8. WS Effective use of thermal energy in industry_Circe

VI CDTI-NEDO JOINT WORKSHOP

Efficient Furnaces

CIRCE Foundation

ELENA CALVOInnovation and

Promotion Unit

Director

Bilbao, 23rd June 2016

#WasteHeat The Effective use of termal energy in industry

01What is CIRCE?

• CIRCE is a private Foundation, created in 1993 by the University of Zaragoza, the

Regional Government of Aragón and the Endesa Group.

• Currently, the patronage of CIRCE Foundation is integrated by:

• Since 2001, CIRCE is acknowledged as Centre of Technological Innovation.

• In 2009 the University of Zaragoza –

CIRCE Mixed University Research Institute was constituted.

Organization – CIRCE Foundation


02FIELDS OF WORK

Organization – CIRCE Foundation

The main R&D&i activities of CIRCE are grouped into eight major fields of work, and

include almost all the stages within the energy sector, covering from power generation

to its consumption by the final consumer

Wind and solar energy

Electric grids and substations

Natural resources and biomass

Smart-Grids and storage

Energy efficiency

Sustainable mobility

Thermal power systems and emission reduction

Energy socioeconomics


03Organization – CIRCE Foundation

INNOVATION AND PROMOTION UNIT (UIP)

• Positioning of CIRCE’s activities in Europe and

Latam with Permanent delegation in Brussels

• Life cycle management of R&D&I projects:

o Identification of public and private

financing opportunities

o Preparation of tenders and technical

reports

o Collaborative projects management

o Administrative support

• Communication office

• Multidisciplinary team consisting on 18

specialists on project management

23 FP7 & 18 H2020 projects

o 10 coordinated

o More than 15 M€ of economic

revenue

Initiatives from

industries

Initiatives from

CIRCE researchers

COLLABORATIVE

PROJECTS

UPUIP

45 collaboration agreements

with companies and institutions

from 17 Latin-American countries


04Solutions, technology, capacities

EFFICIENT FURNACES / In Which FIELD OF WORK CIRCE has experience?

Different

SECTORS:

• Aluminum

• Glass

• Cement

• Ceramic

• Steel and Iron

Type of Furnaces:

• Melting

• Holding

• Pre-heating

Type of Energy Recovery Systems:

• Conventional

• Thermal Energy Storage Systems – Phase change materials (PCMs)

Analysis of

different

heating

systems for

industrial

furnaces:

• Induction

• Plasma

• Electric

• Combustion

• Etc.

Energy, Environmental and Economic

OPTIMIZATION


05Solutions, technology, capacities

EFFICIENT FURNACES / Though which CAPACITIES ?

Development of in-house tools

for process optimization

Study and

optimization of

induction systems

Modeling

and

simulation

of industrial

furnaces

Exergy and Thermo-economic

Analysis

Analysis of Life Cycle Assessment (LCA) and Life Cycle Cost (LCC)

Analysis of

combustion

conditions

and different

fuels

Analysis of system

integration to reduce

emissions (CO2)

Energy characterization

of processes and industrial

furnaces


06R&D projects

VULKANO – Novel integrated refurbishment solution as a key path towards

creating eco-efficient and competitive furnaces

Total Budget6.940.813,75 €

1.114.687,50 €

2016 - 2020

CIRCE Budget

Length

€

i OBJECTIVESThe main goal of VULKANO is the retrofitting of two types of industrial

furnaces, namely preheating and melting, applied on three energy–intensive

sectors (steel, ceramic and aluminium) with a huge number of potential users in

Europe.

VULKANO aims to design, implement and validate an advanced retrofitting

integrated solution to increase the energy and environmental efficiency in

existing industrial furnaces fed with NG; through the combined implementation of

new solutions based on:

• high temperature phase change materials

• new refractories

• optimised co-firing of NG and syngas from biomass or process gas

• an advanced monitoring and control system and

• an holistic in-house predictive tool

All together will achieve a 20% increase in the energy efficiency of furnaces.


07R&D projects




08R&D projects



GERMANY

FRANCE

SPAIN

UNITED KINGDOM

CIRCE

TURKEY

Tecnalia

TORRECID

CIDAUT

FIVES STEIN

PCM Products

Fraunhofer

VALJI

ASAS AluminyumITALY

CSM

POLAND

Institute of Power Engineering

SLOVENIA

BOSIO


09R&D projects

MAGNHEAT – Induction oven with rotating permanent MAGNets for energy

efficient aluminium HEATing

Total Budget2.025.205 €

150.270 €

2014 - 2017

CIRCE Budget

Length

€

i OBJECTIVESThe overall goal of the project is to demonstrate the first full-scale industrial

application of a novel concept of DC induction heating furnace, to

mitigate the energy, environmental and economic impact of metal extrusion

process. It will be based on rotating permanent magnets for Aluminium

extrusion, and developed through a combination of ecodesign and engineering,

exploiting and valorising previous R&D activities carried out by the project

partners.

• CIRCE performs a thermo-economic analysis

providing an energy-efficiency diagnosis and

advisory feedback over industrial scale

developments.

• CIRCE also leads LCA and LCC studies to analyse and

advice the developed innovative technologies and

novel processing techniques.


10R&D projects

ITALY

CIRCE

SAET SpA

Pandolfo Aluminio

SPAIN

Assomet

MAGNHEAT – Induction oven with rotating permanent MAGNets for

energy efficient aluminium HEATing


11R&D projects

EDEFU – New Designs of Ecological Furnaces

Total Budget13.453.129,82 €

1.024.070,27 €

2010 - 2014

CIRCE Budget

Length

€

i

www.edefu.eu

OBJECTIVESThe overall goal of the project is to improve the energy efficiency of intensive

industries in the use of energy, and reduce their environmental impact.

This project focuses in various types of industrial furnaces, creating and

implementing a methodology of study, design and construction to be applied in a

multi-sectorial way.

Developments and advances will lead to a reduction in the energy consumption

of 20% compared with current systems, in addition to satisfy the industrial

needs and reduce the emission of pollutant gases.


12R&D projects

GERMANY

FRANCE

SPAIN UNITED KINGDOM

POLAND

CIRCE

LITHUANIA

CALCINOR

Tecnalia

Indal Casting

GIS

Vidrala

Marion Tecnologies

Bertin Technologies

SAIREM

CNRS – National Centre of ScientificResearch

CARBOLITE

C- Tech Innovation

Fraunhofer

CERApro

Laser Zentrum Hannover

VDZ

CEMEX

JIESIA

EDEFU – New Designs of Ecological Furnaces


13R&D projects

NIWE – New Induction Wireless Manufacturing Efficient Process for

Energy Intensive Industries

Total Budget11.085.990 €

1.183.200 €

2013 - 2016

CIRCE Budget

Length

€

i

www.niweproject.eu

OBJECTIVES

To develop and demonstrate new processes and equipment for the

metallurgical energy intensive industries, (in the Aluminium, Steel and Iron

sector) to reduce the energy consumption in the casting and manufacturing

processes, as well as the GHG emissions, thus achieving lower carbon

footprint products.

The expected energy efficiency gains are due to a new furnace based in

induction.

The rapidity of the power transmission system, as well as the wireless

operation, will allow a higher flexibility in the production chain, and the use

of smaller furnaces. Therefore, the reserve of melted material for feeding

the moulds will be smaller obtaining energy savings.


14R&D projects

BULGARIASPAIN

GERMANY

ITALY

CZECH REPUBLIC

Fundación CIRCE

SEMATEC

GIS

Tecnalia

Basque Country SmeltersAssociation

FURESA

ABP Induction

Fonderie 2a

Bilbobul S.L

SEEIF Ceramic

NIWE – New Induction Wireless Manufacturing Efficient Process for

Energy Intensive Industries

THANK YOU

どうも有難う御座います

ESKERRIK ASKO

GRACIAS

Elena Calvo

[email protected]

CIRCE Foundation

For further information

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8. WS Effective use of thermal energy in industry_Circe