Energy management Plan (Draft)

D1.8 – Energy Management Plan (Draft) November 2023 Authors: Clara Navarro Van Iseghem (REG); Victor Fabregat Tena (REG) Ref. Ares(2023)8041486 - 24/11/2023 A2C – Deliverable D1.8V2.0 Page 2 of 25 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 – September 2024 (36 months) Deliverable No. D1.8 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), 3 (SAPERATEC), 4 (IRIS), 6 (EPOCH), 7 (CETBIO), 8 (UNIMIB), 13 (CTNC) Due date of deliverable 30 September 2022 Actual submission date 30 September 2022 * 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 V Date Comments v0.1 08/09/2022 First draft of document v0.2 19/09/2022 Revised version based on the comments of Sofía Martínez - CTNC and Fuensanta Monzó - CETEC v1.0 30/09/2022 First final version, approved by the WP leader and the project coordinator, (will be) submitted to EC. v2.0 24/11/2023 Second version after review according to the comments from REPA1 A2C – Deliverable D1.8V2.0 Page 3 of 25 Document Distribution Log Version Date Distributed to v0.1 08/09/2022 Fuensanta Monzó Sánchez and Sofía Martínez v1.0 30/09/2022 Fuensanta Monzó Sánchez and Jaime Ortiz Aragón V2.0 24/11/2023 Fuensanta Monzó Verification and approval Name Date Verification Final Draft by WP leader Jaime Ortiz Aragón (ECOTRACE) 24/11/2023 Approval Final Deliverable by coordinator Fuensanta Monzó Sánchez (CETEC) 24/11/2023 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 D1.8V2.0 Page 4 of 25 Table of contents 1 Executive summary ..................................................................... 7 2 Introduction .................................................................................. 8 3 Energy Management Plan ........................................................... 9 4 Processes description ................................................................ 10 4.1 Process 1: Green hybrid technologies for extraction of bioactive substances from agrifood wastes ................................................................................................... 13 4.1.1 Description ....................................................................................................... 13 4.1.2 Energy performance assessment .................................................................... 15 4.2 Process 2: New food, nutraceuticals & cosmetic formulations using extracts from agrifood wastes. .................................................................................................. 15 4.2.1 Description ....................................................................................................... 15 4.2.2 Energy performance assessment .................................................................... 16 4.3 Process 3: Identification and sorting of multilayer materials ........................ 17 4.3.1 Description ....................................................................................................... 17 4.3.2 Energy performance assessment .................................................................... 18 4.4 Process 4: Separation of aluminium (Al) from complex multilayer structures 18 4.4.1 Description ....................................................................................................... 18 4.4.2 Energy performance assessment .................................................................... 19 4.5 Process 5: PET/PE enzymatic depolymerisation ............................................ 20 4.5.1 Description ....................................................................................................... 20 4.5.2 Energy performance assessment .................................................................... 21 4.6 Process 6: Plastics decontamination .............................................................. 21 4.6.1 Description ....................................................................................................... 21 4.6.2 Energy performance assessment .................................................................... 22 4.7 Process 7: Aluminium recycling and chemical modification ........................ 22 4.7.1 Description ....................................................................................................... 22 4.7.2 Energy performance assessment .................................................................... 22 4.8 Process 8: Upcycling of enzymatic degradation products (alkanes, TPA, EG) by cell factories ............................................................................................................ 22 4.8.1 Description ....................................................................................................... 22 4.8.2 Energy performance assessment .................................................................... 23 4.9 Process 9: PHBV and C-50 carotenoids development by Hfx. mediterranei haloarchaea cell factory .............................................................................................. 23 4.9.1 Description ....................................................................................................... 23 4.9.2 Energy performance assessment .................................................................... 24 4.10 Process 10: High barrier compounds by extensional flow mixing and compatibilisation .......................................................................................................... 24 4.10.1 Description ................................................................................................... 24 4.10.2 Energy performance assessment ................................................................. 24 5 Conclusions and next steps ....................................................... 25 A2C – Deliverable D1.8V2.0 Page 5 of 25 List of Tables Table 1. Information relating to the processes studied. ..................................................... 12 Table 2. The fruits and vegetables wastes used for revalorization. ................................... 14 Table 3. Extraction and purification technologies. .............................................................. 14 Table 4. Material balance of the process. .......................................................................... 19 Table 5. Process energy demand. ..................................................................................... 19 Table 6. Process 4 energy consumption. ........................................................................... 19 Table 7. Energy consumption of the process. .................................................................... 24 List of Figures Figure 1. Energy management guide. .................................................................................. 9 Figure 2. Flowchart of the extraction and revalorisation of food waste from the agrifood industry. ...................................................................................................................... 13 Figure 3. Multilayer aseptic bags upcycling. ...................................................................... 16 Figure 4. Multilayer soil disinfection films. .......................................................................... 17 A2C – Deliverable D1.8V2.0 Page 6 of 25 List of abbreviations A2C Agro2Circular AE Assisted extraction GS Green solvents EAE Enzymatic assisted extraction UAE Ultrasound assisted extraction MAE Microwave assisted extraction SFE Supercritical fluid extraction PE Polyethylene PET Polyethylene terephthalate PA Polyamide EVOH Ethylene vinyl alcohol HDPE High-density polyethylene LDPE Low-density polyethylene LLDPE Linear Low-density polyethylene PHBV Poly(3-hidroxybutyrate-co-3hydroxyvalerate) PHA Polyhydroxyalkanoate TPA Terephthalic acid EG Ethylene glycol PCA Protocatechuic acid GA Glycolic acid OTR Oxygen Permeability Test EMP Energy Management Plan VOCs Volatile Organic Compounds A2C – Deliverable D1.8V2.0 Page 7 of 25 1 Executive summary This deliverable presents a draft of the energy management plan for the processes and technologies developed in the Agro2Circular, with the aim that once they increase their TRL and reach a semi-industrial scale, they become as efficient and sustainable as possible. Due to the fact that the processes are at a very early stage, in this first draft it has only been possible to present some consumption analyses of those processes that are a little more advanced. Some of them have not yet started at this stage of the project. Over the following months, more information will be gathered from the partners who are carrying out the development of the different processes addressed in the projects, so that more precise data can be obtained on their consumption and possible scaling. Once analysed, a series of more specific recommendations can be made for each one, as well as the calculation of KPIs and consumption in a more precise and reliable way. With all this data, it will be possible to assess their profitability on a semi-industrial scale. A2C – Deliverable D1.8V2.0 Page 8 of 25 2 Introduction The objective of this deliverable is the analysis of the energy requirements of the A2C technologies and processes including time of use, life cycle and load, aimed to optimise the key parameters to reach the maximum energy savings. Due to the fact that one of the objectives of the project is the scalability of the processes, which will go from a TRL between 4 and 5 to one between 6 and 7, increasing all their TRL in 2 steps, this study of the energy requirements will analyse their viability on a large scale. Therefore, it will be possible to estimate more accurately their energy cost in pre industrial plants, as well as their energy optimisation and the use of renewable energies. In order to carry out the scalability of the processes, and consequently their TRL increase, the processes will be implemented and studied in pilot plants, obtaining real data of their operation. Therefore, in this deliverable, which is a draft of the Energy Management Plan, an approximate study has been made of the expected energy requirements of the processes in the pilot plants, which will be compared with the real results obtained. In addition, the other aim of the Energy Management Plan is to establish an energy efficiency guideline for each of the processes being developed at A2C in order to make them as efficient and sustainable as possible. A2C – Deliverable D1.8V2.0 Page 9 of 25 3 Energy Management Plan An Energy Management Plan (EMP) is a broad-reaching document that serves as a longterm planning resource and is used by an entity to drive and guide progress toward a more secure, cost-effective and sustainable energy future. An EMP must include, at a minimum, an energy reduction goal and an implementation plan to achieve that goal. The Guidelines for Energy Management follow seven main steps that are illustrated in the figure below: Figure 1. Energy management guide. As mentioned above, the objective of this deliverable is the definition of an EMP for the processes being investigated. In this case, an EMP for a process under development involves the detailed study of its operation, the forecast of its consumption, the establishment of KPIs and the regulation of the necessary systems to improve energy performance, aiming at the energy efficiency of the process and the possible use of renewable energies. Due to the fact that the processes are not yet 100% defined, this draft studies the expected consumptions of the processes in their final stage. Therefore, firstly, the energy consumption of each process in its initial phase will be studied in detail. In this phase, the times of use of each phase of the process, the estimated useful life of each piece of equipment and its power will be detailed. A2C – Deliverable D1.8V2.0 Page 16 of 25 4.2.2 Energy performance assessment 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. Therefore, as in process 1, the energy consumption of the process and its KPIs cannot be obtained. (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 Figure 3. Multilayer aseptic bags upcycling. A2C – Deliverable D1.8V2.0 Page 17 of 25 Figure 4. Multilayer soil disinfection films. • A2C TECHNOLOGIES FOR THE SORTING AND RECYCLING OF THE MULTILAYER PLASTICS COMING FROM AGRICULTURE AND POSTINDUSTRIAL PACKAGING 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 D1.8V2.0 Page 18 of 25 4.3.2 Energy performance assessment The best optical sorting technology is being analysed. Probably the optical sorting technologies will be installed in continuous processes. At the moment it is not known which exact optical sorting technologies will be used. The only energy data available is the maximum power consumption without the conveyor belt will be around 2 and 4,5 kW. This value will depend on the final configuration of the technology. 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. A2C – Deliverable D1.8V2.0 Page 19 of 25 4.4.2 Energy performance assessment This process, in contrast to the previous ones, is at a very advanced stage of definition, as its consumption has already been studied for an input of 2,000 kg/h of material to be treated, in which it has been assumed that 40% is PE/met and the remaining 60% is PET/PElaminate: INPUT AMOUNT (kg/h) Input material from pre-treatment 2.000 Fresh water 4.754 Chemicals 284 OUTPUT AMOUNT (kg/h) PE-flakes 739 PET/PE-flakes 1.108 Solid waste (water content 40-70%) 393 Wastewater pre-treatment 3.757 Vapours (in exhaust air) 1.041 Table 4. Material balance of the process. PROCESS STEP ELECTRIC POWER DEMAND (kWh) HEAT DEMAND (kWh) Delamination 456 875 Washing % Sorting 944 90 Drying 199 800 Water supply 80 0 Wastewater pre-treatment 38 0 Table 5. Process energy demand. As can be seen from the tables above, two energy sources are needed: electricity and natural gas. The following KPIs are estimated: DATA VALUE UNIT Electrical power consumption 0,31 - 0,36 kWh/kg Input (dry) Natural gas consumption 0,18 - 0,21 kWh/kg Input (dry) TOTAL 0,49 - 0,57 kWh/kg Input (dry) Table 6. Process 4 energy consumption. A2C – Deliverable D1.8V2.0 Page 20 of 25 For the consumption of natural gas (type H) a LHV of 10 kWh/Nm3 and a density of 0.75 kg/Nm3 has been taken. 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: alkanes, TPA & EG products, which will serve as input for further processes. A2C – Deliverable D1.8V2.0 Page 21 of 25 4.5.2 Energy performance assessment This process is still under study, finishing in month 22, so energy information is limited. The tests carried out are at laboratory scale and in batches in batch, so it is too early to evaluate the energy performance. Information on energy consumption involves motors (for agitation and centrifugation, movement of conveyor belts, compressors, extruder and granulator) and the use of heating elements for the oven. 4.6 Process 6: Plastics decontamination 4.6.1 Description The aim of this process is to eliminate 99% of the contaminants that the plastics may contain. This decontamination is carried out in several stages, the first consists of a preliminary washing with water, which will eliminate solvent traces, ground, chemicals and organic contaminants. The water used for washing will be collected and fully recovered through various filtration and treatment processes. Subsequently, a centrifugation process is carried out to remove the water content, followed by a granulation process to achieve the appropriate size. Finally, a vacuum extrusion process is carried out to remove all the Volatile Organic Compounds (VOCs) and odours. A2C – Deliverable D1.8V2.0 Page 22 of 25 4.6.2 Energy performance assessment The energy consumption will mainly come from the pumps to increase the water pressure in the washing process and in the subsequent water treatment processes such as filtrations, which are usually energy-intensive. In addition, there will be consumption of motors to drive the different mechanisms of the centrifuge, the granulator and the vacuum extrusion process, where a compressor is also required. Energy consumption data are not yet available, so the analysis will be completed in the final deliverable. 4.7 Process 7: Aluminium recycling and chemical modification 4.7.1 Description The objective of this process is the aluminium purification and treatment for reuse. For this purpose, aluminium from the physical separation will be chemically modified. The result of the chemical modification is that the aluminium achieves optimal compatibility and dispersion in a polyethylene matrix. Two strategies will be investigated: i) direct binding of an organic-ligand and further modification with a polyethylene compatible shell ii) a two step procedure were the particles are modified with aluminium oxide/silicon oxide in a first step, followed by well-established polymer-shell synthesis protocol. Finally, the aluminium is dispersed in a matrix of LDPE/EVOH/LDPE and LDPE/PA/LDPE through an extrusion process. These blends will be analysed by serial block-face scanning electron microscopy to obtain real 3D distribution, orientation and concentration of filler materials. 4.7.2 Energy performance assessment The most efficient route has not yet been selected, so there is not enough data. Once the data from the pilot plant is collected, the analysis will be completed. • A2C TECHNOLOGIES FOR THE UPCYCLING OF THE RECYCLED PLASTICS MATERIALS: 4.8 Process 8: Upcycling of enzymatic degradation products (alkanes, TPA, EG) by cell factories 4.8.1 Description The objective of this process is the upcycling of enzymatic degradation products (alkanes, TPA, EG) by biotransformation to obtain high added value building blocks for cosmetic: • Alkanes. Result: ω-hydroxyacids • Terephthalic acid-TPA. Result: protocatechuic acid. • Ethylene glycol-EG. Result: glycolic acid. The best results will be scale up at 10L reactors. A2C – Deliverable D1.8V2.0 Page 23 of 25 4.8.2 Energy performance assessment It is foreseen that at least a temperature of 30°C, air inlet (1 vvm) and agitation of 300 to 800 rpm is needed. The expected time per cycle is from 5 to 7 days of fermentation, depending on the amount of substrate fed. The mode of fermentation: fed, and if feasible repeated (fed)-batch. Power and steam will also be required for autoclaving the bioreactors. This process is still under development, and testing is about to start, so more energy data will be available in the next deliverable. 4.9 Process 9: PHBV and C-50 carotenoids development by Hfx. mediterranei haloarchaea cell factory 4.9.1 Description The objective is the production of PHBV bioplastics and carotenoids by a cell factory. The by-products of the previous cell factories in combination with organic waste from the agrifood industry will be used as nutrients. The result is PHBV for its application in flexible packaging and agricultural films, carotenoids for cosmetics applications. The work to be carried out to increase the TRL of the process are: upgrading the fermentation of the haloarchaea from lab scale to pilot scale of 100 L and upgrading the extraction process at pilot scale of 1-3 L. A2C – Deliverable D1.8V2.0 Page 24 of 25 4.9.2 Energy performance assessment This process has provided some more preliminary information, so that it has been possible to obtain a consumption ratio: Process/Machine Power (kW) Working Time (h) Consumption (kWh) Reactor 1,2 0,5 144 86,4 Tangential filtration 4 1 3 10,5 Centrifugation 6,5 1 2 13,0 Freezer 1 1 24 22,8 Freeze Dryer 4 1 24 96,0 Pump 1 1 1 12 5,3 Pump 2 0,55 0,8 12 5,3 Air compresor 4 1 144 345,6 Thermostatic bath 15 1 144 1.044,0 TOTAL 1.628,9 Table 7. Energy consumption of the process. Therefore, this consumption is required to obtain 1 kg of PHBV, the KPI is 1,628.9 kWh/kg. 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 Energy performance assessment There is still not enough information on this process as its development stage has not yet begun (M13). Once data on energy consumption and the machinery involved is obtained, guidelines can be provided to optimise it as much as possible. A2C – Deliverable D1.8V2.0 Page 25 of 25 5 Conclusions and next steps The deliverable presents a draft of the energy management plan for the processes and technologies developed in the Agro2Circular, with the aim that once they increase their TRL and reach a semi-industrial scale, they will be as efficient and sustainable as possible. Due to the fact that the processes are at a very early stage, in this first draft it has only been possible to present the flow diagrams of the processes and some consumption data of those processes that are somewhat more advanced. Therefore, over the following months, more information will be gathered from the partners carrying out the development of the projects, so that the processes can be defined more concretely. In addition, it will also be possible to provide data on the machinery involved, the energy consumption of each stage of the process (so that the most critical points can be identified), the useful life of each machine involved, the individual and total power demanded, the KPIs and the recommendations on energy efficiency.