Case Studies RA6

Case studies will be performed to obtain measurable results from the implementation of HighEFF technologies in different industry sectors. A goal is to obtain a 20-30 % energy reduction and/or a minimum of 10 % reduction in CO2 emissions by implementing HighEFF technologies and solutions.

To obtain uniform results, we have developed a standard methodology for the case studies. Throughout HighEFF's lifetime, 5-6 case studies will be conducted for each industrial sector represented in the Centre. Each case study will provide important results for the industry, potentially spurring innovations and industrial implementation of HighEFF technologies. They may also provide input to the research in other RAs.

Potential innovations:

  • Power production cycles and heat pumping technologies for HighEFF industries
  • Business methods for collaboration between industrial plants for reduction of energy use

Case Studies consists of the following Work Packages (WP)

RA6 Cases Marit Mazzetti SINTEF Energy Research
WP6.1 Metal, Material Ida Teresia Kero SINTEF Industry
WP6.2 Oil, Gas, Energy Monika Nikolaisen SINTEF Energy Research
WP6.3 Food, Chemical Michael Bantle SINTEF Energy Research
WP6.4 Industry Clusters Kristian Einarsrud NTNU

 Metals, Materials and Industry Parks

The use of waste heat from aluminium electrolysis has been studied as a case in WP6.1 and 6.4, jointly. For external use, several possibilities were investigated. Vegetable/fruit production in (heated) greenhouses, fish production on land, and the drying of algae seem to be good solutions, partly due to similar existing collaborations between different industries.

For internal use, pre-heating of raw materials has been investigated. Heating of anodes has proven efficient and beneficial, both for energy efficiency and process stability. Pre-heating of the alumina feed has been investigated as well but it seems that the pre-heating temperature would need to be least 500°C, a technical challenge yet to be resolved.

Oil, Gas & Energy

A new tool for evaluation of surplus heat upgrading and heat production at industry partner sites has been developed in collaboration with WP2.1 Heat Exchangers. The tool was applied to a case study on heat production at an electrified LNG plant, which also involved evaluation of a novel and compact heat pump concept that can potentially improve the cost-efficiency of large-scale heat pump implementation. The work package has also contributed to an evaluation of heat-to-power conversion at MIP with WP3.1 Energy-to-power conversion.

Food

Two main case studies were performed in 2018; one related to chocolate production and another related to fish meal production. The chocolate production requires large amounts of electricity and gas for heating. Until recently, no alternative to gas was available, but recent development of high temperature heat pumps now enables large reductions in energy use. The gas demand can be entirely or partially removed, and electricity for direct heating reduced by about 40-80 %. Results for the fish meal case show that the suggested modifications can provide energy savings of up to 55 %, with a reduction in CO2-emissions of over 60 %.

2017 Results

Metals, Materials and Industry Parks:

Novel and conventional uses of CO rich off-gas from Mn-alloy production have been explored based on input from several consortium partners. The most relevant ideas will be evaluated from two different perspectives in future work; an industrial cluster in Mo i Rana and a stand-alone plant in Sauda. Potential for new business opportunities and technological solutions will be prioritized when selecting ideas for further study. Spin-off activities include a KPN application to EnergiX on reduced CO2 emissions in metal production, which was granted in December 2017.

Oil, Gas & Energy:

The main activity in Oil, Gas & Energy was a case study on waste heat upgrading and heat production at an electrified LNG facility. Simulation results demonstrate that state-of-the-art, high temperature heat pumps can save in the order of 30 % electricity consumption at the facility compared to a scenario where the total heat demand is covered with electric heating. The work package has also been involved in a spin-off KPN application to PETROMAKS2 on compact bottoming cycles for offshore use entitled COMPACTS2, granted in December 2017.

Food:

5 initial studies of different industry cases relevant for the food sector have been completed, with focus on novel concepts for thermal upgrading of excess heat and improved process efficiency. Applications for support funding by ENOVA have been submitted and approved for two of the cases, including a green field plant at TINE that is currently in the design phase. For this case, more than 38 % reduction in electricity demand and 40 % reduction in CO2 emissions has been determined using state-of-the-art heat pumps.

Deliverables Case Studies RA6