IK4-IKERLAN is a non‐profit technological research centre located in Mondragon, in the North of Spain. IK4-IKERLAN research areas are divided among the three technological specialization units: 1) Electronics, Information and Communication Technologies, 2) Energy and Power Electronics and 3) Advanced Manufacturing. IK4‐IKERLAN’s mission is to solve the technological challenges of the companies, improving their competitiveness and collaborating with the sustainable social and economic development of the environment, all of that from a position of technological leadership and with differential abilities in their areas of expertise. Faithful to that mission, IK4-IK4-IKERLAN has been working daily since 1974 to develop solutions that allow our customers to become more and more competitive.
Thanks to a unique cooperation model, which combines technology transfer activities, internal research and training of highly qualified personnel, IK4-IKERLAN is currently the trusted technological partner of major companies in the country. With an extensive experience in other European projects, it is coordinating ETEKINA project. It has a significant expertise in the development of technological solutions to optimise the energy efficiency for domestic, transport and industrial applications. IK4-IKERLAN is also involved in the development of electrical and thermal energy management solutions for the industrial and transport sector.
In ETEKINA, IK4-IKERLAN will evaluate and analyse the waste heat of the non‐ferrous use case. In addition, it will be responsible of the design of the plant balance of the heat recovery systems ensuring the same quality obtained before the implementation of these systems. IK4-IKERLAN will also develop a Decision Tool Model to identify the appropriate applications and to assess the replicability of the solution. Finally, IK4-IKERLAN will collaborate on the exploitation plan definition of the heat recovery systems developed in the project.
FAGOR EDERLAN is as a private company dedicated to the manufacture of components for the automotive sector. It is one of the main Spanish foundries, which understands innovation as the key for development and has vast experience in RTD projects.
FAGOR EDERLAN heads the group that comprises its business units and associate companies, aligned within an organisation based on the business lines of Suspension, Brakes, Engine and Transmission. They respond to the market as a supplier of global solutions covering a broad range of value added proposals in each business line.
They have also consolidated their internationalization strategy being closer to their customers through production plants in Brazil, Slovakia and China, and through business projects of international projection in NAFTA and China.
Due to their work, together with EDERTEK, the research and development of the group, FAGOR EDERLAN has a broad experience in innovation projects and many of them have already been co financed by Spanish public bodies. Thus, an efficient methodology has been developed in order to tackle new ideas: conduction of a critical state‐of‐the‐art study, tests defined by the technique of experimental design are carried out and final assessment of the results.
In ETEKINA, FAGOR EDERLAN is one of the use cases that will be implemented in the project for the validation of using heat pipes in the aluminium processing. FAGOR EDERLAN aims to identify the way to reuse the waste heat and to design and validate the heat recovery solution for use case 1.
Industrial Furnaces Insertec, S.L.U., is a leading company in the design and manufacture of industrial furnaces. The company belongs to a group of companies with a significant presence in the casting industry. INGENIERÍA Y SERVICIOS TÉCNICOS SA (INSERTEC), matrix of the Group and the company, and REFRACTORY SOLUTIONS INSERTEC SLU (RSI), dedicated to the manufacture and marketing of refractory products belong to this group, too. INSERTEC is nowadays a holding of international companies with own subsidiaries and production facilities in México, Brazil, Italy, Russia and China with an overall human resources over 250 people. It aims to be one of the best manufacture companies of industrial furnaces and achieve the full satisfaction of its customers, providing high added value products.
To reach this goal, one of its pillars is its permanent commitment to R&D, devoting significant resources to the fulfilment of relevant international projects, to become one of the most important technological manufacturers in the sector.
In ETEKINA, INSERTEC, as furnaces engineering company, will adapt the heat exchanger to the existing furnace model, and will modify the existing technology to adapt the furnace to work with the heat exchanger in order to reduce the energy consumption keeping the final part characteristics.
Econotherm (UK) Ltd is a manufacturer of patented industrial waste heat recovery equipment utilising heat pipe technology. The company focuses on hitherto difficult heat recovery applications not addressable by conventional equipment. As such the companies strap line “recovering the irrecoverable” summarises the track record of recovering industrial waste heat that would otherwise remain unrecovered. The company has in its over 8‐year history achieved several breakthroughs across a range of challenging heat recovery applications including high sulphur and acid exhausts, high particulate and high temperature. Specifically, Econotherm recovery units are now operating successfully on aluminium furnaces, ceramic tile kilns, heavy fuel oil fired boilers and many other dirty and acidic exhaust streams.
Econotherm’s patented super conductor Heat Pipe technology is used in a wide range of applications across many diverse industrial sectors. The technology is renowned for being extremely robust and able to operate in many challenging heat recovery environments for the benefit of high energy users seeking to reduce ever increasing energy costs.
In ETEKINA Econotherm will manufacture the heat pipe systems (lab and full scale) that will be designed in the project. Econotherm will also be working with the partners on installing and monitoring the systems in addition to any other activities in relevant work packages. Econotherm has successfully implemented heat recovery solutions in a range of applications previously considered not suitable for conventional equipment.
Brunel University London is a dynamic British institution with over 14,000 students and more than 1,000 academic staff operating in a vibrant culture of research excellence. Brunel has a long history of successfully bidding for and managing EU projects.
The research for ETEKINA will be coordinated by the thermal management and heat pipe research group that is led by Professor Hussam Jouhara in Brunel. This research group has proven international track record in many areas of strength, including heat pipes, advanced refrigeration systems, waste heat recovery technologies, renewable energy harvesting as well as electronic thermal management. Accordingly, the thermal management and heat pipe research group possesses extensive state of the art experimental and computational facilities that are well suited to supporting research projects in this area.
Professor Hussam Jouhara is the Scientific coordinator of the ETEKINA project overlooking the activities that will lead to the demonstration of the heat pipe based waste heat recovery systems in the three demo sites. In addition, Brunel University London will be the leader of WP3, which includes optimising the integration of heat pipes into the waste heat recovery Systems and developing heat pipes that make optimal use of the waste heat streams and the available/required heat sinks. New designs will be generated and optimised using a combination of theoretical models laboratory testing. The university will also undertake the challenge of developing a methodology for the utilisation of the waste heat recovery system based on the industry type and the required heat sinks. A range of designs, from steam generators/condensers to recuperators, will be evaluated based on the amount and quality of waste heat streams and the form of heat energy required.
SIJ Metal Ravne Ltd is a is part of the SIJ Group, the largest vertically integrated metallurgical group in Slovenia and a leading player in the European and global niche steel markets. SIJ Group ranks among the top ten Slovenian business groups and top five Slovenian exporters.
SIJ METAL RAVNE’s is a renowned niche steel producer with wide production range including bar products made of tool, special and structural steels in forged, rolled, peeled and ground types for the needs of the machine processing, automotive, construction, metal processing, chemical, medical and pharmaceutical, electrical and energy industries.
The company looks for opportunities in a niche production, which is distinguished by specific knowledge and experience, greater flexibility and high added value, and therefore our production and sales are constantly rising.
The company continues to build its future with modernization of its technological equipment. With their attitude to the environment SIJ METAL RAVNE was among the first in Slovenia to obtain the ISO 9001 quality certificate and the ISO 14000 certificate.
Within ETEKINA project SIJ METAL RAVNE has the opportunity to improve its energy and environmental performance and consequently the overall competitiveness. We expect a consequently lead to additional energy efficiency improvements at the main production processes. We see this project as an important step towards complete replacement of traditional fuels for heating and hot water preparation with alternative energy sources, namely waste heat utilisation, during the next five years.
Additionally, ETEKINA project is fully in line with SIJ METAL RAVNE’s commitment to actively support the introduction of the most modern and cleanest technologies that enable environmental protection at the highest achievable level. This project has high potential for replicability at other furnaces in our company and in other companies within the SIJ Group. We see added value of the ETEKINA project in foreseen early achievement of visible results which is necessary to boost the confidence of employees and management.
The Jozef Stefan Institute is the main Slovanian technological institute, complementing the role of universities and bridging the gap between science and applications. Jozef Stefan Institute – Energy Efficiency Centre (JSI/EEC) research main objectives include improvement of energy efficiency and reduction of greenhouse gas emissions in industry and other economic sectors.
The interest of JSI‐EEC is identified within the main goal of ETEKINA related to improve the energy performance of industrial processes by supporting the development of heat recovery market in industry. Implementation of innovative technologies for the reuse of waste heat in large industries will contribute to investigate the functioning of the entire industrial energy system, the ability to reduce energy loss and environmental impact. Implementation of the innovative heat recovery will give opportunity to testing integrated energy model for different processes and industrial units.
Jozef Stefan Institute interest is to:
- develop an integrated energy model for energy flow balance between sources and demands (energy input/output model) by processes,
- cooperation in defining energy parameters of installation technology,
- energy analysis and environmental impact of integrated model,
- integration of new technologies in the energy management system,
- economic cost analysis of energy model,
- study replicability for the new installation of technology within the company, and
- measurement of flue gas and emissions.
Ceramiche Atlas Concorde is a benchmark player in the entire ceramic tile industry and one of the most important and solid companies worldwide. Its mission is to provide interior designers, architects and the most demanding customers with ceramic solutions suitable for every destination of use, ensuring an aesthetic appeal that is in line with market needs and, at the same time, combine them with excellent technical performance. In its forty years of activity, Atlas Concorde has been synonymous with strength, ethics and reliability, with positive financial results since foundation. A veritable reality that, every year, wins the confidence and trust over 2,700 customers in more than 100 countries.
Atlas Concorde knows that ceramic industry is to be surely considered an energy intensive process, given that ceramic energy will (mainly natural gas and power) has over the years come to be the third cost item. In a global scenario of increasing energy prices in the last decade, and urged to compete in a global market with producers which can take advantage of cheaper power and natural gas prices, improving energy efficiency has become one of the topics that Italian ceramic industry is focusing on. In the last years Ceramiche Atlas Concorde has been carrying out several energy efficiency projects, mainly focused on revamping of ceramic machinery, installation of new cogeneration plants or upgrade of existing ones and waste recovery. In order to move forward on the path of energy efficiency, new technologies and solutions have to be tested and employed.
Kiln exhaust gas is a potential source of high specific enthalpy (at least for ceramics industry standards) up to now discarded due to high dust and pollutants concentration. Since the stream has interesting temperature potential, Ceramiche Atlas Concorde shall be committed to investigate and demonstrate disposal of this energy, transferred to the dryer, leading to sensitive energy savings. Alongside with ETEKINA partners Atlas Concorde aims to solve corrosive and dusty characterization problems associated with the kiln exhaust will, identifying the appropriate thermal medium (oil, superheated water or other). The modifications of existing machinery will be supervised in order to successfully employ useful heat.
Founded in 1176, the University of Modena and Reggio Emilia (UMR) is the third oldest University in the world, and has been ranked among the first Italian universities for quality of teaching and research since 2007. UMR is a networked campus located in the towns of Modena and Reggio Emilia. It counts about 20000 students, 3500 postgraduates, 900 faculty members, 13 PhD schools. It has over 300 international exchange and cooperation programs.
UMR will be involved through the Department of Sciences and Methods for Engineering (DISMI). The activity of the department consists of methodological and applied researches, and education in various areas of engineering and basic sciences. The DISMI assemble professors and researchers with a wide international range of experiences and knowledge, active in the main sectors of engineering and basic sciences applied to engineering.
One of the main research areas of the Department of Sciences and Methods for Engineering of University of Modena and Reggio Emilia is the investigation of the energy systems in terms of energy efficiency, thermo‐fluid‐ dynamics analysis and economics assessment. Cogeneration and heat recovery applications are research topics of the researchers’ group involved in ETEKINA project. In particular, the many numerical models and tools for the evaluation of the performance of combined heat and power (CHP) and heat recovery effects on the studied process have been recently developed for different cases with specific attention to the ceramic industry. The role of UMR in ETEKINA project will cover the definition of the effects on the actual kiln operation of the HP and the exploitation of the recovered heat on the selected heat sink. Different scenarios will be analysed and the pros and cons of each solution will be highlighted in terms of energy efficiency as well as of return of investment and critical aspects with respect of the impact with the target process.
The European Science Communication Institute (ESCI) is a not‐for‐profit organisation that empowers scientists and engineers, helping them to communicate a non‐expert audience to bridge the gap between science, technology and society.
As a truly European organisation, ESCI draws on key contributors from across the continent. Their senior science communicators work in France, Belgium, the UK and Germany. The European Science Communication Institute also enjoys close ties with science communication specialists in almost every EU country, which enables it to deliver locally adapted solutions in different languages. The ESCI team has experience in web, social media, print, audio‐visual and direct 1:1 communication to accomplish a successful mix of communication and dissemination activities. This includes also the tracking of this activity to be able to measure the impact of the communication and dissemination measures to adapt it, if necessary.
ESCI believes that the success of a new technology is not only dependent on the technology itself, but also on the way it is communicated and disseminated to the relevant target groups and exploitation channels. For the ETEKINA project, ESCI sees plenty of opportunities to use its creativity and expertise to work together with a strong consortium for a successful communication, dissemination and exploitation of the project.
ESCI will lead the communication and dissemination in close cooperation with the exploitation leader. The aim of this activity is to identify the communication needed to fulfil this task.