Energy management Plan (Final)

D1.9 – Energy Management Plan (Final Version) October 2024 Authors: Victor Fabregat Tena (REG) Juana María Pagán Carpe (REG) David Campos Peñalver (REG) Francisco David Gallego Martínez (REG) Ref. Ares(2024)8938267 - 13/12/2024 A2C – Deliverable D1.9V1.0 Page 2 of 102 Technical references Project Acronym Agro2Circular Project Title TERRITORIAL CIRCULAR SYSTEMIC SOLUTION FOR THE UPCYCLING OF RESIDUES FROM THE AGRIFOOD SECTOR Project Coordinator Fuensanta Monzó Sánchez CETEC [email protected] Project Duration October 2021 – March 2024 (42 months) Deliverable No. D1.9 Dissemination level* PU Work Package WP 1 – A2C Specifications, Residues Management and Data Integration System Task T1.3 – A2C water and energy efficiency assurance Lead beneficiary 11 (REGENERA) Contributing beneficiary/ies 1 (CETEC), 2 (GWC), 3 (SAPERATEC), 4 (IRIS), 6 (EPOCH), 7 (CETBIO), 8 (UNIMIB), 13 (CTNC), 29 (VTT) Due date of deliverable 30 September 2024 Actual submission date 13 December 2024 * PU = Public PP = Restricted to other programme participants (including the Commission Services) RE = Restricted to a group specified by the consortium (including the Commission Services) CO = Confidential, only for members of the consortium (including the Commission Services) Document history A2C – Deliverable D1.9V1.0 Page 3 of 102 V Date Comments V0.1 21/10/2024 First draft of document. V0.2 25/10/2024 Revision of the document after internal review. V0.3 08/11/2024 Review of the document by VTT and GWC. Some quality improvements have been made, such as grammatical errors, references or clarifications needed to improve clarity. V0.4 04/12/2024 Review of document by demonstrators’ partners with feedback about public/confidential information V1.0 13/12/2024 Grammar and technical corrections by WP leader and the coordinator Verification and approval Name Date Verification Final Draft by WP leader Jaime Ortiz Aragón (ECOTRACE) 13/12/2024 Approval Final Deliverable by coordinator Fuensanta Monzó Sánchez (CETEC) 10/12/2024 Disclaimer and acknowledgement This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 101036838 Disclaimer This document reflects only the views of the author(s) the European Research Executive Agency (REA) is not responsible for any use that may be made of the information it contains. Whilst efforts have been made to ensure the accuracy and completeness of this document, the A2C consortium shall not be liable for any errors or omissions, however caused. A2C – Deliverable D1.9V1.0 Page 4 of 102 Table of contents Table of contents .............................................................................. 4 List of Tables .................................................................................................................. 8 List of Figures ................................................................................................................ 9 List of abbreviations ........................................................................ 11 1 Executive summary ................................................................... 13 2 Introduction ................................................................................ 14 3 State of the Art ........................................................................... 15 3.1 Energy consumption in current plastic market .............................................. 15 3.2 Plastic consumption and recycling ................................................................. 16 3.3 Overview of energy consumption in the plastic waste recovery sector ....... 19 3.3.1 Recycling and plastic production methods. ...................................................... 19 3.3.2 Energy costs in the plastic fabrication sector. .................................................. 22 3.3.3 Key Performance Indicators’ definition ............................................................. 24 3.3.4 Objectives and goals ........................................................................................ 24 3.4 Concept of an Energy Management Plan (EMP) ............................................. 24 3.5 Regulatory framework ....................................................................................... 26 4 List of Processes ....................................................................... 28 4.1 Process 1: Green hybrid technologies for extraction of bioactive substances from agrifood wastes ................................................................................................... 33 4.1.1 Description ....................................................................................................... 33 4.1.2 Process flow diagram ....................................................................................... 35 4.2 Process 2: New food, nutraceuticals & cosmetic formulations using extracts from agrifood wastes. .................................................................................................. 36 4.2.1 Description ....................................................................................................... 36 4.2.2 Process flow diagram ....................................................................................... 37 4.3 Process 3: Identification and sorting of multilayer materials ........................ 38 4.3.1 Description ....................................................................................................... 38 4.3.2 Process flow diagram ....................................................................................... 39 4.4 Process 4: Separation of aluminium (Al) from complex multilayer structures 40 A2C – Deliverable D1.9V1.0 Page 5 of 102 4.4.1 Description ....................................................................................................... 40 4.4.1 Process flow diagram ....................................................................................... 40 4.5 Process 5: PET/PE enzymatic depolymerisation ............................................ 40 4.5.1 Description ....................................................................................................... 40 4.5.2 Process flow diagram ....................................................................................... 41 4.6 Process 6: Plastics decontamination .............................................................. 42 4.6.1 Description ....................................................................................................... 42 4.6.2 Process flow diagram ....................................................................................... 43 4.7 Process 7: Aluminium recycling and chemical modification ........................ 44 4.7.1 Description ....................................................................................................... 44 4.7.2 Process flow diagram ....................................................................................... 45 4.8 Process 8: Upcycling of enzymatic degradation products (TPA, EG) by cell factories ........................................................................................................................ 45 4.8.1 Description ....................................................................................................... 45 4.8.2 Process flow diagram ....................................................................................... 46 4.9 Process 9: PHBV and C-50 carotenoids development by Hfx. mediterranei haloarchaea cell factory .............................................................................................. 47 4.9.1 Description ....................................................................................................... 47 4.9.2 Process flow diagram ....................................................................................... 48 4.10 Process 10: High barrier compounds by extensional flow mixing and compatibilisation .......................................................................................................... 49 4.10.1 Description ................................................................................................... 49 4.10.2 Process flow diagram ................................................................................... 49 5 Relation between Processes and Demo Sites........................... 50 5.1 Brief description of the demonstrators ........................................................... 52 5.2 Demos 1 and 6-9 ................................................................................................ 52 5.3 Demo 2 ............................................................................................................... 53 5.4 Demo 3 ............................................................................................................... 53 5.5 Demo 4 ............................................................................................................... 54 5.6 Demo 5 ............................................................................................................... 54 6 Energy analysis of Demonstrators ............................................. 55 6.1 Demonstrator 1 .................................................................................................. 55 6.1.1 Demonstrator 1. Process 3 .............................................................................. 55 6.1.2 Demonstrator 1. Process 4 .............................................................................. 56 A2C – Deliverable D1.9V1.0 Page 6 of 102 6.1.3 Demonstrator 1. Process 5 .............................................................................. 57 6.1.4 Demonstrator 1. Total energy consumption and KPI ....................................... 58 6.2 Demonstrator 2 .................................................................................................. 59 6.2.1 Demonstrator 2. EG to biomass and glycolic acid ............................................ 62 6.2.2 Demonstrator 2. Total energy consumption and KPI (EG to biomass and GA) 63 6.2.3 Demonstrator 2. Lemmon to microbial oil ........................................................ 64 6.2.4 Demonstrator 2. Total energy consumption and KPI (lemon to microbial oil) .. 66 6.3 Demonstrator 3 .................................................................................................. 66 6.3.1 Demonstrator 3. Process 1 .............................................................................. 69 6.3.2 Demonstrator 3. Process 2 .............................................................................. 69 6.3.3 Demonstrator 3. Total energy consumption and KPI ....................................... 70 6.4 Demonstrator 4 .................................................................................................. 70 6.4.1 Demonstrator 4. Process 1 .............................................................................. 72 6.4.2 Demonstrator 4. Process 2 (solid phase) ......................................................... 73 6.4.3 Demonstrator 4. Process 2 (liquid phase) ........................................................ 75 6.4.4 Demonstrator 4. Total energy consumption and KPI ....................................... 76 6.5 Demonstrator 5 .................................................................................................. 76 6.5.1 Demonstrator 5. Fermentation, filtration and drying ......................................... 78 6.5.2 Demonstrator 5. PHBV extraction and purification ........................................... 80 6.5.3 Demonstrator 5. Total energy consumption and KPI ....................................... 82 6.6 Demonstrators 6 + 8 .......................................................................................... 82 6.6.1 Demonstrator 6+8. Total energy consumption and KPI ................................... 83 6.7 Demonstrators 7, 9 ............................................................................................ 83 6.7.1 Demonstrator 7 ................................................................................................ 84 6.7.2 Demonstrator 7. Total energy consumption and KPI ....................................... 86 6.7.3 Demonstrator 9 ................................................................................................ 87 6.7.4 Demonstrator 9. Total energy consumption and KPI ....................................... 88 7 Summary of KPIs ....................................................................... 89 8 Energy Efficiency Recommendations for the Operation of Demos Sites ................................................................................................ 90 8.1 Heat recovery from steams............................................................................... 90 8.2 Adopt high energy efficiency technologies for heating ................................. 91 A2C – Deliverable D1.9V1.0 Page 7 of 102 8.3 Use of Variable Speed Drive (VSD) or Variable Frequency Drive (VFD) in air compressors ................................................................................................................. 92 8.4 Renewable installations for electricity production ......................................... 92 9 Energy performance improvement targets ................................ 94 9.1 Aligning targets with KPIs ................................................................................ 94 9.2 SMART Targets .................................................................................................. 94 9.3 Short-Term vs Long-Term Targets ................................................................... 94 9.4 Balancing ambition with realism ...................................................................... 95 10 Monitoring, Measurement and Verification ................................ 96 11 Communication Plan .................................................................. 97 12 Conclusions ............................................................................... 98 13 References ................................................................................ 99 A2C – Deliverable D1.9V1.0 Page 8 of 102 List of Tables Table 1. Primary energy consumption in production of selected plastics. [1] ..................... 15 Table 2. Energy and water requirements for virgin and recycled plastic production [36]. .. 22 Table 3. Required investment in recycling technologies [36]. ............................................ 23 Table 4. Energy consumption in the plastic fabrication industry, Spain [37]. ..................... 23 Table 5. Energy consumption in the plastic fabrication industry, Spain. Source: [37] ........ 25 Table 6. List of most relevant regulations and standards for EMPs. .................................. 26 Table 7. Information relating to the processes studied. ..................................................... 30 Table 8. The fruits and vegetables wastes used for revalorization. ................................... 34 Table 9. Extraction and purification technologies. .............................................................. 34 Table 10. Relationship between Processes and Demonstrators ........................................ 50 Table 11. Process summary. Demo 1 (process 3). ............................................................ 56 Table 12. Process summary. Demo 1 (process 5). ............................................................ 57 Table 13. Demonstrator 1. Total energy consumption. ...................................................... 58 Table 14. Demonstrator 1. KPIs. ........................................................................................ 59 Table 15. Process summary. Demo 2 (EG to biomass and glycolic acid). ......................... 62 Table 16.Demonstrator 2. EG to biomass and Glycolic Acid. KPIs. ................................... 63 Table 17. Process summary. Demo 2 (yeast fermentation line). ....................................... 64 Table 18. Demonstrator 2. EG to biomass and Glycolic Acid. KPIs. .................................. 66 Table 19. Demonstrator 3. Total energy consumption. ...................................................... 70 Table 20. Demonstrator 3. KPIs. ........................................................................................ 70 Table 21. Process summary. Demo 4. Process 1. ............................................................. 72 Table 22. Process summary. Demo 4. Process 2 (solid phase). ....................................... 73 Table 23. Process summary. Demo 2 (liquid phase). ........................................................ 75 Table 24. Demonstrator 4. Total energy consumption. ...................................................... 76 Table 25. Demonstrator 4. KPIs. ........................................................................................ 76 Table 26. Process summary. Demo 5. Mass and energy balances in the general line. ..... 78 Table 27. Process summary. Demo 5. Mass and energy balances in PHBV extraction and purification. ................................................................................................................. 81 Table 28. Demonstrator 5. Total energy consumption. ...................................................... 82 Table 29. Demonstrator 5. KPIs. ........................................................................................ 82 Table 30. Process summary. Demonstrators 6+8. ............................................................. 82 Table 31. Demonstrators 6+8. KPIs. .................................................................................. 83 A2C – Deliverable D1.9V1.0 Page 9 of 102 Table 32. Process summary. Demo 7. ............................................................................... 84 Table 33. Demonstrator 7. Total energy consumption. ...................................................... 86 Table 34. Demonstrator 7. KPIs. ........................................................................................ 86 Table 35. Process summary. Demo 9. ............................................................................... 88 Table 36. Demonstrator 9. KPIs. ........................................................................................ 88 Table 37. Summary of KPIs. .............................................................................................. 89 List of Figures Figure 1. Distribution of the global plastics production. Source: [9] ................................... 17 Figure 2. Distribution of plastics production in the world in 2019. [11] ............................... 17 Figure 3. Distribution of European Union Production in 2022. [12] .................................... 18 Figure 4. Plastics waste produced and recycled in EU. [13] .............................................. 18 Figure 5. Circularity of plastics scheme. Source: [17] ........................................................ 19 Figure 6. Evolution of plastic waste treatment in the European Union. [18] ....................... 20 Figure 7. Plan-do-check-act cycle ...................................................................................... 25 Figure 8. Agro2Circular diagram flow. ............................................................................... 29 Figure 9. Flowchart of the extraction and upcycling of food waste from the agrifood industry. .................................................................................................................................... 32 Figure 10. Multilayer aseptic bags upcycling. .................................................................... 33 Figure 11. Multilayer soil disinfection films. ........................................................................ 33 Figure 12. Process 1 flow diagram. ................................................................................... 35 Figure 13. Process 2 flow diagram. ................................................................................... 37 Figure 14. Process 3 flow diagram. ................................................................................... 39 Figure 15. Process 5 flow diagram. ................................................................................... 41 Figure 16. Process 6 flow diagram. ................................................................................... 43 Figure 17. Process 7 flow diagram. ................................................................................... 45 Figure 18. Process 8 flow diagram. ................................................................................... 46 Figure 19. Process 9 flow diagram. ................................................................................... 48 Figure 20. Process 10 diagram flow. ................................................................................. 49 Figure 21. Flowchart of the relationship between processes and diagrams....................... 51 Figure 22. Diagram of the Relationship between Demonstrators 1 & 6-9. ......................... 52 Figure 23. Diagram of the Relationship for Demonstrator 2. .............................................. 53 Figure 24. Relationship Diagram of Demonstrator 3. ......................................................... 53 A2C – Deliverable D1.9V1.0 Page 16 of 102 The value of the indicator “energy consumption from non-oil energy carriers” consists of energy consumption derived from solid fossil fuels (coal), gaseous fuels (natural gas), and renewable energy sources. The calorific value of plastic represents the amount of heat generated during the complete combustion of a unit mass of plastic. The ratio between the calorific value of plastic and the total energy consumption in plastic production indicates the portion of invested energy that can be recovered through the thermal treatment of plastic waste. 3.2 Plastic consumption and recycling Plastic can be defined as a material consisting of a polymer (a substance consisting of molecules characterized by the sequence of one or more types of monomer units [2]) to which additives or other substances may have been added, and which can function as a main structural component of final products, with the exception of natural polymers that have not been chemically modified [3]. Plastics may have different physical properties that make them behave differently when heated. Depending on this, they can be classified into [4]: • Thermoplastics. Thermoplastics melt at high temperatures, thus being possible to mould them. Once they cool down, they harden and keep the final shape that they had been given. This process can be repeated more than once, something that makes them especially good for recycling. • Thermosets. Thermosets are plastics that can only be melted down once. They adopt the shape that is given to them and once they harden, they will burn if heated up again. • Elastomers. Elastomers have elastic properties that allow them to recover their original shape after being deformed. Elastomers’ molecules are rather weakly bonded, when they are stretched, molecules align, returning to their initial state once force is no longer applied. Besides this classification based on physical properties, the classification using label numbers is widely used to identify the type of plastic a product is made of and whether it can be recycled. This classification is the following [5]: 1. PET or PETE. 2. HDPE. 3. PVC. 4. LDPE or PEBD. 5. PP. 6. PS. 7. Other plastics. From the previous list, plastics 1 – 5 can be recycled, while PS, on the other hand, generally cannot be recycled but it can be used to produce plant pots or used in building materials. This recycling capability is something of great importance, considering that due to plastic’s versatility and ease of modification, it has been widely used in the last decades. A2C – Deliverable D1.9V1.0 Page 17 of 102 There are different personalities who have had ahuge importance in the early development of plastics: Alexander Parkes invented an early plastic in 1855 that is now known as celluloid [6], the first synthetic polymer was invented in 1869 by John Wesley Hyatt [7] and it was not until 1907 that Leo Baekeland invented Bakelite, the first fully synthetic plastic. This new material offered a world of possibilities due to its properties such as durability, insulation capability, heat resistance, and ease of production. As a result, global plastic production in 1950 was 1,3 million tons [8]. By the year 2010, 265 million tons were produced worldwide and in 2021 we reached 391 million tons. From this gigantic amount, less than 10% is part of a circular economic model [9]. Figure 1. Distribution of the global plastics production. Source: [9] Worldwide plastic production is expected to keep growing, reaching 417 million tons by the year 2030 [10], as its properties make it a perfect material for many different applications. Figure 2. Distribution of plastics production in the world in 2019. [11] A2C – Deliverable D1.9V1.0 Page 18 of 102 In 2019, China reached 31% of global plastic production. With Asia in the lead, they are followed by NAFTA (North American Free Trade Agreement) and then Europe, with 16%. As for the European Union, as can be seen in Figure 3, plastic production in 2022 reached almost 59 million tons. Figure 3. Distribution of European Union Production in 2022. [12] Each EU inhabitant generated an average of 36.1 kg of plastic packaging waste in 2021. The volume of plastic packaging waste generated per inhabitant increased by around 29% (+8.1 kg per person) between 2010 and 2021. The total plastic waste produced in the EU in 2021 was 16.13 million tons. Some 6.56 million tons of plastic waste was recycled. Figure 4 shows the amount of waste produced and recycled in the European Union from 2011-2021. Figure 4. Plastics waste produced and recycled in EU. [13] A2C – Deliverable D1.9V1.0 Page 19 of 102 Regarding the use of plastic in the agricultural field, it started with the use of PVC and cellophane in order to cover greenhouses. Materials such as glass that used to be used to cover greenhouses, or paper and straw that were used for soil mulching have lost the fight against plastics [14]. In 2010, 15,6 million tons of plastics were used in agriculture alone, nearly 4% of the global production. In Europe, plastic demand in agriculture was about 3,1% of total plastic demand in Europe, being LDPE, HDPE, PP, PVC and other thermosets and thermoplastics the most demanded plastics in the agricultural sector [15]. In this context, ensuring that plastics are recycled is key in order to promote circularity. Plastic residues can be used to produce new plastic products or even burnt as fuels to produce energy, being the achievement of a circular economy the goal that should be followed [16]. This circular approach is shown in Figure 5 where it can be seen that plastic products should be produced partly from recycled materials and partly from new ones, used, reused and repaired and then collected and recycled when possible, re-starting the cycle. Figure 5. Circularity of plastics scheme. Source: [17] As a result, a correct waste collection, treatment and recycling methodology must be implemented to assure the circularity of the process, to make sure that raw materials demand decreases, to improve the process viability and, ultimately, to achieve sustainability. It is highly important to understand the recycling process, from the moment in which waste is collected to the moment in which recyclates are produced and prepared to be used again. All this process has a certain energy consumption and subproducts associated and reducing these as much as possible is a must. 3.3 Overview of energy consumption in the plastic waste recovery sector 3.3.1 Recycling and plastic production methods. Rather than using plastic waste to produce energy, as this process involves burning it and thus it has CO2 and other pollutant emissions, the goal should be recycling as much as possible. Governments in Europe seem to have realized that, as the evolution of plastic waste use (Figure 6) shows: the amount of plastic recycled doubled between 2006 and 2020. A2C – Deliverable D1.9V1.0 Page 20 of 102 The total amount of plastic packaging waste sent to recycling facilities has more than doubled since 2006. However, 6.9 million tons of plastic packaging waste were still sent to landfill and 10.2 million tons to energy recovery. For the first time since 2006, the amount of plastic packaging waste sent to energy recovery decreased. Figure 6. Evolution of plastic waste treatment in the European Union. [18] A general classification for plastic recycling is the following [19]: • Primary recycling. • Secondary recycling. • Tertiary recycling. • Energy recovery. Primary recycling, also known as closed-loop recycling, is defined by [20] as the process of taking uncontaminated discarded plastics and directly turning them into the same “new” product, ideally without loss of properties. An example of this would be collecting used bottles to clean and reuse them. Secondary recycling refers to mechanical recycling, in which polymers don’t change chemically but are physically reprocessed and used for a different purpose from the prior one. This would be the case of, for instance, making granules out of waste tires to use them on playground floors or on artificial grass football fields. Tertiary recycling, also known as chemical recycling, uses chemical processes to break down the polymer into value-added commodities that can be later on used as feedstock for the production of fuels and polymers. In this case, there is not a direct reuse of the plastic per se, but a treatment to obtain a new raw material that can be used to produce new plastics. Finally, energy recovery is used when none of the previous options are available because of the low quality of the plastic or the degradation of its properties. By burning the plastic, some of its energy can be recovered and used in other processes, but there are important A2C – Deliverable D1.9V1.0 Page 21 of 102 CO2 emissions and once it is burned, no further uses can be achieved, so this option does not contribute to closing the loop in a circular economy. Regarding recycling methodologies, we can speak of 3 main ones [21]. Some of them have already been mentioned when speaking about the general recycling classification: • Mechanical recycling. • Dissolution recycling. • Chemical recycling. Mechanical recycling recovers plastic by means of heat and shear. Mechanical recycling has traditionally been the only method to recycle plastic waste [22]. This process does not disrupt the polymer chains except due to possible degradation of the polymer itself. Thermoset materials cannot be recycled through these methods, as they don’t melt when heated, so it would only be possible to tear them down to pieces that could be later on used as fillers or for other purposes. Mechanical recycling is key for plastics sustainability. However, mechanical processes are limited by cost, loss of mechanical properties of the plastics and inconsistent quality products. Authors in bibliography suggest that the length of polymer chain and the degree of branching influence degradation kinetics, and that these variables should be kept in mind when considering different recycling methods [23] [24] [25]. Mechanical recycling is often carried out through extrusion: waste plastic is regranulated, then it passes through rotating screws to induce thermal softening of plasticization. Finally, it passes through temperaturecontrolled barrel sections to produce the extrudate. Despite the fact that this process is highly widespread, operating conditions lead to chain degradation, reducing chains’ length and negatively affecting its mechanical properties and processability [10]. As a result, usually new material is added in order to keep plastic properties; for instance, when recycling PET bottles, the new to recycled material ratio is often 70/30 by weight. Dissolution recycling, also known as physical recycling, uses chemical products and heat to dissolve polymers into a solution of polymers and separate them from the rest of the waste and additives. By doing so, it is possible to separate materials without breaking any chain, and including impurities in new materials is prevented, thus allowing the recycling of food related materials that otherwise would not be recyclable because of food scents [26]. Alkanes are used as solvents to perform these processes as they share molecular similarities with products to be treated and can withstand high temperatures and pressures. The process is carried out in 2 steps: in the first one, plastic is submerged in the solvent and everything is heated. High pressure keeps the solvent in liquid state and high temperatures dissolve the impurities from the plastic into the solvent, which is later on drained. In the second step, a fresh batch of solvent is fed to the system, rising temperature to dissolve the plastic itself and then removing it, leaving only undissolved impurities. Then the solution is cooled down until plastic solidifies, removing the solvent away [26] [27]. The main benefit from this method is the fact that no substantial difference in properties from the starting material and the recycled one is found. Besides, the used solvent can be recovered and recirculated within the recycling system, which also reduces process’ costs. Finally, this technology does not require extensive pre-treatment and it obtains high conversion rates making it a very promising technology [28]. A2C – Deliverable D1.9V1.0 Page 22 of 102 Chemical recycling manages to produce monomers or new raw materials by changing the chemical structure of plastic waste through chemical processes such as cracking, gasification or depolymerization, excluding energy recovery and incineration. Its main advantage is its capability to deal with complex plastic waste streams, like films or laminates, that would otherwise end up in landfill or incineration processes [29]. By doing so, the amount of fossil resources required is reduced, moving us towards a circular economy with lower dependence from non-renewable resources. Chemical recycling can be divided into solvolysis, pyrolysis and gasification [30]. Solvolysis includes processes such as alcoholysis, hydrolysis or aminolysis, that is the decomposition of polymers by using alcohols, water, ammonia, etc. Through these processes, using solvents, temperature and pressure oligomers and monomers are produced [31], breaking C – X bonds, where X are hetero (non-carbon) atoms, such as O, N, P, S, Si or halogen among others [32]. Pyrolysis technology manages to convert plastics into high value fuels and chemicals. The main difference of pyrolysis compared to incineration or gasification is the absence of O2 in the process, reducing CO2 and toxic pollutants emissions [33], but this process involves high temperatures (around 500ºC) too. Plastic waste is vaporized in a reactor and then condensed to produce pyrolysis oil along with fuel gas and char, and hydrocarbons [34]. In gasification, a gasifying agent such as steam, oxygen and air is applied to plastic waste at temperatures between 500 and 1300ºC, producing syngas that can be later on used to produce products or as a fuel [35]. 3.3.2 Energy costs in the plastic fabrication sector. One of the main issues to be considered in plastic recycling, once the proper methodology to recycle it depending on the quality of the plastic has been chosen is the process’ cost. During the recycling process, not only energy is consumed, but other resources like water or new plastic can be required too. As a result, the global warming potential of the recycling process is negative, as the process prevents the production of new plastic, but resources’ costs can be high, making companies unwilling to invest in recycling. Table 2 shows energy and water consumption for different virgin and recycled plastics. It is important to note that both energy and water requirements for recycled plastic are lower than those required for new ones. Table 2. Energy and water requirements for virgin and recycled plastic production [36]. Energy requirement (GJ/ton) Water requirement (m3/ton) Virgin PET 82,7 66 Virgin HDPE 76,7 32 Virgin LDPE 78,1 47 Virgin PVC 56,7 46 A2C – Deliverable D1.9V1.0 Page 23 of 102 Virgin PP 73,4 43 Virgin PS 87,4 140 Recycled plastics 8-55 3,5 Besides energy and water costs (the main inputs of the process, apart from waste plastic), another point of huge importance that needs to be considered is the required investment to build a working plastic recycling plant and its cost of operation and maintenance. These costs are usually known as CAPEX (capital expenditure) and OPEX (operational expenditure). While CAPEX includes all actives acquired by the company (acquisition of machines, terrains, buildings, initial investment…), OPEX includes those expenses related to daily operation and services’ payments (electricity and water costs, employees’ payment, machines’ maintenance…). An estimation of these costs can be seen on Table 3: Table 3. Required investment in recycling technologies [36]. Investment cost to process 1 ton/day Annual operation and maintenance to process 1 ton/day Mechanical recycling 1.795 – 8.980 € 449 – 1.347 € Chemical recycling (pyrolysis) 769.752 € 449 – 898 € Chemical recycling (gasification) 345.804 € 11.091 € Incineration 455.000 – 480.000 € 40.000 € The costs in Table 3 give an idea of the amount of money required to install a plastic recycling plant. Regarding energy consumption, according to [37], the plastic production industry is responsible for nearly 5% of the total electricity consumption of the manufacturing industry in Spain. Thus, it is vastly important to introduce elements and strategies that help reduce energy consumption, improve energy efficiency and, if possible, adopt renewable energies to reduce the activity’s carbon footprint. Table 4. Energy consumption in the plastic fabrication industry, Spain [37]. Electricity (m€) Gas (m€) Diesel (m€) Fuel (m€) Other petroleum products (m€) Biofuels (m€) Heat (m€) Total energy consumption (m€) 2015 333.002 33.840 14.791 29 2.453 0 1.394 385.509 2017 309.342 48.417 12.982 742 3.047 584 1.190 376.303 2019 345.067 34.843 20.634 1.116 1.124 6 1.439 404.229 A possible strategy to improve energy efficiency and ultimately to reduce energy consumption in a company is the use of key performance indicators, its monitoring and comparison to previously established goals. A2C – Deliverable D1.9V1.0 Page 24 of 102 3.3.3 Key Performance Indicators’ definition A key performance indicator (KPI) is a critical quantitative indicator of progress towards an intended result [38]. In order to successfully adopt the use of key performance indicators, a company needs to analyse the process in which this methodology will be applied, so that the most relevant variables are identified and the focus is set on them. Once the process is understood and key variables identified, it is needed to determine which of them can be quantified and monitored so that more or less regular feedback on how the process is advancing is obtained. Then, targets need to be set, and measures need to be taken to effectively track the value of these variables, comparing them to the established targets to get to know the situation in which the process is. 3.3.4 Objectives and goals As it was explained in the previous paragraph, in order to effectively adopt the use of KPIs, establishing objectives and goals is required. Objectives and goals need to be specific, measurable and achievable: • Specific goals rather than undefined ones are properly chosen, based on evidence of their effect on the process, and they define clearly the part of the process in which they are expected to be reached. By doing so, vain efforts trying to reach impossible results or to achieve those results in parts of the process where they are not required are avoided. • Results need to be measurable so that it is possible to compare KPIs with the obtained result and determine how near or far results are from the desirable goals. Furthermore, by using measurable results and KPIs, objectivity is gained since there is no room for opinions when comparing 2 values. • Finally, goals need to be achievable, it does not make sense establishing goals that cannot be reached, obtaining bad results when comparing KPIs with the expected value. For instance, reducing the process energy consumption by around 20% could be possible if certain energy efficiency measures were taken, but reducing it to 100% is not realistic. 3.4 Concept of an Energy Management Plan (EMP) An EMP is a specific document or set of documents usually elaborated to serve as a support tool for the implementation of an Energy Management System (EMS). These documents serve as a long-term planning resource that outlines the goals, strategies, and actions that have been set to optimize energy consumption. An EMP must include, at a minimum, an energy reduction goal and an implementation plan to achieve that goal, and usually includes the methodology to verify the achievement of the proposed reduction, for example, by calculating a baseline of energy consumption. An Energy Management Plan must be followed taking continuous improvement as a philosophy. In that sense, the Plan-do-check-act (PDCA) cycle is proposed in most of the standards for implementing an EMS such as the Standard ISO 50001. The following figure shows the philosophy of the PDCA cycle: A2C – Deliverable D1.9V1.0 Page 25 of 102 Figure 7. Plan-do-check-act cycle Different stages of the PDCA cycle and actions to be taken in each of them are shown in Table 5: Table 5. Energy consumption in the plastic fabrication industry, Spain. Source: [37] Plan - Establish the objectives and scope of the Energy Management Plan. - Conduct an energy assessment or audit to determine the current energy consumption and identify areas for improvement. - Set specific energy goals, targets, and performance indicators. - Develop strategies and action plans to achieve the energy objectives, considering energy-saving measures, equipment upgrades, employee training, etc. Do - Implement the strategies and action plans defined in the planning stage. - Allocate necessary resources, including budget, personnel, and technology, to support the implementation. - Execute energy-saving measures, optimize processes, install energyefficient equipment, and integrate renewable energy sources as applicable. - Ensure proper documentation and communication of the implemented actions. Check - Monitor and measure energy consumption and performance against the established goals and targets. - Collect and analyse energy data, such as utility bills, meter readings, and process-specific measurements. - Compare the actual energy performance with the planned objectives and identify any deviations or gaps. PDCA cycle Plan Do Check Act A2C – Deliverable D1.9V1.0 Page 32 of 102 Each of the technologies to be studied are explained in more detail below: (1) Green hybrid extraction, purification & stabilisation routes for the obtaining of high valuable bioactives The aim is to achieve high extraction yields and high purity bioactives with high stability for new foods, nutraceuticals & cosmetics. • A2C technologies for the recycling of the organic agrifood wastes: Figure 9. Flowchart of the extraction and upcycling of food waste from the agrifood industry. (2) Synergistic combination of sorting, physical delamination, enzymatic depolymerisation, decontamination & mechanical recycling for the multilayers recycling and biotransformation processes & extensional flow mixing for the upcycling of the recycled multilayers. The aim is to obtain a range of high barrier recyclable compounds as alternative to current multilayers in food packaging & agriculture, PHBV bioplastics compounds for biodegradable food packaging & agriculture and carotenoids for cosmetics A2C – Deliverable D1.9V1.0 Page 33 of 102 Figure 10. Multilayer aseptic bags upcycling. Figure 11. Multilayer soil disinfection films. 4.1 Process 1: Green hybrid technologies for extraction of bioactive substances from agrifood wastes 4.1.1 Description This process is in the initial phase within the block of the upgrading of fruit and vegetable waste. The process aims to develop the best extraction route of the bioactive substances A2C – Deliverable D1.9V1.0 Page 34 of 102 from the organic wastes. The raw material used for these extraction routes is derived from waste produced by agrifood industries. The types of residues used are shown below: Table 8. The fruits and vegetables wastes used for revalorization. Product Waste (% of generation) Citrus Peel, pulp, skins, seeds (50-60%) Apples Peel, seeds and cores, exhausted pulp (10-15%) Grapes Pomace (peel, seeds, stems and pulp residues) and grape remains (25%) Artichoke Leaves and bracts (60-65%) Cauliflower Stems, florets not suitable for marketing, and leaves (40%) Broccoli Stems and florets not suitable for marketing, leaves (25-30%) First of all, this raw material is conditioned, choosing a specific treatment according to the type of waste and its state. Among the treatments used are: drying, crushing, grinding, filtering, etc. In this way, concentration and attack surface are increased, which makes the subsequent extraction stages more effective and shortens the time required. Once the raw material has been conditioned, the bioactive compound extraction stage is carried out. The route chosen will depend on the results obtained in the laboratory scale. After extraction, on the one hand, the solid part is obtained, which accounts for approximately 20% and contains the fibres, and on the other hand, the liquid part, which accounts for the rest (80%) and contains the phenolic compounds and carotenoids. To carry out the concentration of the compounds, a purification route is carried out to achieve a suitable composition of each compound. These routes and expected results can be found below: Table 9. Extraction and purification technologies. Extraction route Purification tech. Expected results Green solvents + ultrasounds assisted extraction Membrane Filtration Dietary fibre (Yield≥60%, Purity≥70%) Membrane Filtration + Adsorption Phenolic compounds & Carotenoids (Yield≥60%, Purity≥70%) Green solvents + enzymatic hydrolysis + MW assisted extraction Membrane Filtration Dietary fibre (Yield≥70%, Purity≥80%) Membrane Filtration + Adsorption Phenolic compounds & Carotenoids (Yield≥70%, Purity≥80%) A2C – Deliverable D1.9V1.0 Page 35 of 102 4.1.2 Process flow diagram Figure 12. Process 1 flow diagram. A2C – Deliverable D1.9V1.0 Page 36 of 102 4.2 Process 2: New food, nutraceuticals & cosmetic formulations using extracts from agrifood wastes. 4.2.1 Description The objective of this process is the production of a range of new formulations using the bioactive substances extracted from wastes for their application in cosmetics, nutraceutics and food. This process is a continuation of process one. Once the extraction is done, the aim is to separate and stabilise the most interesting compounds for use in nutraceutical, food and cosmetic formulations. In order to do this, filtration is first carried out, separating the solid part from the liquid. The solid part, which accounts for approximately 20% of the total, contains the fibres and the liquid part, which accounts for the remaining part, contains the phenolic compounds and carotenoids. To stabilise the fibres, the solid part is placed in an oven for dehydration. To obtain the phenolic compounds and carotenoids, a concentration stage is first carried out in which part of the water contained is evaporated, and then, depending on their subsequent use, different stabilisation and conservation processes have been tried out, such as: atomisation, freezedrying and spray-drying. The scaling up of this process aims to obtain prototypes for food & nutraceuticals (3000L vegetable desserts, 2000L enriched juices, 20.000 kg-juices & jams, 1000L nutraceuticals), and cosmetic (1 kg antioxidants formulations). A2C – Deliverable D1.9V1.0 Page 37 of 102 4.2.2 Process flow diagram Figure 13. Process 2 flow diagram. A2C – Deliverable D1.9V1.0 Page 38 of 102 The power, pressures and times indicated in the flow diagram are those expected in the pilot plant, due to the fact that these values are impossible to quantify through laboratory scale tests because almost all the stages are manual and discontinuous. 4.3 Process 3: Identification and sorting of multilayer materials 4.3.1 Description The aim of this process is the use of optical sorting to separate the metallised fraction from the multilayer food packaging plastic waste, by a synergistic combination of technologies resulting in the separation of the different multilayers into the fractions: 1. Metallised fraction (PE/met-PET/PE and PE/Al/PA/PE) 2. Non metallised fraction (PE/EVOH, PE, PE/EVOH/PA) A2C – Deliverable D1.9V1.0 Page 39 of 102 4.3.2 Process flow diagram Figure 14. Process 3 flow diagram. A2C – Deliverable D1.9V1.0 Page 40 of 102 4.4 Process 4: Separation of aluminium (Al) from complex multilayer structures 4.4.1 Description The objective of this process is the physical separation of the aluminium from the multilayers based on delamination technology. The result is to obtain separated flows of LDPE/PET, LLDPE/PET, LDPE, PE/PA and Al. To carry out this process, a large number of equipment is involved. 4.4.1 Process flow diagram The flow diagram of this process is considered as confidential information. 4.5 Process 5: PET/PE enzymatic depolymerisation 4.5.1 Description The objective of this project is the depolymerisation of the PE/PET multilayers by a synergic strategy of customisation of enzymes and plastic wastes pre-treatments. In order for the degradative enzyme to perform its function most effectively, it is first pretreated by applying heat and humidity while exposing in a UV chamber with a Xenon-arc lamp to increase PE polarity and hydrolyse PET. The UV exposure method will reach 90ºC of BST and the Xenon lamp irradiance is going to be 60 W/m2 (300nm to 400 nm broadband). Finally, it is processed through an extruder and then through a granulator. At the same time, in parallel, the enzyme capable of degrading PE/PET is produced in a reactor (in the pilot plant it will be 30 L). Once produced, the mixture will be mixed with the pre-treated PE/PET waste in the appropriate proportion and the enzymatic biodegradation will start (in the pilot plant it will be carried out in a 50 L reactor). The result is water, which will be treated and recirculated, the enzymes, which will be recovered and the reaction products: TPA & EG products, which will serve as input for further processes. A2C – Deliverable D1.9V1.0 Page 41 of 102 4.5.2 Process flow diagram Figure 15. Process 5 flow diagram. A2C – Deliverable D1.9V1.0 Page 48 of 102 4.9.2 Process flow diagram Figure 19. Process 9 flow diagram. A2C – Deliverable D1.9V1.1 Page 49 of 102 4.10 Process 10: High barrier compounds by extensional flow mixing and compatibilisation 4.10.1 Description The objective of this process is the development of PHBV bioplastics compounds through a synergistic strategy of compatibilisation and extensional flow mixing generation during the extrusion process to develop morphology-controlled blends. The neat PHBV range obtained will be formulated and compounded for their application in the flexible food packaging and agricultural films development. 4.10.2 Process flow diagram Figure 20. Process 10 diagram flow. A2C – Deliverable D1.9V1.1 Page 50 of 102 5 Relation between Processes and Demo Sites To clarify the relationship between processes and demonstrators, a table is presented categorising processes according to their corresponding demonstrators. Additionally, a general diagram is provided to illustrate the interrelationship between the various processes and demonstrator groups. Table 10. Relationship between Processes and Demonstrators Demonstrators Processes 1 3, 4, 5 6 & 8 10 7 & 9 4, 6, 7 2 8 3 1, 2 4 1, 2 5 9 A2C – Deliverable D1.9V1.1 Page 51 of 102 Figure 21. Flowchart of the relationship between processes and diagrams. A2C – Deliverable D1.9V1.1 Page 52 of 102 To facilitate understanding, the demonstrators have been grouped into five categories, according to their interrelation and the processes involved. 5.1 Brief description of the demonstrators 5.2 Demos 1 and 6-9 Figure 22. Diagram of the Relationship between Demonstrators 1 & 6-9. Figure 22 illustrates the interrelationship among Demonstrators 1, 6, 7, 8 and 9, which operate in a coordinated manner. Starting with Demonstrator 1, after an initial pretreatment, optical sorting will be employed to separate the metallised fraction from the multi-layered plastic packaging waste (Process 3). Subsequently, these will undergo a physical separation process for aluminium based on delamination technology (Process 4), which will divide them into two groups. The PET/PE multi-layers will be subjected to pretreatment and enzymatic degradation, producing reaction products such as TPA, and EG (Process 5). The aluminium, on the other hand, will be purified and treated for reuse, proceeding directly to Demonstrator 9 (Process 4). In relation to Demonstrators 7 and 9, the LDPE multi-layers will undergo a decontamination process (Process 6). This process will be carried out independently in Demonstrators 7 and 9. Demonstrator 9 receives the aluminium from Demonstrator 1, subjects it to a modification process (Process 4), and then directs it to the extrusion stage, where the recycled aluminium will be used for food packaging and agricultural applications (Process 9). Similarly, Demonstrator 7 will not require the use of aluminium but will undergo a compatibilisation process, and its final product will also be used for food packaging and agricultural applications (Process 6). In Demonstrators 6 and 8, the bioplastic compounds of PHBV, obtained from Demonstrator 5, will be developed through a synergistic strategy of compatibilisation and blending during the extrusion process. This aims to produce biodegradable pellets intended for plastic packaging and agricultural films (Process 10). A2C – Deliverable D1.9V1.1 Page 53 of 102 5.3 Demo 2 In Demonstrator 2, the products obtained in Demonstrator 1 (EG and TPA) will be used alongside lemon peel, which has been enzymatically treated in Demonstrator 3, with the aim of recycling them through biotransformation (Process 8). Figure 23. Diagram of the Relationship for Demonstrator 2. For each input, a distinct process will be carried out: • EG (ethylene glycol) will undergo a centrifugation process for its conversion into glycolic acid. This process has been tested on a pilot scale for a volume of 10 litres. In later stages of the project, scaling up to 30 litres will be undertaken. • TPA (terephthalic acid) will be transformed into PCA (protocatechuic acid) through a biotransformation process. This process is being developed with a bacterial strain, and results are not yet available as of the date of preparing this deliverable. • Lemon peel will be sterilised in a bioreactor, then centrifuged for fermentation, and finally, the solvents will be evaporated to obtain the microbiological oil. This process has been tested on a pilot scale for a volume of 2 litres. In later stages of the project, scaling up to 10-30 litres will be undertaken. 5.4 Demo 3 Figure 24. Relationship Diagram of Demonstrator 3. In Demonstrator 3, agri-food waste will undergo an enzymatic extraction process, from which a solid phase and a liquid phase will be obtained. A2C – Deliverable D1.9V1.1 Page 54 of 102 The solid phase will be purified and dehydrated in an oven to produce a dry extract with a high fibre content (Process 2). For its part, the liquid phase will be concentrated and purified using adsorption resins, and then freeze-dried to obtain an extract enriched in phenolic components (Process 2). Remaining liquid after purification., rich in sugars, will be concentrated and sent to Demonstrator 5 (Process 1). 5.5 Demo 4 Figure 25. Relationship Diagram of Demonstrator 4. In Demonstrator 4, agri-food waste will undergo an enzymatic extraction process, from which a solid phase and a liquid phase will be derived. The organic phase, rich in sugars, will be concentrated and transferred to Demonstrator 5 (Process 1). The solid phase will be purified using microwave-assisted extraction, resulting in a residual organic fraction (Process 2), or it will undergo a purification and concentration process to obtain carotenoids, flavonoids, and polyphenols. The liquid phase will be subjected to centrifugation and ultrafiltration (they may or may not go through this process) and then dehydrated in an oven, thereby obtaining dietary fibre (Process 2). Simultaneously, the flavonoids recovered from ultrafiltration will be incorporated into the purification of the solid phase, where they will be concentrated to obtain the carotenoids, flavonoids, and polyphenols mentioned earlier. 5.6 Demo 5 Figure 26. Relationship Diagram of Demonstrator 5. In Demonstrator 5, the residues from Demonstrators 2, 3, and 4 will undergo a fermentation process, followed by filtration and drying, with the aim of obtaining PHBV bioplastics and carotenoids (Process 9). A2C – Deliverable D1.9V1.1 Page 55 of 102 6 Energy analysis of Demonstrators 6.1 Demonstrator 1 Figure 27. Relationship Diagram of Demonstrator 1. The following describes the energy consumption for each process that comprises Demonstrator 1. 6.1.1 Demonstrator 1. Process 3 Process 3 consists of two stages: pretreatment and optical sorting: • Pre-treatment This step includes operations such as: - Shredding: The multilayer material is cut into smaller pieces to facilitate subsequent processing. - Washing: The material undergoes two washes to remove any contaminants, organic residues, or food particles. To optimise water usage, a recirculation system is implemented. It is worth noting that the washing process is carried out with chilled cold water supplied by chillers, which also serve other equipment in the plant, such as extruders. Washing and extrusion are the processes that demand the most cooling. - Centrifugation and drying: Moisture is removed from the material through centrifugation and drying to prepare it for the subsequent stages. The energy consumption in the pretreatment depends on the level of contamination of the plastic to be recycled; however, in the absence of monitoring data, an estimation has been made based on the plant's capacity to process 25 kg/h with a consumption of 60 kW. Thus, to process the target of 1,200 kg, an energy consumption of 2,880 kWh will be required. • Optical sorting For optical sorting, the electrical consumption is as follows: - Sensor equipment - Conveyor motors - A vibrating table to ensure the proper distribution of the plastic to be recycled A2C – Deliverable D1.9V1.1 Page 56 of 102 - A lighting module to ensure that the colour of the plastic remains uniform to facilitate the identification of the plastic colour for accurate classification - A separation module that allows selected plastics to be removed from the conveyor belt - Cooling system to ensure that the temperature of the electrical components and the computer remains within the appropriate operating range The total power of these components adds up to 5.5 kW. Considering 48 hours of operation, the energy consumption of this process is 264 kWh. Table 11. Process summary. Demo 1 (process 3). Process 3 PRETREATMENT Raw materials input Bags waste plastics (postpretreatment only) 1,200.00 kg Electricity capacity 60 kW Time of operation 48 h Energy consumption Electricity 2,880.00 kWh Gas oil 27.72 kWh Outputs Recycling plastic 1,000.00 kg Waste OPTICAL SORTING Raw materials input 1,000 kg Electricity capacity 5.5 kW Time of operation 48 h Energy consumption 264 kWh Outputs LDPE multilayers - PET/PE + Al - Waste 6.1.2 Demonstrator 1. Process 4 This process is scheduled to be implemented in November, so no data will be available until then. A2C – Deliverable D1.9V1.1 Page 57 of 102 6.1.3 Demonstrator 1. Process 5 Process 5 primarily involves the following equipment that consumes energy during the pretreatment necessary to facilitate enzymatic attack in the subsequent two stages of the process: extruder, cutting system, cooling system. Table 12 summarises the mass and energy balance of the three stages of Process 5 in Demonstrator 1: Table 12. Process summary. Demo 1 (process 5). Process 5 PET/PE pretreatment (to enhance enzymatic attack) Raw materials input PET/PE 1.00 kg water 0.20 kg NaOH 0.00 kg Ice cubes 6.00 kg Electricity capacity Extruder, cutting system, cooling system 6.20 kW Time of operation Extruder, cutting system, cooling system 1.00 h Energy consumption Extruder, cutting system, cooling system 6.20 kWh Outputs Pre treated PET/PE 0.99 kg Waste PET/PE not useful 0.01 kg PET PE enzimatic degradation Raw materials input 1.34 kg PET 1.00 kg PET Hydrolase 0.00 kg Na2HPO4 0.14 kg NaH2PO4 0.19 kg Electricity capacity 0.5 kW Time of operation 48 h Electricity consumption 24 kWh A2C – Deliverable D1.9V1.1 Page 64 of 102 Biomass (0.5l) 32.41 Total output volume (8.5l) 1.91 6.2.3 Demonstrator 2. Lemmon to microbial oil The process for obtaining microbial oil from the lemon in Demonstrator 2 is shown in Figure 30: Figure 30. Demonstrator 2. Lemmon to microbial oil. The following summarises the consumption for a pilot scale of 2 litres: Table 17. Process summary. Demo 2 (yeast fermentation line). Process 8 (Input: lemon) Yeast Fermentation Raw materials input Lemon Extract (from Demo 3) 0.8 L Polypropylene Glycol 0.001 L Demineralized H2O 0.2 L KOH 0.5 g HCl 0.525 mL Compressed air 2880 L Cooling water 12 L Electricity capacity 9 kW Autoclave 7.50 kW Stirred tank reactor 0.09 kW Cooling bath 1.30 kW Time of operation 48 h Autoclave 2 h Stirred tank reactor 48 h Cooling bath 48 h Energy consumption 22 kWh A2C – Deliverable D1.9V1.1 Page 65 of 102 Autoclave 15.00 kWh Stirred tank reactor 4.09 kWh Cooling bath 0.230 kWh Air compressor 2.38 kWh Outputs (Fermentation broth (cells + spent medium)) 0.915 l Waste 0 kg DWP: centrifugation Raw materials input Fermentation broth 0.915 L Electricity capacity Centrifuge 0.00 kW Time of operation Centrifuge 0.33 h Energy consumption Centrifuge 0.00 kWh Outputs Spent medium 0.860 L Cell slurry 0.055 L DWP: extraction Raw materials input Cell slurry 0.055 L Solvent BA 0.500 L Solvent K1 1.000 L Electricity capacity Stirring plate 0.80 kW Time of operation Stirring plate 24.00 h Energy consumption Stirring plate 13.44 kWh Outputs Organic phase (containing the oil) Waste A2C – Deliverable D1.9V1.1 Page 66 of 102 Acqueous phase 0.655 L Solvent evaporation Raw materials input Organic phase (containing the oil) 0.9 L Electricity capacity Rotavapor 1.40 kW Vacuum pump 0.18 kW Time of operation Rotavapor + vacuum pump 8.00 h Energy consumption Rotavapor + vacuum pump 9.28 kWh Outputs Microbial oil 11.79 g Waste Solvent mix BA/K1 (emissions to air) 0.900 L 6.2.4 Demonstrator 2. Total energy consumption and KPI (lemon to microbial oil) The total energy consumption of this process is 44.42 kWh for a scale of 10 litres, which would produce 11.79 g of microbial oil. The energy consumption KPI would be 3.77 kWh/g. Table 18. Demonstrator 2. EG to biomass and Glycolic Acid. KPIs. KPI (kWh/l) Microbial oil 3.77 6.3 Demonstrator 3 In these demonstrators, CTNC has implemented the green extraction + ultrasound-assisted extraction pilot plant to extract dietary fibres, phenolic compounds & carotenoids (100 kg/h), including preliminary conditioning, and purification and conservation after the extraction processes (15 kg). DMC has implemented the green extraction + enzymatic hydrolysis assisted extraction+ microwave-assisted extraction (50 kg/h) pilot plant to obtain high solubility fibres, phenolic substances & carotenoids, including preliminary conditioning, and purification and conservation after the extraction processes (25kg). Demonstrator 3 has been installed in CTNC’s facilities. The process aims to obtain products that can be used on food, nutraceutical and cosmetic formulations. To do so, organic residues and subproducts are pretreated by washing and cutting them if required. After this A2C – Deliverable D1.9V1.1 Page 67 of 102 initial stage, an extraction operation is applied to these substances. At pilot scale, both enzymatic and ultrasound assisted extractions have been tested. As a result of the extraction, two different phases are obtained, a solid and a liquid one. Solid phase is purified, finally stabilizing it through dehydration in an oven. In this way, a dehydrated extract with high content of fibre is obtained. Liquid phase is treated in a concentration/filtration process and then submitted to an adsorption and desorption treatment with resins. Then, this phase is stabilized through lyophilization (atomization was discarded). Finally, a freeze-dried extract rich in phenolic compounds is obtained. Consumption in Demonstrator 3 (process 1) is due to the resistors for heating the solutions and the agitators for mixing them. Figure 31. Demonstrator 3. High added value substances from agri-food waste by green extraction + ultrasound As part of demonstrator 3, there is a set of equipment that needs to be used. This involves a vacuum reactor for enzymatic extraction, an oven to dehydrate the purified solid phase, a filtration station and resins treatment in which the liquid extract is concentrated and a lyophilization machine to freeze-dry the liquid extract. The following is a detailed analysis of each energy-consuming equipment: • Cutter In the pre-treatment stage, the energy consumption arises from the cutting process of the raw material. The power of the cutting machine is 3 kW, and it operates continuously for about 20 minutes. Therefore, the energy consumption of this equipment during the process is 1 kWh. • Decanter A2C – Deliverable D1.9V1.1 Page 68 of 102 For the filtration process, a decanter is used, which is equipped with a 10.3 kW motor. This motor operates for 10 minutes, resulting in an energy consumption of 1 kWh. • Mixing tank For the enzymatic extraction process, a mixing tank is used that operates with natural gas. It is known that the consumption of the tank is 6 m³/h, and it operates for a duration of 1 hour and 25 minutes, resulting in a total natural gas consumption of 8.5 m³. To calculate the energy associated with that volume of natural gas, it is necessary to consider that the conversion factor for natural gas can vary depending on its quality and energy content. According to the IPCC (Intergovernmental Panel on Climate Change) guidelines, a commonly used value for 1 m³ of natural gas ranges from 9.69 to 11.68 kWh. For the calculation, a Inferior Calorific Power (ICP) of natural gas of 10.83 kWh/m³ has been used, which is one of the most commonly used by gas supply companies in Spain. Thus, an energy consumption of 92.06 kWh is obtained. • Concentrator For the concentration phase, a membrane filtration equipment with a power of 36 kW is used. This process lasts for one hour, resulting in an energy consumption of 36 kWh due to the concentration process. • Adsorption equipment For the purification process, an adsorption and desorption equipment using resins (1–2 kg of adsorption resins) is employed. The adsorption phase lasts for 3 hours and requires a power of 0.25 kW. Meanwhile, the desorption phase lasts for 1 hour and demands a power of 0.37 kW. Therefore, the total energy consumption of this equipment is 1.12 kWh (0.75 kWh during adsorption and 0.37 kWh during desorption). • Oven For the dehydration process, a small oven with a power of 0.8 kW is used for 48 hours, resulting in a consumption of 38.40 kWh. This process yields 3.6 kg of fibre extract, with the remainder (36.4 kg) being evaporated water. • Lyophilisation Lyophilisation is a process in which a completely frozen sample is placed under vacuum to remove water or other solvents from the sample, allowing the ice to change directly from solid to vapour without passing through a liquid phase. For this process, a machine with a power of 2.5 kW is used, and the process lasts for 96 hours. The total consumption for this phase is 240 kWh, yielding 0.6 kg of phenolic extract, with the remainder (79.40 kg) being evaporated water. The following summarises the energy consumption calculated for each process. A2C – Deliverable D1.9V1.1 Page 69 of 102 6.3.1 Demonstrator 3. Process 1 Figure 32. Demonstrator 3, process 1. The process comprises three stages: 1. Pre-treatment • Inputs: 50 kg of agri-food waste processed. • Outputs: no waste generated; all material processed remains intact. • Energy: 1 kWh. 2. Enzymatic extraction and filtration • Inputs: 0.15 m³ of water, 50 kg of agri-food waste and 0.005 kg of enzyme. An additional 0.19 m³ of water was used for the boiler. • Outputs: 190 kg of water evaporated; no residual waste. • Energy: 93.06 kWh (92.06 kWh from natural gas and 1 kWh electricity). 3. Purification • Inputs: 200 kg of solid-liquid mixture after extraction and 1.5 kg of resins. • Outputs: 0.08 m³ of condensed water; no additional waste. • Energy: 37.12 kWh. 6.3.2 Demonstrator 3. Process 2 Figure 33. Demonstrator 3, process 2. The process consists of two stages: 1. Dehydration • Inputs: 40 kg of agri-food waste. • Outputs: 3.6 kg of dehydrated fibre and 36.4 kg of evaporated water. • Energy: 38.4 kWh. 2. Stabilisation (Lyophilisation) • Inputs: 80 kg of agri-food waste. • Outputs: 0.6 kg of dehydrated liquid extract and 79.4 kg of evaporated water. A2C – Deliverable D1.9V1.1 Page 70 of 102 • Energy: 240 kWh. 6.3.3 Demonstrator 3. Total energy consumption and KPI The total energy consumption calculated for this demonstrator, taking into account the energy consumption of the solid phase and the liquid phase processes, is 409.58 kWh. Table 19. Demonstrator 3. Total energy consumption. Process 1 Process 2 Solid phase Liquid phase Electricity 39.12 kWh 38.40 kWh 240.00 kWh Natural gas 92.06 kWh 0.00 kWh 0.00 kWh For a scale of 50 kg, the energy consumption ratios per kg of output are shown in Table 20: Table 20. Demonstrator 3. KPIs. KPI (kWh/kg) Fibre extract (169.58 kWh) 47.10 Phenolic extract (371.18 kWh) 618.63 6.4 Demonstrator 4 This demonstrator consists of two processes. The first is for obtaining the organic waste to be processed in demonstrator 5. The second is for the treatment of the remaining solid and liquid phases. The following describes the energy-consuming equipment associated with the processes: • Industrial cutter In the pre-treatment, the artichoke waste is chopped for subsequent processing. The industrial cutting machine has an electrical capacity of 3.4 kW. This equipment is used for 5 minutes to process 100 kg of artichoke, resulting in an energy consumption of 0.28 kWh for the cutting process. • Microwave Both for the enzymatic extraction and for the microwave-assisted extraction (MAE), the industrial microwave equipment produced by SAIREM specifically for the project is used. This industrial microwave has a power of 6 kW. For the enzymatic extraction, this equipment is used for 30 minutes to process 100 kg of artichoke, resulting in a total energy consumption of 3 kWh. A2C – Deliverable D1.9V1.1 Page 71 of 102 On the other hand, for the MAE, the equipment is used 10 times in 40-minute intervals, leading to an energy consumption of 40 kWh (4 kWh per batch). Figure 34. Microwave extractor EMU06. • Centrifugation To separate the solid phase from the liquid phase, a centrifuge model Comicondor TMS-IV 1000 – 500 is used. This equipment has an electrical power of 20 kW. For the process, it operates for 1 hour, resulting in an energy consumption of 20 kWh. Figure 35. Centrifuge Comicondor TMS-IV 1000 – 500. • Vacuum destillator This equipment is used during the purification and concentration process. It has a power rating of 0.15 kW and is operated for 10 hours, resulting in an energy consumption of 1.5 kWh. • Freeze-dryer This equipment is also used during the purification and concentration process. It has a power rating of 0.04 kW and is operated for 24 hours, resulting in an energy consumption of 0.96 kWh. • Ultrafiltration equipment For ultrafiltration, the M500UF equipment from Bionet is used. This equipment has an electrical power rating of 7.5 kW and operates for 1 hour, resulting in an energy consumption of 7.5 kWh for the ultrafiltration process. A2C – Deliverable D1.9V1.1 Page 72 of 102 • Dehydration For dehydration, an oven is used to process 30 kg of a dietary fibresolution, extracting 1.2 kg of solid enriched in dietary fibres through heating. The energy consumption for this process is 48 kWh. The oven's operating time varies based on the water content in the fibre extract, ranging from 10 to 24 hours. 6.4.1 Demonstrator 4. Process 1 In the following table, the balance for Process 1 within Demonstrator 4 is presented: Table 21. Process summary. Demo 4. Process 1. Process 1 Pre-treatment Raw materials input Artichoke waste 100 kg Water 205 kg Electricity capacity Industrial cutter (MAINCA CM-22) 3.4 kW Time of operation Industrial cutter 0.08 h Energy consumption Industrial cutter 0.28 kWh Outputs Washed and cutted artichoke 100 kg Waste None 0.0 kg Enzimatic extraction Raw materials input Washed artichoke 100 kg Water 300 kg Enzymes 10 ml Citric acid 0,1 kg Electricity capacity Microwave extractor EMU06 6.0 kW A2C – Deliverable D1.9V1.1 Page 73 of 102 Time of operation Microwave extractor EMU06 0.5 h Energy consumption Microwave extractor EMU06 3.00 kWh Outputs Solid phase (antioxidants) 100 kg Liquid phase (dietary fibres) 300.11 kg Waste None 0.0 kg Centrifugation (could be omitted) Raw materials input Liquid phase (dietary fibres) 300 kg Electricity capacity Centrifuge (Comicondor TMS-IV 1000 - 500) 20 kW Time of operation Centrifuge (Comicondor TMS-IV 1000 - 500) 1.00 h Energy consumption Centrifuge (Comicondor TMS-IV 1000 - 500) 20kWh Outputs liquid phase II (dietary fibres) 300 kg Solid Negligible Waste None 0.0 kg 6.4.2 Demonstrator 4. Process 2 (solid phase) Table 22 presents the energy summary of the solid phase of Process 2 within Demonstrator 4: Table 22. Process summary. Demo 4. Process 2 (solid phase). Process 2 (solid phase) Microwave extraction (MAE) - To be repeated 10 times to process the 100kg of solid Raw materials input Solid phase (antioxidants) 10 kg Water 40 kg A2C – Deliverable D1.9V1.1 Page 80 of 102 Filtration Raw materials input Fermentation culture 200.0 L Electricity capacity Tangential filtration unit 1.5 kW Time of operation Tangential filtration unit 24 h Energy consumption Tangential filtration unit 36.0 kWh Outputs Concentrated biomass 15 l Water brine 185 l Waste Wash water 50.0 l Drying Raw materials input Concentrated biomass 15.0 L Electricity capacity Drying oven 2.7 kW Time of operation Drying oven 48 h Energy consumption Drying oven 129.6 kWh Outputs Dried biomass 2 kg Waste None 6.5.2 Demonstrator 5. PHBV extraction and purification Table 27 summarises the energy consumption of the PHBV extraction and purification process: A2C – Deliverable D1.9V1.1 Page 81 of 102 Table 27. Process summary. Demo 5. Mass and energy balances in PHBV extraction and purification. Process 9 PHBV extraction and purification Raw materials input Biomass 13.0 kg Electricity capacity Motor Stirrer 0.5 kW Heating jacket and heated oil unit 3.0 kW Inline solvent vapor condenser unit 1.0 kW Temperature control unit 1.0 kW Time of operation Motor Stirrer 1.5 h Heating jacket and heated oil unit 1.5 h Inline solvent vapor condenser unit 1.5 h Temperature control unit 1.5 h Energy consumption 8 kWh Motor Stirrer 0.8 kWh Heating jacket and heated oil unit 4.5 kWh Inline solvent vapor condenser unit 1.5 kWh Temperature control unit 1.5 kWh Outputs PHBV 500 g Water brine - Waste - - A2C – Deliverable D1.9V1.1 Page 82 of 102 6.5.3 Demonstrator 5. Total energy consumption and KPI Table 28 summarises the energy consumption in each process line and the total. Table 28. Demonstrator 5. Total energy consumption. Energy consumption (kWh) Liquid lemon extract (from Demonstrator 3) 131.2 kWh Fermentation-Filtration-Drying 203 kWh PHBV extraction and purification 8 kWh Total 211 kWh Table 29 summarises the KPIs of demonstrator 5 for the production of 500g of PHBV: Table 29. Demonstrator 5. KPIs. KPI (kWh/kg) PHBV (excluding consumption for obtaining lemon liquid) 422.10 PHBV (including consumption for obtaining lemon liquid) 684.45 6.6 Demonstrators 6 + 8 Within the framework of demonstrators 6 and 8, an extrusion and compounding installation has been built, consisting of a feed hopper and an extruder with auxiliary components such as motors for transportation and mixing, air compressors, and heating systems for melting the polymers. The installation can handle an input flow of 648 kg/h to produce 625 kg/h of pellets. The electrical power of the demonstrator is 280 kW. To achieve the project's production target of 500 kg, an operating time of 48 minutes is required. Considering this, the necessary electrical consumption to obtain the 500 kg is 224.0 kWh. Table 30 summarises the estimated energy balance of these demonstrators: Table 30. Process summary. Demonstrators 6+8. Demos 6 + 8 General process Raw materials input 518 kg Electricity capacity 280 kW Time of operation 0.8 h Energy consumption 224 kWh A2C – Deliverable D1.9V1.1 Page 83 of 102 Outputs 500 kg Waste - 6.6.1 Demonstrator 6+8. Total energy consumption and KPI The energy consumption of this demonstrator is estimated at 224 kWh for the production of 500 kg. For this same scale, the project's KPI is 0.448 kWh/kg. Table 31. Demonstrators 6+8. KPIs. KPI (kWh/kg) Biodegradable pellet for food packaging (DEMO 6) and agricultural film (DEMO 8) 0.448 6.7 Demonstrators 7, 9 Demonstrators 7 and 9 begin with multilayer treatment through decontamination using the Erema vacuum reactor. For this reason, they are considered together, although the remaining processes differ slightly between the two demonstrators, as Demonstrator 9 incorporates modified aluminium and recycled agricultural mulching into the process. The structure of the processes in both demonstrators is as follows: • Multilayer Treatment for Decontamination of LDPE: In the “Multilayer Treatment” process, decontamination of the polyethylene (PE) is carried out to remove impurities, gases, and contaminants present in the layers of the multilayer materials. • Extrusion and Compatibilization: Extrusion is performed to promote a uniform dispersion of polymers, improving the quality of the final material. Compatibilization is carried out to ensure that the polymers can mix homogeneously, which requires the use of compatibilizers. • Transformation (Conventional Compounds): The recycled material undergoes blown extrusion and cast extrusion processes to shape products or more complex structures. The first extrusion process (blown extrusion) is used to create thin plastic films, such as those used in wraps or bags, while the second (cast extrusion) is used to create thicker films or produce films with a uniform quality. Analysing the Erema Vacuum Reactor, Common to Both Demonstrators: • Erema vacuum reactor The use of vacuum in the decontamination process ensures the effective extraction of volatile contaminants, guaranteeing that the material is pure enough to be recycled in subsequent stages. To achieve this, the Erema vacuum reactor is employed to treat PET. This technology has proven to be up to 36% more energy-efficient than other technologies in terms of energy consumption, thanks to its compact design and optimised use of vacuum and inline A2C – Deliverable D1.9V1.1 Page 84 of 102 crystallisation. The consumption of this reactor is calculated at 0.35 kWh/kg, including the expected power consumption of the necessary water chillers at the customer's facility. Next, the remaining processes will be analysed. 6.7.1 Demonstrator 7 Figure 37. General scheme of demonstrator 7 • Extrusion and compatibilization After decontamination, extrusion takes place at GWC facilities, processing 520.6 kg of plastic bags to obtain 500 kg of recycled plastic. To enhance the mixing process, 10.4 kg of compatibiliser is used. Along with the 500 kg of recycled plastic, 31 kg of filter chunk is produced. The energy consumption of this process is estimated at 380 kWh. • Transformation (blown extrusion and cast extrusion) In demonstrator 7, a PE extrusion process is carried out. The current tested values indicate a power demand of 380 kW to handle an input flow of 833 kg/h. Thus, the proportional consumption to obtain 500 kg will be 237.5 kWh. The compatibilisation of polyethylene (PE) refers to the process of enhancing the interaction between PE and other polymers in blends or compounds, as polyethylene alone tends to be chemically inert and does not mix well with other materials due to its low polarity. Table 32. Process summary. Demo 7. DEMO 7 Multilayer treatment Raw materials input LDPE multilayers - Electricity capacity Erema vacuum reactor - Time of operation Erema vacuum reactor - Energy consumption Erema vacuum reactor 182.2 kWh A2C – Deliverable D1.9V1.1 Page 85 of 102 Outputs bags waste plastics (postpretreatment, sorting and delamination) 520.6 kg Waste - - Extrusion + compatibilization (Demo 7) Raw materials input bags waste plastics (postpretreatment, sorting and delamination) 520.6 kg Compatibilizer 10.4 kg Electricity capacity Extrusion 380.0 kW Time of operation Extrusion 1.0 h Energy consumption 380.0 kWh Extrusion 380.0 kWh Outputs Recycling plastic 500 kg Filter chunk 31 kg Waste - Transformation Extrusion speed 5 kg/h Raw materials input 1,000 kg LDPE 680 kg EVOH 80 kg PA 180 kg COMPATIBILIZER 40 kg Al 20 kg Electricity capacity 6.99 kW Extruder 4.70 kW Feeding 0.24 kW Cutting 1.05 kW A2C – Deliverable D1.9V1.1 Page 86 of 102 Heater (for extruder) 1.00 kW Time of operation 200 h Extruder (200hx70%) 200 h Feeding (200hx70%) 200 h Cutting (200hx70%) 200 h Heater (for extruder) (27.5h) 27.5 h Energy consumption 1,226 kWh Extruder 940 kWh Feeding 48 kWh Cutting 210 kWh Heater (for extruder) 28 kWh Outputs Pellets 1,000 kg Film 1,000 kg Waste None 0.00 kg 6.7.2 Demonstrator 7. Total energy consumption and KPI The following tables summarise the energy consumption and KPIs of demonstrator 7 for the production of 500 kg of product, pending the determination of the remaining consumptions: Table 33. Demonstrator 7. Total energy consumption. Consumption (kWh) Multilayer treatment 182.21 Extrusion + compatibilization (Demo 7) 380.00 Transformation 1,225.50 Total 1,787.71 Table 34. Demonstrator 7. KPIs. KPI (kWh/kg) Pellets 0.559 Film 0.559 A2C – Deliverable D1.9V1.1 Page 87 of 102 6.7.3 Demonstrator 9 Figure 38. General scheme of demonstrator 9 Demonstrator 9 includes the following energy consumers: • Grinder, drying silo and flake storage silo: There are two grinder units with a flake grinding mesh of Ø25 for grinding recycled agricultural mulching, a drying silo to reduce the moisture content of the flakes below 5%, and a silo for storage of the flakes. The consumption of this line, including grinders, conveyor motors, etc., is 360 kW. To achieve 500 kg of agricultural mulching flakes at the output of the extrusion (the next process), the line needs to operate for approximately 37 minutes, as it can process 1,400 kg/h of material, generating an output of 833 kg/h. Thus, the estimated consumption of this line will be 225.0 kWh, with an input of 875 kg and an output of 520.63 kg of agricultural mulching. • Extruder and final product mixing Silo The material from the previous line is fed into an extruder, and the output is directed to a silo. The power of the extruder, including the auxiliary elements (motors) of the line, is 375 kW, with a capacity to process agricultural mulching of 833 kg/h to obtain 800 kg/h. Operating the line for 37.5 minutes, the consumption will be 234.4 kWh to produce 500 kg at the output of the process. Figure 39 summarises the flows for a 37.5-minute operation time of these last two processes. Figure 39. Grinding and extruding processes' description. Finally, a decontamination process is carried out; however, at this stage of the project, there is still insufficient information to conduct the energy analysis of this process. A2C – Deliverable D1.9V1.1 Page 88 of 102 Table 35. Process summary. Demo 9. Demo 9 Process Raw materials input 875 kg Electricity capacity 735.0 kW Time of operation 0.63 h Energy consumption 459.4 kWh Outputs 500 kg Waste Unknown 6.7.4 Demonstrator 9. Total energy consumption and KPI Table 36 summarises the KPIs for demonstrator 9 for the production of 500 kg of product, pending the determination of the remaining consumptions. Table 36. Demonstrator 9. KPIs. KPI (kWh/kg) Erema vacuum reactor 0.35 Grinder + dryer + extrusion 0.919 Decontamination Unknown Total > 1.269 A2C – Deliverable D1.9V1.1 Page 89 of 102 7 Summary of KPIs The following table provides a summary of KPIs related to the energy consumption associated with the production of various products across the different demonstrators in the Agro2Circular project. These KPIs, expressed in kWh per kilogram or litre, serve as essential metrics for evaluating the efficiency of each process in terms of energy usage. By examining these values, it is possible to identify which processes or products have higher energy demands and thereby establish opportunities for improving energy efficiency. The results presented in this table highlight the current energy consumption levels required for producing each product, offering valuable insights for further optimisation efforts and enhancing the sustainability of these processes as they scale. Table 37. Summary of KPIs. Product KPI Unit Demo 1 EG 4,054.96 kWh/kg TPA 10,859.05 kWh/kg Demo 2 Glycolic acid 24 g/L 2.03 kWh/l Biomass 32.41 kWh/l Microbial oil 3.77 kWh/l Demo 3 Dehydrated extract with high fiber content 47.10 kWh/kg Freeze-dried extract rich in phenolic compounds 618.63 kWh/kg Demo 4 Solution of antioxidants 0.29 kWh/kg Antioxidant extract 2,626.11 kWh/kg Resin (HP20) 393.92 kWh/kg EtOH 15.76 kWh/kg Demo 5 PHBV (excluding consumption for obtaining lemon liquid) 422.10 kWh/kg PHBV (including consumption for obtaining lemon liquid) 684.45 kWh/kg Demo 6 Biodegradable pellet for food packaging 0.448 kWh/kg Demo 7 Recyclable conventional pellet for food packaging 0.559 kWh/kg Demo 8 Agricultural film 0.448 kWh/kg Demo 9 Recyclable conventional pellet for agricultural applications 1.27 kWh/kg A2C – Deliverable D1.9V1.1 Page 96 of 102 10 Monitoring, Measurement and Verification For the Energy Management Plan, measurement and verification methods are essential to ensure the effectiveness of energy-saving initiatives and to track progress towards energy goals. Firstly, a system should be established to monitor and track energy consumption regularly. This system will provide real-time insights into energy usage patterns, allowing for timely adjustments and ensuring continuous optimisation. To accurately capture energy consumption, metering and sub-metering systems should be implemented across different areas or processes. These systems will help break down overall energy use into more manageable sections, making it easier to identify where potential savings can be made and to assess the impact of any implemented efficiency measures. It is important to define key performance indicators (KPIs), which will serve as benchmarks for evaluating progress towards the set energy efficiency objectives. These KPIs should be specific to the areas of focus and reflect meaningful metrics that demonstrate improvements in energy performance. Regular energy performance assessments should also be conducted to evaluate progress taking into account the evolution of the KPIs. These assessments will compare actual energy usage against the defined KPIs and established targets, enabling the identification of any discrepancies and the need for corrective actions. This structured approach ensures that energy efficiency efforts remain aligned with organisational goals and deliver measurable improvements. All of these points are part of the Plan-Do-Check-Act strategy. A2C – Deliverable D1.9V1.1 Page 97 of 102 11 Communication Plan For the effective communication and transparency of the Energy Management Plan, it is essential to establish a clear and consistent reporting and communication strategy. First, it is necessary to develop a reporting framework that will enable the communication of energy performance, achievements, and areas for improvement. This framework should ensure that all relevant information is captured and presented in a clear and concise manner, tailored to the needs of different audiences, including management and key stakeholders. Regular reports should be provided to management and stakeholders, highlighting key outcomes such as energy savings, cost reductions, and environmental benefits. These reports will not only demonstrate the success of energy efficiency initiatives but also identify areas where further improvements can be made, ensuring continuous progress towards energy goals. Additionally, it is important to foster a culture of energy awareness and engagement within the organisation. Sharing energy-related information with employees helps raise awareness of the importance of energy efficiency and encourages active participation in energy-saving practices. This can be achieved through internal communications, workshops, or energy performance updates, creating a shared responsibility for energy management across the organisation. By promoting transparency and open communication, the Energy Management Plan will ensure that all parties are informed and engaged, driving further progress in energy efficiency. A2C – Deliverable D1.9V1.0 Page 98 of 102 12 Conclusions This deliverable presents an energy analysis of each demonstrator in the project, identifying the equipment that represents the main energy consumption within each process. To pinpoint the products that entail the highest energy expenditure, the energy consumption per unit of product obtained (kilograms or litres) has been used as a KPI, with the products EG, TPA, and Antioxidant extract emerging as the highest energy consumers. It is worth noting, however, that each demo has been tested at different scales, which may affect the efficiency of the processes and influence the KPIs. Furthermore, a series of opportunities for improving the energy efficiency of the processes were identified during the energy analysis. These measures have been listed and described to serve as a basis for enhancing process efficiency at the scaling stage. Notable measures include: heat recovery from steam generated during processes, selection of more efficient heat generation technologies for heating and drying materials, use of variable speed drives on compressors, and the installation of renewable energy sources with storage capabilities to enable continuous prototype operation. Subsequently, the objectives for a measurement and verification plan have been outlined, with an emphasis on the importance of defining and monitoring KPIs. Finally, a summary of the objectives for the communication plan within the energy management plan has been provided, focusing on the dissemination of results and the awareness-raising of workers responsible for the processes. 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