MORE is a 36-month STREP project supported by the European Commission in the field of ‘Nanosciences, Nanotechnologies, Materials and new Production Technologies (NMP). It aims at identifying resource efficiency indicators (REIs) that could support operational decisions in process industries through the use of real-time data and the implementation of a dedicated online decision support system.
In recent years, indicators for the environmental impact of products and production processes have been developed and are increasingly used in the communication of companies in the process industries with the public as well as in the evaluation of alternative routes and for the decision on investments into new production facilities or revamp measures. In the MORE project, we significantly extend the definition and the use of such indicators by
- Defining real-time resource efficiency indicators that can be efficiently used in daily operations and are computed based upon the processing of real-time data that is available in the monitoring and control systems and from innovative analytical measurements
- Taking the step from monitoring to improving resource efficiency by providing model-based real-time decision support to plant operators and plant managers.
The project deals with resource efficiency as a multidimensional attribute with several indicators that measure different aspects of resource efficiency.
MORE is focused on large integrated chemical and petrochemical plants with many interconnected units. The real-time resource efficiency indicators and decision support tools are developed exemplarily for this domain and tested through the implementation in four industry use cases. After the definition of resource efficiency indicators and their demonstration in the industrial sites, the project will launch an impact assessment which aims at analyzing tangible economic and environmental impact. Moreover, the transferability of the resource efficiency indicators to different sectors with similar production systems will be investigated, e.g. the sugar production and the pulp and paper industry.
An Industrial Stakeholder Panel (ISP) with experts from diverse EU process industry fields has been created as a consulting body to provide feedback on and suggestions for the technical work and to discuss how MORE project outcomes can serve to other industry fields as well.
Achievements at the end of Period 1 (November 2013 – April 2016):
- General principles and a methodology for the definition of process specific REIs was developed and has been applied to four different industrial case studies successfully.
- REI were developed for all industrial case studies.
- A list of generic indicators was developed for batch and continuously operated plants
- A general visualization concept for multi-dimensional resource efficiency indicators to support operators and plan managers was created
- REI Dashboards were developed for two industrial case studies
- A methodological framework to investigate the generalization to other industries was developed.
Analytical measurements and data reconciliation:
- Two different spectroscopy methods were tested at the industrial sites for specific REI-related measurement tasks and promising application cases were defined
- Methods for an optimized calibration workflow were developed
- Data reconciliation methods with new robust estimation techniques were tested in the Petronor and Lenzing case studies
- A prototypical What-If Analysis tool with simulation capability was developed and tested on industrial cases
- Operating policies were optimized based on experimental data, process understanding and rigorous mathematical models for two industrial case studies, the hydrogen network in a refinery and the evaporators in a cellulose plant.
- For these two industrial applications, the results of the analysis were implemented as control structures and significant savings were achieved. In one case, this generated 1.5 MNm3/y savings in natural gas consumption, equivalent to 300 k€/y.
- A new model of a complete evaporation line (heat exchangers, evaporation chambers, cooling tower, saturator and mixing condensers) was developed and used for optimization studies. The fouling dynamics were identified and the cleaning cycle was optimized based on the model.
- A neutral deployment platform for REI computation, visualization and decision support was specified and realized. It consists of three functional components (topology editor, calculation engine, HMI development studio) and interfaces to legacy systems.
- Prototypes of the deployment platform were installed at two industrial sites.
- The Industrial Stakeholder Panel was successfully set up and the first meeting was organized.
- The project visual identity, web site and dissemination materials were prepared.
- Interview with MORE partners published in PEN journal, targeting large public audience.
- Ideas and results from MORE were presented at workshops with strong industrial participation.
- First scientific results are published and contributions to scientific conferences submitted, such as ESCAPE25/PSE2015 and ECCE10. MORE will give a keynote presentation at ECCE10 on Real-time resource efficiency indicators for batch processes.
Exploitation and Standardization:
- An exploitation plan was specified.
- Exploitation goals were classified into commercial, pre-commercial and scientific exploitation objectives. Exploitation strategies to reach these goals were developed.
- The focus of pre-commercial exploitation efforts were on standardization activities. A standardization strategy was developed, relevant international standards (IEC, ISO, CEN/CENELEC) identified. First cooperation with national and international standardization groups were initiated.
- MORE aims at participating in the development of a NAMUR recommendation on resource efficiency monitoring as a basis for further standardization activities.
- The industrial partner started commercial exploitation activities. Important parts of the deployment platform of LeiKon and enhancements of the spectral analysis software of S-PACT were implemented and first business strategies are developed. The partners of the process industry started to implement first REI applications at their sites.
- Development of logical framework emphasizing the causes to effects relationships from the use of REI in industries to their impacts at plant, company, and sector level.
- Development of an evaluation framework comprising the evaluation questions to be answered trough the analysis of impacts in industrial cases of the project, the related criteria, and the indicators.