Periodic Reporting for period 3 - DESTINY (Development of an Efficient Microwave System for Material Transformation in energy INtensive processes for an improved Yield)
Período documentado: 2021-10-01 hasta 2023-03-31
The DESTINY project aims to create a functional, green and energy saving, scalable and replicable solution, applying microwave energy for continuous processing in energy intensive industries. The target is to develop and demonstrate a new concept of firing granular feedstock for materials transformation using full microwave heating as alternative and complement to the existing conventional production.
The DESTINY system is conceived as cellular kilns system in mobile modular plant, with significant advantages in terms of resource and energy efficiency, flexibility, replicability and scalability with reduced environmental footprint.
The DESTINY concept has been proved in a demo site located in Spain, covering high energy demanding sectors of strategic interest as Ceramic (Pigments), Cement (Calcined clay) and Steel (Sinter, Iron Pellets/ DRI, ZnO), to validate the critical parameters of the developed technology in relevant environment (TRL 6). It was implemented 2 feeding modules at the demo site and 1 mobile microwave kiln module and product treatment.
Influence of the DESTINY solutions in terms of stability, process efficiency and quality of raw materials, intermediate/sub/final products was investigated to improve performance of the industrial processes addressed and guarantee the required quality of products. Numerical simulation tools has been used to drive the design and support the testing activities.
The industrialization and sustainability of DESTINY high temperature microwave technology was assessed through the evaluation of relevant KPIs, set using Life Cycle Methodologies. With the final aim of ensuring a large exploitation and market penetration for DESTINY, technology-based solutions business model, economic viability and replicability analysis were conducted. For guaranteeing industrial transferability appropriate exploitation and dissemination activities have been defined during and even after the end of the project.
The DESTINY system is conceived as cellular kilns system in mobile modular plant, with significant advantages in terms of resource and energy efficiency, flexibility, replicability and scalability with reduced environmental footprint.
The DESTINY concept has been proved in a demo site located in Spain, covering high energy demanding sectors of strategic interest as Ceramic (Pigments), Cement (Calcined clay) and Steel (Sinter, Iron Pellets/ DRI, ZnO), to validate the critical parameters of the developed technology in relevant environment (TRL 6). It was implemented 2 feeding modules at the demo site and 1 mobile microwave kiln module and product treatment.
Influence of the DESTINY solutions in terms of stability, process efficiency and quality of raw materials, intermediate/sub/final products was investigated to improve performance of the industrial processes addressed and guarantee the required quality of products. Numerical simulation tools has been used to drive the design and support the testing activities.
The industrialization and sustainability of DESTINY high temperature microwave technology was assessed through the evaluation of relevant KPIs, set using Life Cycle Methodologies. With the final aim of ensuring a large exploitation and market penetration for DESTINY, technology-based solutions business model, economic viability and replicability analysis were conducted. For guaranteeing industrial transferability appropriate exploitation and dissemination activities have been defined during and even after the end of the project.
The DESTINY project, started in October 2018 and ended in March 2023, is fully completed its actions.
During the first 18 months of activities, very relevant advances on DESTINY project were made. The main developments that have been addressed focuses on three aspects: the new microwave-based technology, the selected products and raw materials, as well as the new processing of DESTINY. The requirements of production were collected and summarized to the new DESTINY processing based on microwave technology. The wide campaign of analysis of dielectric properties, as well as the compositional characterization of the raw materials and products, allowed identify the main indicators of processing demand for the microwave treatment.
Progress has covered the detailed analysis of the reactions in all the feedstock, products and constructive materials under microwave conditions (dielectric properties, thermal analysis and compositional) that has been used in simulation tools for design of the process and microwave heating conditions. It has continuous with the design, development, construction and configuration of a microwave applicator, as well as the adaption in the conveying system to the feedstock, has been reached the target temperature for all the materials selected. The main parameters to be monitored and the control tools were also defined.
During the second 18-month period of the project, the preliminary work was translated into advances in the design and pre-commissioning of the microwave demonstrator. Extensive simulations and real product tests were carried out, with the results continuously integrated into adjustments and refinements of the applicators and feeding systems. Materials, processes, and the raw materials to be transformed in the microwave kiln were tested, selected, and adapted when necessary.
During the 3rd period,the project finally deployed the pilot plant installation at the industrial site. The Demo Plant was fully installed and trials of the three sectors were performed. Feeding system was completed and concentrated in a container (top container) and the microwave reactor was installed in another container (bottom container). All data was collected and shared with the partner according to their activities. Identified KPI were analysed based on the data collected to evaluate the general performance of the system.
In terms of the project expoitation, extensive studies to analyse market and leading stakeholders in each sector were performed, ensuring at all times to be align with main industry association data and targets. Moreover, it was fully delivered a project Business Plan which includes the assessment of the sustainability and desirability aspects, as well as the analysis of the next steps required, resources and team provided.
Dissemination and communication activities have been arranged during the life of the project, focused on raising awareness on the project and its results and progresses.
During the first 18 months of activities, very relevant advances on DESTINY project were made. The main developments that have been addressed focuses on three aspects: the new microwave-based technology, the selected products and raw materials, as well as the new processing of DESTINY. The requirements of production were collected and summarized to the new DESTINY processing based on microwave technology. The wide campaign of analysis of dielectric properties, as well as the compositional characterization of the raw materials and products, allowed identify the main indicators of processing demand for the microwave treatment.
Progress has covered the detailed analysis of the reactions in all the feedstock, products and constructive materials under microwave conditions (dielectric properties, thermal analysis and compositional) that has been used in simulation tools for design of the process and microwave heating conditions. It has continuous with the design, development, construction and configuration of a microwave applicator, as well as the adaption in the conveying system to the feedstock, has been reached the target temperature for all the materials selected. The main parameters to be monitored and the control tools were also defined.
During the second 18-month period of the project, the preliminary work was translated into advances in the design and pre-commissioning of the microwave demonstrator. Extensive simulations and real product tests were carried out, with the results continuously integrated into adjustments and refinements of the applicators and feeding systems. Materials, processes, and the raw materials to be transformed in the microwave kiln were tested, selected, and adapted when necessary.
During the 3rd period,the project finally deployed the pilot plant installation at the industrial site. The Demo Plant was fully installed and trials of the three sectors were performed. Feeding system was completed and concentrated in a container (top container) and the microwave reactor was installed in another container (bottom container). All data was collected and shared with the partner according to their activities. Identified KPI were analysed based on the data collected to evaluate the general performance of the system.
In terms of the project expoitation, extensive studies to analyse market and leading stakeholders in each sector were performed, ensuring at all times to be align with main industry association data and targets. Moreover, it was fully delivered a project Business Plan which includes the assessment of the sustainability and desirability aspects, as well as the analysis of the next steps required, resources and team provided.
Dissemination and communication activities have been arranged during the life of the project, focused on raising awareness on the project and its results and progresses.
DESTINY aspires to introduce the “first-of-a-kind” high-temperature microwave processing system at industrial level, offering a variety of vital benefits to energy intensive sectors: reduced energy consumption, lower lifetime operating costs and enhanced sustainability profile. Furthermore, new products with improved qualities will be introduced. Substantial contributions are foreseen towards meeting critical contemporary global-scale challenges: (a) the EU Greenhouse Gas emission targets of the Paris Agreement (>40% reduction by 2030); (b) the EU vision on achieving the UN Sustainable Development Goals (SDG’s) and (c) one of the major topics of the Industry 4.0 initiative (Consistency of Engineering over the whole Lifecycle). Such an ambitious endeavour cannot be accomplished if not exceeding not only the State-of-the-Art, but also the State-of-the-Practice, in terms of securing the promising results already at hand and integrating them into industrial-scale systems.
The DESTINY project is fully in line with the expected impacts of the SPIRE-02-2018 call and is addressing clear and urgent needs towards:
• improving efficiency and competitiveness through a collaborative approach,
• establishing economically feasible environmental and social improvements, and
• developing synergies between innovative technologies and business models, in order to position the European industry ahead in the race for competitiveness and sustainability
These key objectives are the basis on which the DESTINY project builds to move firmly forward. Its novel, disruptive technology will increase energy efficiency in several industries (cement, ceramic, steel) and provide an opportunity to reduce the European external dependency on energy resources. The particular objectives of DESTINY’s project are:
• Allowing for a -30% to +30% energy input within RES fluctuations timeframes, without significant losses in specific energy efficiency,
• Improving energy efficiency by 30%,
• Improving resource efficiency by 30%,
• Decreasing CO2 emissions by 40%,
• Decreasing OPEX and CAPEX by 15%,
• Effective dissemination of major innovation outcomes.
The DESTINY project is fully in line with the expected impacts of the SPIRE-02-2018 call and is addressing clear and urgent needs towards:
• improving efficiency and competitiveness through a collaborative approach,
• establishing economically feasible environmental and social improvements, and
• developing synergies between innovative technologies and business models, in order to position the European industry ahead in the race for competitiveness and sustainability
These key objectives are the basis on which the DESTINY project builds to move firmly forward. Its novel, disruptive technology will increase energy efficiency in several industries (cement, ceramic, steel) and provide an opportunity to reduce the European external dependency on energy resources. The particular objectives of DESTINY’s project are:
• Allowing for a -30% to +30% energy input within RES fluctuations timeframes, without significant losses in specific energy efficiency,
• Improving energy efficiency by 30%,
• Improving resource efficiency by 30%,
• Decreasing CO2 emissions by 40%,
• Decreasing OPEX and CAPEX by 15%,
• Effective dissemination of major innovation outcomes.