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n.

2, OCTOBER 2014

Welcome to the 2nd REEMAIN Newsletter


At the conclusion of its first year of activity, the REEMAIN project is ramping up
and we can be confident that Year 2 will mark a leap forward in our technical
progress. Lot of interesting things have happened in the last six months. We
managed to advance on several fronts, from a deeper identification of
potential places for improvement at our demo production sites to the
identification of relevant technology options, from the formulation of the
performance indicators to the first wave of input to the rough cut modelling for
our factories simulations.

Anibal Reones, Project Coordinator,


Fundacin CARTIF

Inside
In the spotlight:
SCM Foundry

REEMAIN Interviews

News from REEMAIN

Recommended
events

10

Thanks to an impressive collective effort, guided by our partners Jakob Energy


RES and EURAC, we have produced an exhaustive Technology Roadmap for
RES, storage and waste heat recovery in industrial production. The roadmap is
addressed more extensively in the spotlight section of the newsletter. Given
the range of our demonstration activities throughout the foundry, textile and
food sectors, we have analysed combinations or clusters of technological
solutions applied to those different productive contexts. A summarised version
of our deliverable will soon made available to the FoF community and to those
interested, via our website.
Important progress has been done in selecting some of the KPIs (Key
Performance Indicators). While we paid attention to review the most
important ones from the REEMAIN perspective, we also based our approach on
previous activities carried out in the framework of the KAP project. We expect
to complete the definitive list probably by the end of October.
On the outreach front, we have participated in a workshop on energy efficiency
in industrial processes at SCM in Rimini at the end of September, in connection
with the LETs conference that took place in Bologna. This happens also at the
time when we are connecting to the colleagues of other projects addressing
similar issues, like Daphne, Factory Ecomation and FoundEnergy in what
promises to become an interesting cluster of innovation in energy efficiency for
manufacturing.
Efficiently yours,
Anibal Reones
REEMAIN Project Coordinator, Fundacin CARTIF

pag. 2

REEMAIN newsletter - n. 2, October 2014

In the spotlight:
JER
Pushing innovation through technology roadmaps.
Interview to Dr. Uli Jakob
From his office nested among the
historical buildings of Weinstadts city
centre in Baden-Wrttemberg, Germany,
Dr. Uli Jakob enjoys an especially warm
day. I look in the sun he says with a
great smile thats where we find life,
energy and energy solutions. With his
small and specialised team at JER (dr.
jakob energy research), Uli is busy
identifying, studying, profiling and
matching factories, their processes and
possible solutions originating from a wide
range of innovative technologies.
Together with partners EURAC, Solera,
CARTIF, DMU, R2M, Ikerlan and CRIT, JER
has produced a robust Technology Roadmap for RES, Storage and Waste
Recovery for Efficient Manufacturing listing and ranking different types of
technologies that can be applied in industrial processes. We have made efforts
clarifies Uli to extrapolate detailed information and data for each technology
under exam, designing a SWOT (Strengths and Weaknesses, Opportunities and
Threats) matrix for each case, so that we can suggest sufficiently detailed
approaches for different cases. The idea was to build upon a first deliverable
from the REEMAIN project, the Analysis of Factory Typologies, which already
provided indications in terms of sectors for which technologies would be
broadly suitable. It goes without saying continues Uli - that not all
technologies can apply to all sectors. For instance, foundries have specific
requirements at much higher temperatures than other processes. To run our
exercise EURAC and JER have developed our own version of a ranking
methodology based on MCDA (Multi Criteria Decision Analysis). It has been our
starting point, to assign values to the different angles by which we can look at
technologies, like technical, economic, marketing or environmental aspects and
adapt them to the needs of industrial production. What we are trying to do
with the Technology Roadmap is to go deeper in the level of detail, so that we
can deliver what we can consider a building block for the REEMAIN simulation
tool, which will have to be designed by our colleagues of IES, as something that
plant managers can use to make their decisions.
Technology roadmaps tend to be dynamic documents, especially in areas
characterised by fast innovation, which may make updates necessary soon. We
are aware of that and one of the issues wed like to address is the shift from

About JER
dr. jakob energy research (JER) is an
international consultancy for RES
research and product development
as well as marketing, dissemination,
education and training, established in
2009.

Area of expertise are solar


process heat, solar cooling,
thermal cooling, poly-generation,
faade integrated solar systems as
well as building physics, energyefficient buildings and industrial
processes. JER is also involved in
other European funded FP7
demonstration and R&D projects
like InSun (Industrial Process Heat
by Solar Collectors) and FRESH
NRG (Fresnel for Solar Heat with
New Receiver and Geometry).
Website
www.drjakobenergyresearch.de
Contacts for REEMAIN project:
Dr. Uli Jakob, Managing director

pag. 3

REEMAIN newsletter - n. 2, October 2014

(Continued)
treating technologies individually, to evaluating combination of different technologies. Thats something at which we will
work in the future, hoping to make at least part of the Technology Roadmap public, when we get closer to the completion of
our project.
According to Dr. Jakob, there is still much to be done in energy efficiency for industries: For some reason the agenda until
now has been dominated by the residential context. I believe the work being done in REEMAIN is the first one, at least of
this scale, to address the challenges of energy efficiency in industrial environment. Thats also why we pay huge attention
to standardisation, through the involvement of a standardisation body, AENOR from Spain. Standardisation is in a way a precondition to achieve impact also on the level of policy making, which in our case will come in the long run.

pag. 4

REEMAIN newsletter - n. 2, October 2014

Roughly one month before its formal completion, the


FOUNDENERGY project led by Tecnalia in Spain, is
finalising the validation phase with three demonstrators.
Launched as a Capacity project in the SMEs associations scheme, the project has
gone deep in studying efficiency problems and bottlenecks within the foundry
and metal industry. All in all explains Ane Irazustabarrena Murgiondo,
coordinator of the project we are quite satisfied with the results we have
achieved. We are reaching what can be defined now according to the new H2020
terminology, a TRL 6 for the demonstrator we will run within our facilities
demonstrating the whole system with a shell and tube heat exchanger, able to
recover gases up to 350C, combined with an ORC to generate electricity. The
foundry environment is actually very complex and full measurements were not
feasible in the framework of our project. So as an alternative we developed
realistic simulation, in particular on temperatures and gas particles, checking
corrosion, wear resistance and overall performance of the heat exchanger, which
we believe can be perfectly extrapolated.

REEMAIN interviews

Insight into the


foundries
processes: the
FOUNDENERGY
project comes to
its conclusion

The FOUNDENERGY project actually tried different approaches to adapt to the


needs of distinct foundries. In the UK, at Saint Gobain, where we can work in a
real industrial environment, we use a heat pipe to test what efficiency gains we
could generate. We are also proposing an ORC in the range of 200-250 though
there is a bit of uncertainty whether we will be able to demonstrate electricity
production in the whole system, due to technical characteristics of the
demonstration factory. Finally, we are also organising a demonstration by our
Croatian partners, with a serpentine bundle, which is going to be shown at the
industry days in Cimos.
FOUNDENERGY has natural links with REEMAIN and several commonalities in its
approach to optimise energy efficiency, also by looking at a partial recovery of the
heat, which is of course one of the areas where the potential for optimisation is
higher. The innovation we have brought about - continues Ane - is among others
that we did very analytical testing on coating solutions and have been quite good
at adapting solutions to the specific needs of industrial environments that,
needless to say, change from case to case. On the other hand, we have also
encountered scalability issues and with the technologies we deploy, we definitely
need large scale plants and processes to generate relevant gains. A challenge
that Tecnalia will soon take up with a new project, called TASIO, focusing on
mature technologies for continuous process industries like cement. This will be
much closer to the market says Ane and will hopefully present partners with
clear exploitation opportunities at the end of the work. Three years from
January 2015, enough to establish a fruitful exchange of information and
experience with the REEMAIN group.

pag. 5

REEMAIN newsletter - n. 2, October 2014

REEMAIN is
developing a
tool to assess
a dataset of
technology
solutions

Developing a support tool to allow factory managers to evaluate energy consumption and
materials use and thus make informed decisions with respect to where best invest their
limited resources.
In a nutshell, this is the innovative tool that the REEMAIN
technical partners are planning to deliver as one of the
main outcome of the project. It will be based on the
existing IES-THERM State of the Art (SOTA) modelling
tool to virtually assess a dataset of technology solutions
and identify an optimal configuration which can then be
installed and tested within the factories. The tool will
facilitate the identification of appropriate solutions in the
context of both the building level elements and
manufacturing elements within the entire facility.
The REEMAIN tool is now in its requirements specification
phase, which is the crucial step before starting the real
software coding phase. IES together with the other
partners involved in developing the technical solutions
and tools for efficient manufacturing, have already
defined the overall approach to modelling and
simulations to be followed by the tool: how the tool will
work, which renewables technologies will be modelled
and included (solar cooling systems, PVs, solar thermal
collectors and solar concentrators, ORC and CHPC
systems, hot water thermal storage and Li-ion batteries),
how simulations will be done and the overall time
schedule for that.
It is very important to have a common vision and
agreement on how this will be done in the software as

modelling manufacturing sites is very complex, every


process being different from each other even in factories
of the same sector.
Requirements specifications for the rough cut
methodology implementation are also under preparation,
and it is expected to be a web based tool linked to the
REEMAIN tool.

pag. 6

REEMAIN newsletter - n. 2, October 2014

REEMAIN
closer to
definition of
simulation
models
following
workshop at
DMU
A further step has been taken towards the definition of the renewable energy models to
be used in the REEMAIN demo sites at a meeting held last June in Leicester at De
Montfort University.

pag. 7

REEMAIN newsletter - n. 2, October 2014

KPIs (Key
Performance
Indicators)

KPIs (Key Performance Indicators) are of fundamental importance in order to evaluate


the effectiveness of measures deployed.

Given the complexity of industrial production in


general, and of the specificities to be taken into
account in the REEMAIN demonstration fields, this is
a specially complex task, with clear implications on
all successive project phases.
Coordinated by EURAC, work in the definition of
KPIs has moved from the KAP project work
summarised in its Standardisation proposal and
dissemination activities report. While the main
structure of the KPI description proposed by KAP
was maintained, the REEMAIN group involved in the
activity soon realized the importance of adding a
field concerning, among other things, the time scale
of the KPI acquisition/update.

sector.

Further specifications will have to be proposed for


the actual deployment of activities at the REEMAIN
demo sites (Gulln biscuit factory, SCM foundry,
Bossa textile factory). This work is currently going on
and in the next few weeks, a definitive KPI list will be
prepared, including both general KPIs (suitable for
application to different sectors) and specific KPIs
(specialized for the different factories).

pag. 8

REEMAIN newsletter - n. 2, October 2014

Preliminary
report on
efficiency
measures

Problems mapping and first efficiency measures planned

A Preliminary report on selection of efficiency


measures was issued at the end of the first
assessment of the efficiency improvements needed
in the three demo sites. This extensive report
concludes provides an initial identification of
problems, opportunities and corresponding
measures proposed to reduce inefficiencies and
optimise processes. In this first phase, the three
factories have been analysed in detail in terms of
processes, auxiliary services, layouts, production
schedules, and a first list of possible efficiency
measures has been identified for each of them
following a traditional analysis of the manufacturing
sites.
These preliminary solutions will be further studied,
ranked and evaluated in the second phase of the
task to obtain a roll-out plan for the full deployment
of optimisation arrangements. In parallel to the
traditional analysis, IES have applied its existing
(non-commercial) analysis tool for manufacturing
environment to create models of the three factories
and to analyse SCM factory (the foundry case in
REEMAIN) in detail, starting from the already

extensive amount of metered data available for this


site. The final proposal for efficiency measures is due
by the end of this year.

pag. 9

REEMAIN newsletter - n. 2, October 2014

The SCM
Workshop

The importance of technology foresight and patent trends: some conclusions from the
REEMAIN workshop within the LETs 2014 Conference

A workshop gathering a
little more than 40
participants took place in
Rimini (Italy) at the SCM
headquarters at the end
of September, focussing
on
Improved
efficiency
and
resources
management in Factories, in connection with the
LETs 2014 Conference held in Bologna.
As a side event to the LETs Conference says
Giuseppe Lucisano of SCM foundry, one of
REEMAINs industrial partners our workshop
proved an excellent opportunity to do work together
with colleagues from the Daphne, Factory Ecomation
and Foundenergy projects. We share several
common issues and an efficient exchange of
information and experiences is fundamental to
enhance the uptake of innovative solutions for our
production processes.
The workshop followed a visit to the SCM foundry
and touched upon both technical and economic
issues, looking also at management practices. In our

view - says Lucisano it is also very useful to invest


on technology foresight to detect innovation
trends, to know for instance what has been
patented, what kind of knowledge has emerged and
what will come next.
According to Franco Cavadini of Synesis, scientific
and technical coordinator of the Factory Ecomation
project, Events like these must be seen as an
occasion to bridge the gap between research and
industry. Work done in our projects can potentially
benefit control optimisation approaches in several
industrial settings, and it is very important for us to
be challenged also with requirements and needs
from different contexts.
The workshop has also been the occasion to formally
start the clustering activity among the four EU
research projects (REEMAIN, Daphne, Factory
Ecomation and Foundenergy), focussing on energy
efficiency topics in energy intensive industrial
sectors.

pag. 10

REEMAIN newsletter - n. 2, October 2014

Recommended Events
Interesting upcoming events selected by the REEMAIN team

REEMAIN
Industrial webinar
on
the WP3
Technologies
Athens,
9 11 April
Technology
Roadmap
3 December 2014
14.30 CET

Future
of
Industrial
European
Technologies
Athens,
9 11 April
Manufacturing
Enabling the Next
Industrial
Renaissance
London - UK, 27 November

The webinar is intended to present and discuss the unique and robust REEMAIN
"Technology Roadmap for RES, Storage and Waste Recovery for Efficient
Manufacturing". It contains a listing inlcuding detailed SWOT analysis and ranking
different types of innovative energy technologies that can be applied in industrial
processes.
The webinar is a previous step before face-to-face workshops where the current
ranking and scores of the technologies will be reviewed by international
specialists.
Info:
http://www.reemain.eu/News/Events/REEMAIN_webinar_on_the_WP3_Tech
nology_Roadmap.kl

After five years of the Eurozone crisis and with the first preliminary signs of
recovery in sight, businesses, labour and policy makers are intensely seeking new
avenues to strengthen manufacturing and re-energise this vital sector for the
European economy.
The Financial Times will bring together senior business leaders and policy makers
for a unique, high level discussion on the particular opportunities and challenges
facing industry in Europe. The debate will be centered on the fundamental
adjustments that policy makers and business leaders need to make in order to
revitalise European industry and strengthen long-term European
competitiveness.
Info: http://event.ft-live.com/ehome/index.php?eventid=94960

pag. 11

SET PLAN
Conference 2014
Rome - Italy,
10 - 11 December

REEMAIN newsletter - n. 2, October 2014

The move towards a low-carbon Europe with secure energy at affordable prices,
with the achievement of the EU 2020 and 2030 energy targets, requires a
profound transformation of the entire energy system, from the supply to the
demand side. The SET Plan aims at increasing and focusing the efforts in research
and innovation while enhancing the market uptake of new solutions as well as
strengthening EU leadership in the development of low-carbon energy
technologies.
The Conference will represent a unique forum for all stakeholders (experts,
energy companies, universities, research institutes etc.), and representatives of
national and EU institutions to have in-depth discussions on the new
developments of the SET Plan in view of the Integrated Roadmap, and the actions
needed to respond to the grand energy challenges ahead of us.
Info: http://www.setplan2014.it/

ICIT 2015
Seville - Spain,
17 - 19 March 2015

IEEE ICIT is one of the flagship yearly conferences of the IEEE Industrial
Electronics Society, devoted to the dissemination of new ideas, research and
works in progress within the fields of intelligent and computer control systems,
robotics, factory communications and automation, flexible manufacturing, data
acquisition and signal processing, vision systems, and power electronics. IEEE ICIT
2015 will be held in Seville, Spain, from March 17th to 19th, 2015. Seville is well
connected to the world by an international airport, a high speed train, four
motorways, and a river port, and contains the longest bycicle track system
in Europe. Touristic attractions include historic district with the gothic Cathedral
and the Arabic Palace Alcazar, Baroque churches, a theme park, river cruises, and
nearby National Parks and beaches. Seville combines a rich historical past, when
it was the main gate to Europe from the Americas, with a vibrant present as a
technological center and meeting point.
Info: http://www.icit2015.org/

Energy Storage
World Forum
Rome - Italy,
27 30 April 2015

The Energy Storage Conference With 7 Past Successful Events And A Community
Of Over 5700 Professionals Worldwide.
In 2015 our 8th Energy Storage World Forum will take place in Rome and it will
feature new value to our followers and newcomers! There will be 2 training
courses and 5 conference days. In the meantime see below what our speakers
covered in London in April 2014.
Info: http://www.energystorageforum.com/

pag. 12

REEMAIN newsletter - n. 2, October 2014

About REEMAIN
More information on this Newsletter and related
dissemination and communication activities of the project
available at:

REEMAIN D&C Secretariat


e-mail:
secretariat@reemain.eu

Project Coordinator
Centro Tecnolgico CARTIF
Parque Tecnolgico de Boecillo 205. C.P. 47151
Boecillo, Valladolid - Espaa
Tel. 0034 983 54 65 04
Fax 0034 983 54 65 21

Coordinator
Anibal Reones
Industrial Diagnosis Area
Fundacin CARTIF

Register on www.reemain.eu or get access with your


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REEMAIN newsletter via e-mail.
For the purposes of media law, editorial responsibility rests
with the REEMAIN Communication Secretariat.

This project has received


funding from the European
Unions Seventh Framework
Programme for research,
technological development
and demonstration under
grant agreement no 608977