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REEMAIN Report Summary

Project ID: 608977
Funded under: FP7-NMP
Country: Spain

Periodic Report Summary 2 - REEMAIN (Resource and Energy Efficient Manufacturing)

Project Context and Objectives:
Resource and Energy Efficient ManufacturINg (REEMAIN) combines cutting edge knowledge and experience from production processes, professional energy simulation software tools, energy and resource planning standards, and renewable energy and storage technologies to develop and demonstrate an integrated approach, methodology and platform for the boost, at factory level, of efficiency of both energy and material resources. Based on the knowledge of who are the energy consumers in manufacturing REEMAIN proposal offers four solutions. REEMAIN as a demonstration, seeks to test the selected efficiency solutions in three different and complementary factory environments. Demonstration activities will take place in 3 different strategic European factories: Bossa textiles, Gullon biscuits and SCM foundry. Through these factories, REEMAIN will demonstrate and make possible replication to the important EU textile, food and steel production industries which account for more than 50% of CO2 emissions and more than 20% consumption of electricity in industry. In addition to these factories, REEMAIN has the Fraunhofer IWU “Research Factory”. This large scale laboratory is a new building dedicated to the integration of factory energy flows, production processes, and the surrounding environment, with the aim of achieving a zero-carbon factory example for Europe. As important as the technical work will be the ability to bring it to the market at large to achieve meaningful impact across Europe. For this, REEMAIN will pursue three high impact exploitation avenues. 1) We will link to existing Standards and eco-factory labelling concepts through the creation of CEN workshops and participation in CEN technical committees where appropriate. 2) We are leading an “MTP project extension” called iProSPER in the Intelligent Manufacturing Systems program that provides international outreach and the exchange of information to the USA, Korea, and Mexico. 3) We will communicate REEMAIN project results to target audiences in the relevant industry sectors maximizing the impact beyond the project scope. Within this framework, REEMAIN then moves toward zero carbon manufacturing and Energy Efficiency 2.0 through the intelligent employment of renewable energy technologies and resource saving strategies that consider energy purchase, generation, conversion, distribution, utilization, control, storage, re-use in a holistic and integrated way.
The aim of REEMAIN project is, based on a holistic methodology for achieving a breakthrough to zero carbon and environmentally neutral factories, to demonstrate in real manufacturing scenarios that it is possible to evolve towards these targets while maintaining productivity and decreasing product life-cycle costs by 20%. This general objective is supported by four pillars. Following, the set of sub objectives including the work packages in which will be achieved are presented:
1.Innovation in the main areas needed to boost the efficient use of resources (energy and materials) at the factory: optimization of the production-process-product (PR3), seamless integration of renewable energy systems (RES), the recovery of wasted energy (REC) and measurement of the environmental improvement with a life cycle approach.
2.Creation of a decision making tool to support factory owners in the complex task of analysis, decision and planning the best strategies to drive their factories towards resource efficiency and minimal impact.
3.Demonstration activities in three different factories to validate and promote the material and energy efficiency taken measures.
4.Dissemination at European and International level together with a strong support for standardization activities

Project Results:
The work done in REEMAIN in the 2nd period of the project is organized around the following WPs:
WP1: Creation of manufacturing reference scenarios methodology as a basis for later extrapolation of demonstration results in each of the three factories.
WP2: Definition of data acquisition architecture and interfaces for REEMAIN modelling tool based on the analysis of acquisition systems in industry, and the current architecture of Fraunhofer IWU’s architecture for their E3 factory.
WP3: Development and delivery of advancements and additional functionalities for the final REEMAIN platform: optimization strategies, the final integration of the final four selected REEMAIN technologies (Combined Heat, Power and Cooling, Solar Colling, Organic Rankine Cycle and Electric Energy Storage), Automated Demand Response, Heat recovery and Tariff Analysis.
WP4: Development of the requirements for Resource Networks compared to the state of the art in energy management and which integrates all the different into factory planning and control methods.
WP5: The final list with the selected efficiency measures was finally closed at the beginning of the 2nd period. A preliminary selection was already made at the end of the first period, but some possible measures were left in an undefined state. In addition, in the case of SCM, a new efficiency measure was discovered, analysed and approved , PlasmaPour system.
WP6: WP partners have defined 4 Key Exploitable Results (KER) with specific interest for the REEMAIN project. A Market Analysis for the KERs managed by CRIT with support from R2M and the involved partners has been done. From M31 to M35 WP6, and the exploitation activities, have beneficiated of an external consulting from De Tullio & Partners Studio regarding IPR assistance and patenting service linked with ESIC project. The result of the consulting activity is aimed to define the easiest way for define an IP, and follow the indication from the 1st Exploitable Strategy Seminar (M18) and will be part of the replication plan (T6.3).
WP7: The Dissemination and Communication plan was updated to reflect minor adjustments in the dissemination and communication strategy. The website has been enriched with updated news, newsletters and the additional section for public deliverables (6 at the moment) made available since September 2016 and the link to the project video .
WP8: Two scheduled face-to-face meetings have been organized during the second period of the project: 4th periodic meeting in October 2015 held in Gullon factory and 5th periodic meeting in March 2016 held in EURAC Bolzano headquarters. During this 2nd period an amendment of the contract has been done to accommodate some modifications like the change status of some partners (SCM and JER) and to reflect the final list of efficiency measures to be demonstrated into the three factories

Potential Impact:
The project expects to achieve the following impacts:
• The application of the methodologies, tools and lessons learnt will result in increased factory energy efficiency and improved use of renewable resources that will cause a reduction of around 20% in the total lifecycle costs of factories.
• The project will deliver a major step forward towards zero-carbon footprint manufacturing systems and processes, with drastic reductions in the total lifecycle environmental impacts of factories.
• The project will strongly contribute to a strengthening in the global position of the European manufacturing industry through the introduction and demonstration of new technologies and methodologies related to an improved use of renewable resources and contributions to international standardisation.
• The project will strongly support and collaborate in the the ecolabelling policies and standardisation activities in the related areas of the project.
The holistic methodology that REEMAIN will develop will contribute to the achievement of the expected impacts:
• Analysis and definition of baseline reference scenarios in WP1 that will ensure a replicable demonstration results to a wider range manufacturing sectors. This analysis will consist not only in the point of view of REEMAIN partners but will come also from the interaction with international external key stakeholders of the manufacturing sector (e.g. through the MTP project extension later explained).
• Calculation of the appropriate economic KPIs (WP2) that will be the basis to the definition and calculation of the foreseen total lifecycle costs savings as is mentioned in the work programme.
• Industrial real demonstration in the demo sites to provide a solid base of achieved efficiencies of material and energy.
• Extrapolation of results at the end of WP5 to extend the best practices at the European manufacturing sector.
• Generation of software tools for modelling and decision-making conceived and developed to be applied to a wider range of manufacturing sectors rather than particular solution for the three demonstration factories.
• Interaction with relevant stakeholders to appropriately transfer the results. The main instruments will be: international exchange of experiences with other non Eu countries through the IMS organization, participation in the relevant standardization activities and dissemination using a wide spectrum of menas (web, tv, social networks, fairs, congresses, etc)
The REEMAIN project will develop and implement a very ambitious dissemination and communication programme focused on professional audiences:
• Large industries and SMEs, addressing specific associations of the manufacturing scenarios where the demonstrations will take place; textile, food and steel production industries
• Clients and users: key players providing their perspectives in the formulation and assessment of project results in aspects such us, adoption of new technologies, adaptability for the future and new business models
• Building industry providers & installers through national and EU associations (mostly SMEs).
• Energy Management Agencies: local, regional and national energy agencies that are promoting efficient and innovative building-related energy technologies in buildings
• Standardization bodies at European level CEN and national level.

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