Periodic Reporting for period 3 - RETROFEED (Implementation of a smart RETROfitting framework in the process industry towards its operation with variable, biobased and circular FEEDstock)
Reporting period: 2022-11-01 to 2023-10-31
RETROFEED main objective is to enable the use of an increasingly variable, bio-based and circular feedstock in process industries through the retrofitting of core equipment and the implementation of an advanced monitoring and control system, and providing support to the plant operators by means of a DSS (Decision Support System) covering the production chain.
This approach has been demonstrated in five Resources and Energy Intensive Industries (REII), namely ceramic, cement, aluminium, steel, and agrochemical, reaching in average an increase of 23% in resource efficiency and 8% in energy efficiency, with a consequent reduction in GHG emissions of 73 kton of CO2.
To achieve this, RETROFEED (1) has developed a Digital Twin (DT) of the core process equipment for all demo sites to deeply characterise the behaviour of this equipment and to analyse the impact of several retrofitting scenarios and the modification of the process conditions without affecting the product quality; (2) has demostrated that the solutions increase the amount of waste and recycled material that can be feed into the processes of ASAS, TCID and FTIB; (3) has boosted the utilisation of bio-based materials to reduce their fossil fuel reliance in SECIL, FENO and SILCOTUB; (4) has improved the existing control systems in the plant by acting in two levels: (i) designing new control loops and (ii) designing the control commands on the new actuators to allow a more precise and rapid response; (5) has developed a holistic Decision Support System (DSS) tool by integrating the advanced models developed for each demonstrator in order to fully exploit the information provided about the process energy and material flows and overall performances; and (6) has prepared a replication methodology, an analysis of technical and non-technical barriers, policy recommendations, an environmental framework and a capacity building program to ensure a proper transfer of the project outcomes
This approach has been demonstrated in five Resources and Energy Intensive Industries (REII), namely ceramic, cement, aluminium, steel, and agrochemical, reaching in average an increase of 23% in resource efficiency and 8% in energy efficiency, with a consequent reduction in GHG emissions of 73 kton of CO2.
To achieve this, RETROFEED (1) has developed a Digital Twin (DT) of the core process equipment for all demo sites to deeply characterise the behaviour of this equipment and to analyse the impact of several retrofitting scenarios and the modification of the process conditions without affecting the product quality; (2) has demostrated that the solutions increase the amount of waste and recycled material that can be feed into the processes of ASAS, TCID and FTIB; (3) has boosted the utilisation of bio-based materials to reduce their fossil fuel reliance in SECIL, FENO and SILCOTUB; (4) has improved the existing control systems in the plant by acting in two levels: (i) designing new control loops and (ii) designing the control commands on the new actuators to allow a more precise and rapid response; (5) has developed a holistic Decision Support System (DSS) tool by integrating the advanced models developed for each demonstrator in order to fully exploit the information provided about the process energy and material flows and overall performances; and (6) has prepared a replication methodology, an analysis of technical and non-technical barriers, policy recommendations, an environmental framework and a capacity building program to ensure a proper transfer of the project outcomes
The basis for the modelling and simulation of the industrial processes, the baseline of the project by means of the characterization of the current situation of the RETROFEED demo-cases and the analysis of the market and the feedstock variability has been set. At the same time, a preliminary methodology to guide the retrofitting actions has been presented, all in PR1.
Flame monitoring developed by CIRCE to SECIL has been finished and the two developments for clinker monitoring system have been installed by AIMEN in SECIL successfully. Finally, monitoring infrastructure and the control strategy has been defined. Additionally, DSS for each demo case has been tested and validated except for FTIB.
For the demo sites, the following developments have been carried out:
1)TCID: digital twin and DSS tested and validated. Engineering and installation for the retrofitted heat recuperator. Validation by melting 9 different frits in the retrofitted furnace. Improved high temperature recuperator. Feedstocks optimized in the production optimizing process draining smelter. Experimental campaign carried out.
2)SECIL: digital twin and DSS tested. Satellite burners has been installed and tested, allowing to use higher rates of RDF. Almost all sensors have been installed. Experimental campaign carried out.
3)ASAS: digital twin and DSS tested and validated. Design and construction of the oxygen lance, O2 level measurement system and delacquering system by STEK. Detailed engineering and design of control system. Commissioning and installation of all equipments and experimental campaign carried out.
4)FENO and SILCOTUB: digital twin and DSS tested. Design and construction of the innovative burner by HTT and CFD simulations by CSM. Commissioning of installation and experimental campaign carried out. Feasibility study of waste heat utilization done
6)FERTIBERIA: digital twin and DSS tested. Tests in pilot plant. Detailed engineering of the novel reactor. Preparation for commissioning.
Additionally, the correct performance of the RETROFEED solutions in each of the demo sites have been fine tunned. Its replicability potential has been analysed and their overall impact and improvements achieved. As well, the lessons learnt from the project in a methodology to support REIIs to undertake their retrofitting actions has been carried out.
Besides, within business plan and exploitation, final exploitation plan, final business plan, business models and bankability opportunities has been provided. Also, the standardization analysis and the environmental framework have been developed.
Finally, a successful social media campaign, several event organisations, the participation in national and international conferences and the organization of the final event have been carried out. Besides, development of training modules and e-learning platform have been finished.
Flame monitoring developed by CIRCE to SECIL has been finished and the two developments for clinker monitoring system have been installed by AIMEN in SECIL successfully. Finally, monitoring infrastructure and the control strategy has been defined. Additionally, DSS for each demo case has been tested and validated except for FTIB.
For the demo sites, the following developments have been carried out:
1)TCID: digital twin and DSS tested and validated. Engineering and installation for the retrofitted heat recuperator. Validation by melting 9 different frits in the retrofitted furnace. Improved high temperature recuperator. Feedstocks optimized in the production optimizing process draining smelter. Experimental campaign carried out.
2)SECIL: digital twin and DSS tested. Satellite burners has been installed and tested, allowing to use higher rates of RDF. Almost all sensors have been installed. Experimental campaign carried out.
3)ASAS: digital twin and DSS tested and validated. Design and construction of the oxygen lance, O2 level measurement system and delacquering system by STEK. Detailed engineering and design of control system. Commissioning and installation of all equipments and experimental campaign carried out.
4)FENO and SILCOTUB: digital twin and DSS tested. Design and construction of the innovative burner by HTT and CFD simulations by CSM. Commissioning of installation and experimental campaign carried out. Feasibility study of waste heat utilization done
6)FERTIBERIA: digital twin and DSS tested. Tests in pilot plant. Detailed engineering of the novel reactor. Preparation for commissioning.
Additionally, the correct performance of the RETROFEED solutions in each of the demo sites have been fine tunned. Its replicability potential has been analysed and their overall impact and improvements achieved. As well, the lessons learnt from the project in a methodology to support REIIs to undertake their retrofitting actions has been carried out.
Besides, within business plan and exploitation, final exploitation plan, final business plan, business models and bankability opportunities has been provided. Also, the standardization analysis and the environmental framework have been developed.
Finally, a successful social media campaign, several event organisations, the participation in national and international conferences and the organization of the final event have been carried out. Besides, development of training modules and e-learning platform have been finished.
KEY RESULTS
1) DSS Tool: tested and finished for all demo sites
2) In-line H2SO4 reactor for NPK process: not installed due to lack of time
3) Aluminium furnace redesing towards scrap use: Aluminium melting furnace, O2 injector system and delacquering drum system finished successfully
4) Flame monitoring & diagnosis: The flame monitoring development has been finished successfully
5) Multi-spectral FTIR sensors for product quality: clinker monitoring system (two developments) finished successfully
6) Multi fuel burner for a rotatory kiln: satellite burner for burining more RDF shares is finished successfully. Only some seconday equipment is still missing.
7) Advanced monitoring and control for frits smelter: Engineering and installation of new sensors and equipment were carried out successfully
IMPACTS
1) Increase of 23% in resources efficiency and 8% in energy efficiency
2) Reduction of 8% in GHG emissions
3) Reduction of 23% in the utilisation of fossil resources
4) Reduction of 3% in OPEX and increase of 17% in productivity
5) WEbsite, disseminaition event and e-learnign platform hava allowed an effective dissemination of major innovation outcomes.
6) DSS Increase the overall plant performance
7) Sensors and monitor & control system created has incresased the monitoring of the plant conditions
7) Modelling and simulation through the development of DT and the DSS (that is feeded by DT) is helping to improve control capabilities
9) A more sustainable use of feedstock: TCID has reduced the feedstock waste, SECIL has incresed the use of RDF, ASAS has increased the scrap taht they can use, FENO and SILCOTUB are using plastic byproducts as new feedstock and FTIB is using ashes as P alternative
10) Improved health and safety conditions: the monitoring and control systems developed within the project reduce the requirements for human inspection of the processes.
11) Replication: Replication of activities has been analysed by the partners in D10.4 and the technical deliverables produced during the project should greatly facilitate the adoption of the innovations. The replication in plants belonging to other companies inside the EU is addressed in D10.5
12) Use of alternative materials and reduction of use of fossil fuels reduce the EU external dependence
13) No impact on EU employability but expected due to training
14) Impact on industrial trends from an environmental and technical point of view
1) DSS Tool: tested and finished for all demo sites
2) In-line H2SO4 reactor for NPK process: not installed due to lack of time
3) Aluminium furnace redesing towards scrap use: Aluminium melting furnace, O2 injector system and delacquering drum system finished successfully
4) Flame monitoring & diagnosis: The flame monitoring development has been finished successfully
5) Multi-spectral FTIR sensors for product quality: clinker monitoring system (two developments) finished successfully
6) Multi fuel burner for a rotatory kiln: satellite burner for burining more RDF shares is finished successfully. Only some seconday equipment is still missing.
7) Advanced monitoring and control for frits smelter: Engineering and installation of new sensors and equipment were carried out successfully
IMPACTS
1) Increase of 23% in resources efficiency and 8% in energy efficiency
2) Reduction of 8% in GHG emissions
3) Reduction of 23% in the utilisation of fossil resources
4) Reduction of 3% in OPEX and increase of 17% in productivity
5) WEbsite, disseminaition event and e-learnign platform hava allowed an effective dissemination of major innovation outcomes.
6) DSS Increase the overall plant performance
7) Sensors and monitor & control system created has incresased the monitoring of the plant conditions
7) Modelling and simulation through the development of DT and the DSS (that is feeded by DT) is helping to improve control capabilities
9) A more sustainable use of feedstock: TCID has reduced the feedstock waste, SECIL has incresed the use of RDF, ASAS has increased the scrap taht they can use, FENO and SILCOTUB are using plastic byproducts as new feedstock and FTIB is using ashes as P alternative
10) Improved health and safety conditions: the monitoring and control systems developed within the project reduce the requirements for human inspection of the processes.
11) Replication: Replication of activities has been analysed by the partners in D10.4 and the technical deliverables produced during the project should greatly facilitate the adoption of the innovations. The replication in plants belonging to other companies inside the EU is addressed in D10.5
12) Use of alternative materials and reduction of use of fossil fuels reduce the EU external dependence
13) No impact on EU employability but expected due to training
14) Impact on industrial trends from an environmental and technical point of view