Hvordan skape klimavinnere i industrien

Transkript

1 Hvordan skape klimavinnere i industrien Marit Larsen, Managing director Tel-Tek Anne Marie Fatnes, Project Leader,Tel-Tek 20/ Zero Emission Conference 2012 Hvordan skape klimavinnere i industrien How to make industry champions for a climat friendly future

2 Tel-Tek is a national R&D institute with focus on effective production processes and low emission Competence areas Flow technology/cfd Process simulations Design of process units Pneumatic transport, cyclones, fluidized bed Software development within process efficiency Smart Manufacturing CO 2 capture technology and CCS system solutions Environmental evaluations (e.g. climate, waste, environmental aspects with CCS) Bio energy from waste Low Carbon Economy Key figures Established: 1986 Turnover (2011): 47 MNOK Employees: 41 Values Robust Generous Enthusiastic Knowledge building

3 Effective processes for a climate friendly future Powder technology Energy CCS* Smart Manufacturing Transport Storage Handling Separation Characterization CO 2 capture combined with bioenergy Biogas Combustion and environment Modelling and flow Energy effective processes Calculation of costoptimal energy utilization Post-combustion capture technology CO 2 transport and infrastructure Degradation of amines Early phase cost estimation Solutions for energy-producing and energyintensive industry CO 2 -lab Multivariate - analysis/diagnostics - modelling - simulation - optimization Understanding/ hypothesis Verification Implementation * Carbon capture and storage

4 Tel-Tek Academy Courses o Smart Manufacturing o Powder handling o Cost estimation o Tailor maid/in-house courses Workshops Seminars Conferences Fun to run

5 Contribution to the Low Carbon Action Plan Ref: IEA

6 The main elements in Low Carbon Economy Land-use patterns / spatial planning Comsumption / lifestyle Behavioural elements Buildings / Heating / Cooling Specific North Sea Region Industry Transport infrastructure Modal shifts Financial elements Taxation, emission trading etc. Downsizing (e.g. of vehicles ) Fuel efficiency/ Alternative fuels Optimaizations of energy carriers + smart grids Carbon capture + storage (Energy) efficiency CCS

7 CO 2 handling in the Skagerrak/Kattegat-region Industrial CO 2 emissions Total emissions from large point sources: Approx 13 mill tonnes CO 2 /year Industy Industrien i Grenland: 2,2 mill t. t. Ca 100 km Power plant and Cement Kraftverk plant og Ålborg: sementfabrikk 5,4 mill i Ålborg: t 5,4 mill t Refinery Raffineri Lysekil: 1,9 mill t t Petrochemical plants Stenungsund: 0,6 mill t Borealis i Stenungsund: Refineries 0,6 mill + t power plants + waste incineration To raffineri + kraftverk Gøteborg: og avfallsforbrennings- 2,2 mill t anlegg i Gøteborg: 2,2 mill t

8 Tel Tek Prosjekt resultat Identified a promising storage structure outside Grimstad/Kristiansand The Gassum Formation. Given a useful economical and technological contribution to the industry partners to calculate their cost for implementing CCS Listed three cases for a realizable transport infrastructure Highlighted six crucial legal barriers

9 Hva har kommet ut av Skagerrak/Kattegatprosjektet videre planer Nytt prosjekt finansiert av Statoil og Gassnova: CO2-injeksjonspilot i Gassumformasjonen Forprosjekt LOWCAP Low Carbon Economy in the North Sea Region Nytt KASK-prosjekt: Optimalisering av energibærerne i Skagerrak/Kattegatregionen Nytt LOWCAP hovedprosjekt i Nordsjøregionen fra 2014 hvor resultatene fra disse prosjektene vil kunne gi et betydelig og nyttig bidrag

10 Stort optimaliseringspotensiale i industrien Smart Produksjon Utfordrende å identifisere rot-årsakene i komplekse industriprosesser Manglende data og/eller dårlig datakvalitet Lite variasjon i historiske data Kvalitetsparametre måles ved bruk av langsomme laboratorieanalyser som introduserer time lag Prosessdata er sterkt korrelerte target Nødvendig med multi-respons betraktninger ved optimalisering av prosessene Vanskelige å skille kausalitet og korrelasjon Manglende modell-baserte tilnærming Manglende kompetanse i avansert dataanalyse spec

11 Jotun CAPASITY 15% improvement of the production capasity Analysis of product quality reduced from 24 hours to 10 minutes (NIR) QUALITY Off-spec from 33% to in practice 0 End-properties of the paint optimized and stabilized MOST Norwegian manufacturing industry do have (9 of 10) some sort of unwanted variation and production away from optimal performance Pronova Biocare Often this may be solved simply by changing the production set-points, being - Quality: From 80% off-spec to zero - very Business cost-efficient performance: improvement from 3 mill without Euro to need + 2 mill for Euro expensive investments! - Value: From. 050 Bill. Euro to 1 Bill. Euro In another case a plant improved their production capacity by 25%;- simply by introducing soft sensors and changing their production set-points

12 Eksempel: Uønsket variasjon Løsning.?. Årsakene.?. variasjoner fra skift til skift? operatørvariasjon Sesongvariasjon variasjoner i råvare? post-mortem analyse! bedre utnyttelse av tilgjengelige data? behov for nye on-line målinger? behov for bedre styring av prosessen?

13 Data for simplified process

14 Korrelasjonen mellom Yield og Katalysator

15 Or study effect from both correlated variables at same time Multivariate - og modellbasert tilnærming er essensen i å forstå prosessers uønskede variasjoner. For i praksis er det som oftest ikke så enkle system som vist her med kun to variable...

16 Powder Technology, Fish feed carrier

17 Conclusions It is a lot to gain in increased capacity and increased performance in existing production processes New softsensors (instruments) will give more (and probably new) information as basis for upgrading of process models for better product quality, increase in capasity Too much focus on new investment/equipment for reduction in kw as basis for funding might be a limitation It is possible to gain a lot in existing industry with minor input factors and with a significant reduction in climat footprint as effect