EU Project MORE. Reduction of the environmental footprint of industrial processes by resource-aware operation

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Lesley Webb
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1 EU Project MORE Reduction of the environmental footprint of industrial processes by resource-aware operation 1

The project in short MORE is a collaborative R&D project funded by FP7 and driven by leading European companies from the chemical industry: BASF (D), INEOS Cologne (D), Petronor-Repsol (ES), Lenzing

2 The project in short MORE is a collaborative R&D project funded by FP7 and driven by leading European companies from the chemical industry: BASF (D), INEOS Cologne (D), Petronor-Repsol (ES), Lenzing (A). MORE aims at monitoring and improving resource efficiency during daily operations of large chemical production plants. The project findings shall contribute to influencing the operational decisions such that the plant efficiency is optimized and the environmental footprint is minimized. 2

Resource efficiency: The challenge The chemical industry is a major consumer of resources, mostly of fossil origin as oil and gas, and a major producer of CO 2 emissions.

3 Resource efficiency: The challenge The chemical industry is a major consumer of resources, mostly of fossil origin as oil and gas, and a major producer of CO 2 emissions. Rising energy prices caused an increase of 3-12% of production costs in chemical plants over the last ten years. Improvement of resource efficiency is a highly complex task in chemical plants, because: Chemical plants are operated under changing conditions, and the resource efficiency is determined by the actual operation, not by the ideal operation assumed during plant design The daily operation currently cannot be steered by existing long-term resource efficiency indicators Local and plant-wide resource efficiency may be in conflict 3

4 MORE: Beyond the state of the art From To Retrospective use of REIs, over long periods of time, e.g. a year No direct connection between the daily operational decisions and the long-term indicators No standards for the measurement of resource efficiency during operations Definition of real-time REIs in order to monitor the daily operations Online computation of REIs based on novel analytic measurements Decision support support systems Proposals for standardized approaches to the definition of real-time REIs Better use of resources and reduction of waste 4

5 Innovative technology Novel analytic measurements of properties of streams for the online computation of resource-efficiency Model-based data reconciliation to assure data consistency Multi-criterial optimization of operational decisions with respect to economics and resource efficiency Improved support for operators and managers using advanced visualization technology Vendor-neutral platform for deployment of the algorithms for the computation and optimization of resource efficiency 5

Expected impacts Increased transparency of the resource efficiency of the production process for producers and customers Better guidance of the plant managers and plant

6 Expected impacts Increased transparency of the resource efficiency of the production process for producers and customers Better guidance of the plant managers and plant operators in their daily and short-term decisions Broad adoption in the process industries beyond chemical production by transfer of the approach and of the supporting technologies 6

7 Steps towards the project goal Decision support Standardization and outreach Implementation and demonstration Definition of realtime resource efficiency indicators Novel analytics and data reconciliation 7

Project actions - Phase 1 Definition of real-time REIs for processing plants Guided by the industrial application cases from the end-users in the consortium Based upon knowledge from the definition

8 Project actions - Phase 1 Definition of real-time REIs for processing plants Guided by the industrial application cases from the end-users in the consortium Based upon knowledge from the definition and use of aggregated longterm REIs The challenges of the dynamic nature of real-time data will be addressed Result: Consistent methodology that can be tailored to the specific processes under consideration 8

Project actions - Phase 2 Development of process analytical solutions for the measurement of properties of streams for the online computation of real-time REIs Development of

9 Project actions - Phase 2 Development of process analytical solutions for the measurement of properties of streams for the online computation of real-time REIs Development of optimization-based decision support systems and visualization tools Oriented on the needs of the application cases but of general nature Development of a vendor-neutral deployment platform 9

Project actions Phase 3 Implementation and validation of the technology developed in four case studies of different European integrated plants: Refinery: Petronor-Repsol, Spain Petrochemical complex:

10 Project actions Phase 3 Implementation and validation of the technology developed in four case studies of different European integrated plants: Refinery: Petronor-Repsol, Spain Petrochemical complex: INEOS Köln GmbH, Germany Production of fine chemicals from renewable feedstock: BASF PCN Düsseldorf, Germany Cellulose plant: Lenzing, Austria Discussions with industrial associations, e.g. NAMUR Generalization to other process industries with the help of the Industrial Stakeholder Panel Standardization and commercialization 10

11 MORE: Project identity card Collaborative research project Supported by the 7 th EU Framework Programme for research, technological development and demonstration, Theme: NMP Duration: November 1 st, October 31 st, 2016 (36 months) Budget: Target group: European process industries and vendors of solutions for operational support. Web site: Svetlana Klessova Project Coordinator inno TSD, France s.klessova@inno-group.com Prof. Dr.-Ing. Sebastian Engell Scientific Leader Technische Universität Dortmund, Germany s.engell@bci.tu-dortmund.de Dr.-Ing. Stefan Krämer Industrial Application Coordinator INEOS Köln GmbH, Germany stefan.kraemer@ineos.com 11

Consortium inno TSD, France one of Europe s leading innovation management consultancy firms, specialised in helping major private and

com/ PETROLEOS DEL NORTE SA - REPSOL, Spain the biggest petroleum refinery in Spain with a deep knowledge of petro-chemical processes

INEOS Group is one of the leading world scale chemical companies http://www.ineoskoeln.

ingredients and one of the most important European research locations for personal care products worldwide http://www.basf.

12 Consortium inno TSD, France one of Europe s leading innovation management consultancy firms, specialised in helping major private and public stakeholders design and implement R&D and innovation projects PETROLEOS DEL NORTE SA - REPSOL, Spain the biggest petroleum refinery in Spain with a deep knowledge of petro-chemical processes INEOS Köln GmbH, Germany operating the INEOS petrochemical site in Cologne, Germany, and part of INEOS Group. INEOS Group is one of the leading world scale chemical companies BASF Personal Care and Nutrition GmbH, Germany a global supplier of nature-based specialty chemical products and nutritional ingredients and one of the most important European research locations for personal care products worldwide LENZING AKTIENGESELLSCHAFT, Austria world market leader in global textile and nonwovens industry with high-quality man-made cellulose fibres, the leading supplier in many business to business markets 12

Consortium TECHNISCHE UNIVERSITÄT DORTMUND, Germany a German research university with a leading position in Europe in chemical engineering and in the operation of

de UNIVERSIDAD DE VALLADOLID, Spain a European university with an excellent research group in chemical process operations http://www.uva.

innovation services, and having extensive knowledge in sustainability assessment and standardization http://www.vtt.

13 Consortium TECHNISCHE UNIVERSITÄT DORTMUND, Germany a German research university with a leading position in Europe in chemical engineering and in the operation of chemical processes UNIVERSIDAD DE VALLADOLID, Spain a European university with an excellent research group in chemical process operations VTT, Technical Research Centre of Finland the largest multidisciplinary research organisation in Northern Europe, providing high-end technology solutions and innovation services, and having extensive knowledge in sustainability assessment and standardization S-PACT GmbH, Germany a Process Analytical Technology solution provider for process industries and scientific research institutions, with a focus on optical online spectroscopy LEIKON GmbH, Germany an innovative technology company working in the area of MES (Manufacturing Execution Systems) and process automation 13

PICASSO Project. Towards new avenues in EU-US ICT collaboration. First meeting of the PICASSO Expert Groups Washington DC, May 20, 2016

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