SPIRE PPP - Sustainable Process Industries through Resource & Energy Efficiency - Loredana Ghinea A.SPIRE Executive Director.

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1 SPIRE PPP - Sustainable Process Industries through Resource & Energy Efficiency - Loredana Ghinea A.SPIRE Executive Director

2 The value chain Raw Materials Process Industry: Chemical, biochemical, and physical transforma9on and formula9on of raw materials using con9nuous and batch processes into Materials with new proper9es and func9onali9es Discrete Manufacturing: Components & Products

3 STEEL METALS WATER MINERALS CHEMICALS CEMENT ENGINEERING CERAMICS

4 A.SPIRE membership by countries Membership type Number of members Associate member 8 Associations 11 Industry member (intermediate) 1 Industry member (large) 29 Industry member (medium) 3 Industry member (small) 9 Research member (large) 27 Research member (small) 27 Total 115 Sector Number of companies & associations cement 5 ceramics 4 chemicals 25 engineering 6 minerals 2 non-ferrous metals 4 steel 7 water 1 Total 54

5 AMBITIONS! A reduction in fossil energy intensity of up to 30% by 2030! Up to 20% reduction in non-renewable, primary raw material intensity by a significant contribution to a drastic efficiency improvement in CO 2 -equivalent footprints of up to 40% by potential improvements extend beyond process industry KEY PERFORMANCE INDICATORS! By 2020 EU will be leading in the re-use of CO 2 emissions and its transformation in molecules! By 2020 advanced energy systems allow drastic reductions! By 2025 novel recycling process concepts for at least 5 different waste streams demonstrated and ready for markets! By 2020 at least 4 projects realised which report added value from the process industry to end-user sectors! By 2020 a new framework for cross-sectorial technology transfer developed and implemented! etc.

6 SIX KEY COMPONENTS 1. Feed: Increased energy and resource efficiency through optimal valorisation and smarter use and management of existing, alternative and renewable feedstock. 2. Process: Solutions for more efficient processing and energy systems for the process industry, including industrial symbiosis. 3. Applications: New processes to produce materials for market applications that boost energy and resource efficiency up and down the value chain. 4. Waste2Resource: Avoidance, valorisation and re-use of waste streams within and across sectors, including recycling of post-consumer waste streams and new business models for eco-innovation. 5. Horizontal: underpinning the accelerated deployment of the R&D&I opportunities identified within SPIRE through sustainability evaluation tools and skills and education programmes as well as enhancing the sharing of knowledge, best practices and cross-sectorial technology transfer. 6. Outreach: Reach out to the process industry, policy makers and citizens to support the realisation of impact through awareness, stimulating societal responsible behaviour.

7 SPIRE-1: Integrated Process Control TRL 3-5, RIA 100% Objective: Fast in- line data collection and data treatment techniques for improved "near real- time" closed- loop control concepts allowing an integrated economic, ecological and safety optimisation of the processes Scope: Novelties in: Sensor technologies (fast in- line, dynamic information, spatially resolved information, sensors for intensi>ied processes, ) Process data treatment (dynamic info, spatially resolved info, data management for optimisation, etc.) Process data mining and process knowledge extraction R&D to address: Miniaturised and cross sectorial Discrete application Manufacturing: of PAT & PPMT Methodologies for extensive integration of control systems New (soft- )sensors and sensing concepts, swarm sensors, disposable sensors, Control strategies using integrated and validated PAT data Life cycle management Expected impact: Improvement of real- time measurement of properties of process streams, and of European Components PAT and Control technologies & Products Improved process operation (ef>iciency, sustainability, reliability, safety, monitoring, resource and energy ef>iciency, GHG)

8 SPIRE-2: Adaptable industrial processes allowing the use of renewables feedstock for chemical and energy applications TRL 5-7, IA 70% Objective: Develop technologies able to support a signi>icant increase in the utilisation of biomasses and/or re- processing of residues and waste gases in the Process Industry Scope (see call text): Development of integrated systems for biomass, residues and waste gas conversion, including downstream equipment. Provide signi>icant increase in the utilisation of renewables in industry and re- processing of residues and of waste gas Lead to new streams suitable for further industrial processing for production of chemicals and/or fuels Discrete Manufacturing: R&D to address: Mobile, Flexible and Scalable technologies, allowing (pre- ) processing of biomass, residues, waste gases Solution should be able to cope with the >luctuating nature (in availability and quality) of renewables Business feasibility of the technologies LCA and LCC analysis Components The technologies proposed should allow the processing of of signi>icant amount of biomass, & Products residues and waste gases Substantial demonstration activities are expected Desirable: Multi sectorial approach and replicable methodology

9 SPIRE-2: Adaptable industrial processes allowing the use of renewables feedstock for chemical and energy applications TRL 5-7, IA 70% Expected impact (see call text): The technologies proposed should allow a 30% decrease in fossil resources utilisation compared to current practices Provide opportunity for increased utilisation of renewables as feedstock for chemicals and fuels production Contribute to lowering industrial GHG emissions The technologies proposed should provide opportunity for integration in the current industrial landscape Discrete Manufacturing: The concepts should provide direct or indirect impact on rural areas. Signi@icant SME participation is encouraged. Components & Products

10 SPIRE-3: Improved downstream processing of mixtures in process industries Signi>icant improvements in energy and resource ef>iciency. Discrete Manufacturing: Signi>icant reduction in greenhouse gas emissions. Expected impact: Novel and cost effective separation and fractionation technologies applicable to the process industry. Increasing the resource and energy ef>iciency for the process industries by at least 20% Components while leading to a signi>icant decrease in greenhouse gas emission. & Products Strengthening the competitiveness of the European industry developing both engineering know- how as well as economically sustainable industrial processes leading to shorter time to process/market, and higher production capacity. TRL 5-7, IA 70% Speci@ic Objective: The aim is to provide innovative solutions for downstream processing, advance in the integration of different separation techniques into complex hybrid units and provide tools for the design of such units. Scope (see call text): Compatibility with continuous processes and support for the transition from batch processes to more ef>icient and reliable continuous operations (where relevant). Reduction of production costs and time to market by providing tools for process and separation unit design and optimisation. Improvement in safety of the work environment.

11 SPIRE-4: Methodologies, tools and indicators for cross-sectorial sustainability assessment of energy and resource solutions in the process industry CSA 100% Objective: Increase the European knowledge base related to applied sustainability assessment tools, methodologies, indicators and to overcome the bottlenecks for cross- sectorial take- up and further development in the process industry. Scope: The study should include: A comparative overview of current methodologies, tools, indicators and practices in different sectors A selection of the most appropriate solutions, based on their demonstrated robustness An overview of the related opportunities as well as the bottlenecks towards further development and cross- sectorial replication/transfer Discrete Manufacturing: De>initions of the required steps to accelerate further uptake of resource ef>iciency indicators over the value chains Recommendations on the most suitable tools for management and decision making Recommendations for further research and development projects in the >ield of sustainability assessment Collaboration with standardisation Expected impact : Components Identi>ication of best practices for cross- sectorial environmental, social and economic sustainability & Products indicators Identi>ication of research needs within the process industry Identi>ication of cross- sectorial tools for management and decision making within the process industry

12 Other relevant EE18: New technologies for utilization of heat recovery in large industrial systems, considering the whole energy cycle from heat production to transformation, delivery and end use LCE : Solar cooling systems WASTE : Moving towards a circular economy through industrial symbiosis

13 RESULTS 2014 calls

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15 Call 2015 PROCESS: SPIRE New adaptable catalytic reactor methodologies for Process Intensification Research and Innovation Action SPIRE Energy and resource management systems for improved efficiency in the process industries - Research and Innovation Action WASTE2RESOURCE SPIRE Recovery technologies for metals and other minerals Innovation Action TRL 3-5 TRL 4-6 TRL 5-7 APPLICATIONS SPIRE : Solids handling for intensified process technology TRL 5-7

16 What next? - Priority areas FEED! Optimal valorisation of mineral residues, byproducts and recycled material as feed for mass / high volume products! Valorisation of valuables from waste gases! CO and syngas! CO2 + H2! System approach to water as feedstock and energy source for process industries! Upgrading, pre-treatment and valorisation for several (relative clean) waste streams from the process industry at large, including plastics as a feedstock for chemicals! Development of industrial chemical products / (cross-sectorial) materials based on biomass (contrary to SPIRE 2 where most proposals where written as biomass to energy use in energy intensive industries) link to BBI! Advanced location scenarios for biomass transformation (retrofitting of existing plants) link to Process

17 What next? - Priority areas PROCESS! Biomass and carbon based residues valorization as alternative energy sources (need to assess SPIRE 2)! New techniques for industrial furnaces with especial focus on developing knowledge in the design of new equipment (low TRL with the collaboration of a modelling and simulation lab network)! New technologies for utilization of waste heat in large industrial systems, considering the whole energy cycle from the heat production to the delivery and end use, including environmental impact. It aims especially at polluted flows (an emphasis on real industrial gas flows, quite often heavily loaded with dust, blocking any heat exchanger) in different intensive sectors! Robust through process optimization methods including big data DG Cnect?! New energy- and resource efficient process concepts! Process intensification: More flexible and scalable processes (high TRL), lower capital and operating costs check SPIRE3! Industrial symbiosis (2017, materials flows, larger project?) link to WASTE! Research of new designs for processes and equipment enabling integration of renewable electricity (TRL 3-4) (how can we store renewable energy at site?)

18 What next? - Priority areas APPLICATIONS! Novel high temperature materials (e.g. ceramics, metals, etc.) that enable development of novel energy and resource saving industrial processes in energy intensive industries (e.g. furnaces, reactors, etc.)! New industrial processes for the production of energy and resource efficient lightweight materials and multi-material composites for downstream applications beyond buildings (e.g. automotive, renewable energy, aeronautics etc.) TRL 4-6/7! and others

19 What next? - Priority areas WASTE2RESOURCE! Improving resource efficiency by improved waste treatment and industrial synergies! Develop robust pre-processing steps for concentration of valuables and removal of components degrading the product quality! Metal production from industrial waste! Sustainable design methods for resource efficient recovery and recycling! New technologies for selective separation of valuables from process industry wastewater! Technologies for efficient preparation and extraction of valuable materials from waste

20 What next? - Priority areas HORIZONTAL! Development of a comprehensive sustainability assessment approach as part of process and product design in the process industry! SPIRE framework for knowledge sharing and transfer - Dissemination and exploitation of SPIRE results

21 New thinking, new doing No-one can do it alone -> build synergies: across industries across public/private across borders across technologies

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23 Application of the Technology Readiness Levels Where a topic description refers to a TRL, the following definitions apply, unless otherwise specified: - TRL 1 basic principles observed - TRL 2 technology concept formulated - TRL 3 experimental proof of concept - TRL 4 technology validated in lab - TRL 5 technology validated in relevant environment (industrially relevant environment in the case of key -enabling technologies) - TRL 6 technology demonstrated in relevant environment (industrially relevant environment in the case of key enabling technologies) - TRL 7 system prototype demonstration in operational environment - TRL 8 system complete and qualified - TRL 9 actual system proven in operational environment (competitive manufacturing in the case of key enabling technologies; or in space) Policy Research and Innovation