into 4 different levels to adapt to the learning needs of the different groups.
Finally, business and action plans for the different results of the projects were prepared. It was concluded that the CIRMET solution as a whole and the EFFIMELT module are economically viable for the EAFD treatment. The main commercialization partner intends to upscale the technology in the market.
The first of the modules (EFFIMELT) was designed, manufactured and tested at WP3. It is a furnace that can treat different kind of metal-containing wastes thanks to its flexible design. It is powered by a highly efficient thermal plasma system and allows the complete valorisation of the wastes. The possible substitution of coke with biochar as reducing agent was tested. And the use of syngas from the torrefaction unit to substitute N2 in the plasma torch was also tested.
The furnace is the core, but the global EFFIMELT unit is composed of different auxiliary equipment. The briquetting area was designed to prepare the briquettes by mixing waste, reducing agent (either coke or biochar) and binder and compacting them. The heating area was refurbished with new melting furnaces and a new captation system was built.
The second of the modules (RECUWASTE) was designed, manufactured and tested in WP4. This WHRS transforms thermal energy into mechanical energy through an ORC unit to produce compressed air. The CVT is able to self-balance depending on the compressed air demand and the available heat. An energy storage system was integrated. Different systems were built: a system to store energy in batteries transforming the excess energy to be stored in batteries and a flywheel that is a mechanical storage system. The ORC unit included innovations looking at increasing process efficiency, sustainability and safety.
The third of the modules (AFF4.0) is a platform composed of physical and digital tools with a data fusion layer to transfer data from the physical to the digital side. The platform was designed and developed in WP5. Firstly, a soft sensor, a process optimization tool and a M&C tool were developed. Then, a software tool to monitor process data and provide descriptive analytic functionalities was developed and all the components were integrated.
Once individually validated, the modules were transferred to the plant where commissioning works were carried out. WP6 started earlier to perform the conditioning works needed to implement a new module as CIRMET. When ready, the different components of the demonstrators were commissioned and assembled according to the layout. For safety reasons, EFFIMELT and RECUWASTE were separately validated.
EFFIMELT validation trials consisted of operating the furnace in 2 scenarios: 1) only coke used as reducing agent and 2) 50% of coke substituted by biochar. Good metallurgical behaviour was observed in both with similar recovery rates of value elements. The lower environmental impact when using biochar contrasted with the higher processing cost.
RECUWASTE validation trials consisted of testing the system working in 3 different scenarios: 1) heat directly transferred to the air compressor, 2) reduced compressed air demand deriving the excess energy to the batteries and 3) lack of heat releasing the stored energy to the air compressor. The 3 scenarios were successfully tested.
AFF4.0 platform was tested in both RECUWASTE and EFFIMELT and, thanks to the online connection, data was transferred to the descriptive tool. The platform was also tested with the briquetting machine and with the slag produced at the EAF to optimize both processes.
Replicability studies were also done (WP7) for CIRMET and the individual modules for several sectors (steel, cement, glass and wastewater).
The results were disseminated through different channels. Technical webinars and a final workshop were organised. The partners took part in different events (conferences, fairs,..) to reach different stakeholders. Aiming at disseminating the knowledge built in CIRMET, learning resources were also developed, divided in 6 modules and classified into 4 different levels to adapt to the learning needs of the different groups.
Finally, business and action plans for the different results of the projects were prepared. It was concluded that the CIRMET solution as a whole and the EFFIMELT module are economically viable for the EAFD treatment. The main commercialization partner intends to upscale the technology in the market.
CIRMET represents an innovative solution that can be implemented in different industrial sectors with high resource consumption. It is capable of revalorising metallic wastes and recovering and transforming waste heat in an efficient way using monitoring, control and data analytic tools to improve process plant competitiveness.
Compared to current solutions to treat metallic wastes, EFFIMELT represents a sustainable alternative. It is energetically efficient thanks to the plasma heating system, and it has lower fossil-based CO2 emissions thanks to the proven capacity of substituting up to 50% coke by biochar. It contributes to the metal circularity avoiding the need to landfill wastes.
For RECUWASTE, no similar products for the generation of compressed air from exhaust gases were found. Current solutions focus on the recovery of heat for electricity generation. Its competitive advantage is the direct production of compressed air to reduce electricity consumption. The gradual increase in the cost of energy and the energy efficiency directives promoted by the EU are market drivers that positively affect the commercialization of RECUWASTE.
Concerning AAF40, many similar products or competing developments exist. However, they tend to provide specific or too general solutions with expert knowledge requirements in AI. The main competitive advantage of this solution is that it has a general and flexible vision in which data-based optimization is carried out in a friendly way. And it gives agnostic flexibility and is suitable for any process.
The individual demonstrators and the global CIRMET solution were validated at TRL7 and, according to the assessment, their industrialization will have a direct impact on the reduction of landfilled waste and consumption of primary resources, increase of energy efficiency and reduction of fossil-based CO2 emissions. Consequently, it can contribute to the sustainability of different processes and the competitiveness of the companies where these solutions could be implemented. In addition, the knowledge generated will reach students, policymakers and industry experts through the online learning programmes than have been implemented and tested with small groups of students at different universities.
Compared to current solutions to treat metallic wastes, EFFIMELT represents a sustainable alternative. It is energetically efficient thanks to the plasma heating system, and it has lower fossil-based CO2 emissions thanks to the proven capacity of substituting up to 50% coke by biochar. It contributes to the metal circularity avoiding the need to landfill wastes.
For RECUWASTE, no similar products for the generation of compressed air from exhaust gases were found. Current solutions focus on the recovery of heat for electricity generation. Its competitive advantage is the direct production of compressed air to reduce electricity consumption. The gradual increase in the cost of energy and the energy efficiency directives promoted by the EU are market drivers that positively affect the commercialization of RECUWASTE.
Concerning AAF40, many similar products or competing developments exist. However, they tend to provide specific or too general solutions with expert knowledge requirements in AI. The main competitive advantage of this solution is that it has a general and flexible vision in which data-based optimization is carried out in a friendly way. And it gives agnostic flexibility and is suitable for any process.
The individual demonstrators and the global CIRMET solution were validated at TRL7 and, according to the assessment, their industrialization will have a direct impact on the reduction of landfilled waste and consumption of primary resources, increase of energy efficiency and reduction of fossil-based CO2 emissions. Consequently, it can contribute to the sustainability of different processes and the competitiveness of the companies where these solutions could be implemented. In addition, the knowledge generated will reach students, policymakers and industry experts through the online learning programmes than have been implemented and tested with small groups of students at different universities.