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 EUROPE? LESS RESOURCES MORE NEEDS

3 The value chain Raw Materials Process Industry: Chemical, biochemical, and physical transformation and formulation of raw materials using continuous and batch processes into Materials with new properties and functionalities Discrete Manufacturing: Components & Products

4 STEEL METALS WATER MINERALS CHEMICALS CEMENT ENGINEERING CERAMICS

5 SPIRE contractual PPP Roadmap Work programme Open calls

6 MEMBERSHIP OVERVIEW A.SPIRE membership by countries Membership type Number of members Associate member 8 Associations 12 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 116 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

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8 PROCESS INDUSTRY Tomorrow alternative (but sustainable) feedstock less environmental footprint, more efficient processes devices for better monitoring, control & optimisation energy & resource mngt. concepts, incl. industrial symbiosis new materials for (new) products, (new) materials for new processes, processes for new materials: within industrial sectors & down the value chain technologies for valorisation of waste streams

9 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.

10 Call 2014 PROCESS SPIRE Integrated Process Control - R&I Action New technologies suitable for near real time integrated process control are expected to introduce significant novelties with respect to sensor technologies, data treatment and data mining, in particular: - Provision of dynamic information about product properties, stream characteristics and process conditions. - Provision of spatially resolved process data. - Data management for processes optimisation. - Sensors for intensified process technology. - Fast inline measurements (instead of extractive ones). - Robustness and reliability insuring minimum operation and maintenance costs.

11 Call 2014 FEED SPIRE Adaptable chemical processes allowing the use of renewables as flexible feedstock for chemical and energy applications Innovation Action Projects should develop new processes or improved valorisation approaches that would provide efficient biomass, residue and waste gas conversion (or biomass pre-treatment for further refining) while developing a fully integrated system and the associated equipment for downstream use. These processes should allow an increased utilisation of renewables (where economically and technically favourable relative to other potential applications) as feedstock for the production of chemicals (including intermediates) and/or fuels as part of an integrated approach to optimise resource and energy efficiency. Such processes should be presented with a containerised, flexible and scalable approach allowing for (pre-) processing of biomass, residues and waste gases at locations closer to the supply. The proposed solutions should be able to cope with the seasonal or even daily fluctuations of the renewable source to be used. In this respect the unit should also be able to process feedstock from different sources in order to guarantee the level of supply.

12 Call 2014 PROCESS SPIRE Improved downstream processing of mixtures in process industries Innovation Actions Hybrid technologies combining different techniques, such as distillation, membrane permeation, adsorption, extraction, etc. have already been applied successfully to a number of industrial processes. They can provide a cost effective solution to achieve major improvements in separation and fractionation operations, leading to waste reduction, lowering greenhouse gas emissions, and improved energy efficiency. To realise the full potential of these technologies, further investigation and a deeper understanding are required of hybrid separation techniques (e.g. distillation, extraction, drying, crystallisation and reactive separation), in particular leading to a better understanding of how the different components interact with each other. This may also facilitate the transition from batch to continuous processes in the next generation of plants, increasing yield, purity and quality of products while improving productivity.

13 Call 2014 Horizontal: SPIRE Methodologies, tools and indicators for cross-sectorial sustainability assessment of energy and resource efficient solutions in the process industry - Support action A study across multiple sectors in the process industries considering all aspects of sustainability assessment along the whole product life cycles with regard to resource and energy efficiency. It should incorporate: - A comparative overview of currently used methodologies, tools, indicators and practices in different sectors, - A selection of the most appropriate solutions, based on their demonstrated robustness and their ability to provide simplified and easily communicated data, - An overview of the related opportunities as well as the bottlenecks towards further development and cross-sectorial replication/transfer of these approaches, - Definitions of the required steps to accelerate further uptake of resource efficiency indicators over the value chains, and - Recommendations on the most suitable tools for management and decision making at research lab, plant, company, sector and multi-sectorial level.

14 RESULTS 2014 calls Total project proposals Total projects funded Total Funding Million SPIRE 1 Integrated Process Control SPIRE 2 SPIRE 3 SPIRE 4 Adaptable industrial processes allowing the use of renewables as flexible feedstock for chemical and energy applications Improved downstream processing of mixtures in process industries Methodologies, tools and indicators for crosssectorial sustainability assessment of energy and resource efficient solutions in the process industry Success rate: ~ 17%

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 APPLICATIONS SPIRE : Solids handling for intensified process technology WASTE2RESOURCE SPIRE Recovery technologies for metals and other minerals Innovation Action SPIRE PPP info day & brokerage: 21 October

16 For proposers Do not forget to consider: Value Chain Approach Cross Sectorial / Transferable Technologies Lifecycle perspectives Outline Business Plan Valorisation of results and products Address Non-technological barriers / bottlenecks Links to Legislation and Standardisation AND don't forget to Pre-register your proposal and submit IN TIME

17 FEED What next? - Priority areas 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

18 PROCESS What next? - Priority areas 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?)

19 APPLICATIONS What next? - Priority areas 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

20 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

21 HORIZONTAL What next? - Priority areas 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

22 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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24 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 new 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.