KETs Impact: The SusChem flagship for flexible, continuous chemical production

The recent SusChem White paper ‘Impact: Key Enabling Technologies (KETs) in Horizon Europe’ included a number of success stories highlighting publicly funded innovation involving KETs and the SusChem News blog is featuring a selection of these fruitful 'SusChem inspired' initiatives.

KETs are technologies selected for their ability to address global challenges, support the development of new products, and stimulate economic growth.

Sustainable chemistry is essential to the technological advance of KETs including advanced materials, advanced manufacturing technologies, industrial biotechnology, micro and nanoelectronics, nanotechnology and photonics. SusChem's key enabling technologies provide the critical building blocks for the solutions needed to achieve a sustainable low carbon circular economy. You can find out more here.

Our fifth success story features one of SusChem’s original Flagship projects from FP7 - the F3 Factory – and one of its seven case studies. F3 stood for fast, flexible, future factory. Launched in 2009, the €30 million EU-funded project was a major public-private sector initiative under FP7 that sought to define and demonstrate a new paradigm in modular sustainable chemical production technology. You can find more information on all seven F3 Factory case studies here.

Modularised solutions enabling solvent-free process

Improve the Competitiveness of the European Chemical Industry – F3 Factory

Public funding creates cross-sectorial collaboration, breakthrough technology advancement and fast-track-to-market of new products

BASF was part of the consortium behind the “F3 Factory” project. This consortium – consisting of 26 partners from academia and industry – aimed to develop an approach for radical modular process design. This concept enabled significant process intensification and at least 25% less energy consumption.

How was the breakthrough innovation achieved? 

The concept of modularised solutions was investigated for different industrial processes. Results from academia were transferred in business case studies and were demonstrated at commercial scale in an open access backbone plant for modular continuous production (INVITE Research Centre). BASF together with Bayer Technology Services have collaborated to demonstrate the concept of multi-product, small-to-medium scale production for high viscous polymers in a solvent-free manufacturing process. This collaboration was supported by Technical University Eindhoven and the University of Paderborn.

Impact

• In addition to the technological advancement achieved in this project, the transfer from batch to continuous of a new solvent-free polymerisation process has demonstrated both cost (30% reduction of energy demand) and environmental (100% solvent reduction) impact for the production of highly viscous polymers.
• The modularisation concept investigated in the demonstration plant furthermore allows a reduction of investment cost (up to 40%) compared to conventional processes and reduced time-to-market (up to 50%).

More information
F3 Factory 'Flexible, fast and future production processes' (FP7 GA 228867) 

Read the SusChem White Paper ‘Impact: Key Enabling Technologies (KETs) in Horizon Europe’

Making EU industry less energy intensive and more competitive

The Strategic Energy Technology Plan (SET Plan) Working Group 6 on Energy Efficiency in Industry is organising a Workshop on “Continuing efforts to make EU industry less energy intensive and more competitive” on 27 and 28 June 2018 in Brussels.

The Implementation Plan of the SET Plan Action 6 on "Continuing efforts to make EU industry less energy intensive and more competitive" was endorsed by the SET Plan Steering Group on 29 September 2017.  It describes the future activities that will contribute to reaching the targets defined earlier in the Declaration of Intent.

The Cooperation Workshop in June aims to contribute to the realisation of the Implementation Plan by enhancing cooperation between national programmes and further developing the activities into concrete projects.

Cooperative model

Country representatives will meet and discuss existing forms of cooperation, not necessarily in the field of energy efficiency in industry, to identify the best cooperation model(s) for the future. The identified cooperation models will then be shared with the full workshop audience in relation to Action 6 priorities.

In addition, parallel brokerage sessions, open to country representatives and stakeholders, will focus on further developing the activities into potential cooperative projects: presenting ideas of projects, looking for possible cross-border cooperation between similar and/or complementary ideas, and identifying specific actors and potential financing sources for collaborative projects.

To ensure effective and efficient workshop, the number of attendees for the workshop will be limited to 150 persons maximum. In particular, stakeholders will be invited to submit "idea(s) for projects" (or draft projects) before the workshop. In the case of over-registration, priority will be given to stakeholders who have submitted a project.

Plan and programme

Details of the Implementation Plan and the Workshop Programme, including its rationale and objectives, who should attend and why, plus practical information on the organisation of the sessions and a preliminary agenda can be found here.

Registration and the call for "Project ideas" is now open, but will close at the end of April. Confirmation of participation will be announced at the end of May.

Can the EU Chemical Industry go Carbon Neutral by 2050?

The chemical industry’s ambition is to play a leading role in the transformation of the European economy to a sustainable low-carbon and circular economy by creating innovative climate and energy friendly solutions, both for its own processes and for many other industries through chemical products. A new report 'Low carbon energy and feedstock for the European chemical industry' from SusChem founding partners Dechema and released via the European Chemical Industry Council (Cefic) explores how the chemical industry can become carbon neutral by 2050. 

The Dechema study analyses the technological options available for the chemical industry and outlines the conditions necessary to facilitate the transition of the European chemical industry to carbon neutrality.

As well as giving a first full overview of all available technologies for the main chemical production processes, it describes what is needed to refurbish the industrial base we know today in Europe, in a world of shale gas and low oil prices:

• Abundant low-carbon electricity in much larger volumes and at competitive prices;
• Availability of alternative feedstocks (e.g. bio-based raw materials, CO2 or industrial waste gases).
• An enabling fiscal structure to modernise ageing production facilities and equipment or build new plants;
• Government or public-private support to scale-up technologies and share investment risk for those technologies that are first of a kind or high risk
• Innovation and research into new chemical technologies that help overcome these challenges.
• Enabling business models to enhance cross-sectoral collaboration to find sustainable ways to re-use CO2

Role for SusChem and SPIRE

The report concludes that, in order to achieve the EU’s 2050 objectives, an ambitious research and innovation programme will be essential to improve the potential of required advanced technologies, and public-private-partnership efforts will be critical to enable fast deployment and risk sharing for the investments needed. 

In addition, industrial symbiosis opportunities and sustainable materials recycling options should be further explored in order to improve energy and resource efficiency beyond sectorial boundaries. 

Clearly these areas where SusChem and SPIRE are currently working hard to advance sustainable chemistry and sustainable process industry technologies.

Energy intensive

The chemical industry has already halved its energy intensity and greenhouse gas emissions since 1990, but producing chemicals remains one of the most energy intensive industrial processes. Making the sector carbon neutral while retaining its competitiveness in a full circular economy in Europe is a significant challenge, which cannot be solved by the industry on its own.

In an interview with Politico Energy Marco Mensink, Cefic Director General, said that the fact that the industry is looking at how to cut carbon emissions shows that it’s embracing the need for change, “I think we have always taken the position that we are very energy-intensive and that there are huge challenges to become energy neutral,” he said. “But this is a different stance.” Why? Because the attitude of the sector is changing, because the Paris climate agreement has become a reality, and because time is ticking, he added.

The main findings of the report are that the implementation of the technologies investigated in the study would allow for a very significant reduction of CO2 emissions in 2050 (up to 210 Mt annually under the maximum scenario). And including the production and use of fuels related to the pathways considered in the study, the additional CO2 abatement potential in 2050 exceeds the chemical sector’s current emissions even under the intermediate scenario.

Commenting on the report, Marco Mensink said: “Many promising low-carbon technologies are available at a relatively advanced stage of development. The industry will need to find the way to overcome the investment, raw material and energy challenges for them to be implemented on a large scale in Europe.” 

Kurt Wagemann, Executive Director of DECHEMA added: “The implementation of the technologies investigated in this study would allow for a very significant reduction of CO2 emissions of the chemical industry by 2050 even under the least ambitious scenario.”

However, such a transition to carbon neutrality will entail huge challenges for the European chemical industry including availability of low carbon energy, availability of alternative feedstock, investments in new assets that far exceed the typical level of investments in the recent years, uncompetitive production costs. 

The report

The report Low carbon energy and feedstock for the European chemical industry looks into technology options and pathway scenarios to ensure a low-carbon, yet competitive European chemical industry by 2050. The study focuses on the main chemical building blocks used in upstream large volume production processes (ammonia, methanol, ethylene, propylene, chlorine and the aromatics benzene, toluene and xylene), which represent about two-thirds of all GHG emissions in the chemical sector.

Modular White Paper builds on F3 Factory results

A new Dechema paper on ‘MODULAR PLANTS’ summarises results from some recently finished publicly funded research and innovation projects that successfully demonstrated the economic and technical benefits of the flexible and modular plant concept for the production of fine and specialty chemicals as well as pharmaceuticals pioneered by SusChem's flagship F3 Factory project.

Important project examples. including examples from the results of the FP7-funded ‘F3 Factory’ project, clearly demonstrate the advantages of operating modular continuous plant processes that are more economical and sustainable than current operations and are only possible due to new types of equipment design, advanced digital process control and online process analytics (PAT).

The Dechema paper discusses the need for further developments including work on standardised interfaces and standards for modular automation, the reliability of modules, sensors and performance control systems, new continuous downstream processing units, how to enable new business and service models that take advantage of flexible and modular plant concept and other boundary conditions such as the regulations required to build and operate such units.

Modular progress
Building on the ‘F3 Factory’ project concept, the Horizon 2020-funded SPIRE project ‘CONSENS’ as one example that is advancing the continuous production of high-value products that meet high quality demands in flexible intensified continuous plants. It achieves this by introducing novel online sensing equipment and closed-loop control of the key product parameters.

If these concepts were applied in industry, the outcomes of the projects could result in significant cost savings and reduction of CO2 emissions (estimated at 176,000 tonnes per year), less consumption of solvents in pharmaceutical and specialty chemical sectors, and a significant acceleration in the development of new products (estimated at two-times faster additional innovations and halving the time-to-market).

The European chemical industry is facing increasing market competition from outside Europe and challenges with product launches in new and often volatile markets that means a fast response to market requirements and reduced investment risk for new plants is required. In addition, shorter product life cycles and smaller product volumes due to diversification and increasing specialisation of product ranges due to increased customer-orientated products are a feature of the market.

"SusChem has highlighted the modular plant concept enabled by the latest digital technologies as one of its current core priorities," says Martin Winter, Cefic Innovation Manager with responsibility for SusChem activities in this area. "And we are convinced such developments can make a very high impact in modernising Europe's chemicals production capabilities, introduce significantly higher resource efficiency, and would position the European chemical industry in the lead in the race for competitiveness and sustainability."

White paper discussion
This Dechema white paper was produced by the ProcessNet Temporary Working Group on “Modular Plants” and included industry representatives from BASF, Bayer, Clariant, Evonik, Invite and Merck as well as the universities of Ruhr-Universität Bochum and TU Dortmund.

The paper assessed the results of recently completed public funded projects that had demonstrated successfully the technical and economic benefits of modular plants and their applicability especially for small to medium scale (typically 0.1 – 1000 tonnes per year) continuous production.

The experts from across the chemical industries agreed that such modular plant concepts have significant economic potential. General concepts for modular production and the required enabling technologies for process intensification have been jointly  developed in projects such as the F3 Factory and CoPIRIDE projects or the ENPRO initiative for improved energy efficiency and process intensification in the German chemical industry.

Writing in a preface to the white paper Dr. Thomas Weber, Chairman of the VCI Committee of Experts Research and Education policy group highlights that these projects have also shown that multiple challenges exist including a lack of standardisation for modules on equipment level, as well as on the level of a complete production plant. This means that 'off the shelf' modules cannot simply be bought on the market, even though it is broadly accepted in the chemical and pharmaceutical industries that this would result in significant advantages in investment costs, time to market and flexibility of production assets.

Associated with this issue is the unmet market need for process control and automation concepts for modular plants. In addition, the discussion of centralised (classical) process control systems versus distributed (modular) process control systems has only just begun. The supporters of a completely modular design strategy envision the various plant modules acting fully automated and autonomously, with communication existing only via interfaces and communication protocols. This would enable a giant leap forward towards full ex-changeability and re-usability for the modular concept. Having an appropriate concept for modulations of process control and automation could become one of the key enablers for modular production plant concepts, said Dr Weber.

There is also need for further development in the field of equipment and apparatus design, for example in separation and purification that could be quickly and directly scaled-up from laboratory to production scale at an acceptable risk. A simple and safe solution for production scale, is number-up instead of a classical scale-up. However, limitations exist as numbering up in many cases can increase investment costs and complexity.

You can download the Dechema White paper here.

It is hoped that this white paper will inspire new ideas and encourage a spirit of innovation across the a cross chemical industry for modular production plant concepts.

E4Water report demonstrates EU Chemical Industry's water eco-efficiency

Today (18 October 2016), the results of the 'SusChem inspired' E4Water project - a ground-breaking water sustainability initiative - were presented by Cefic during a joint task force meeting with the European Commission in Madrid. The project, which was sponsored jointly by the European Commission under the FP7 Research Framework programme and industry stakeholders, produced real-world outcomes in industrial contexts where companies used less energy, less freshwater, and produced less waste water.

Designed to give a major boost to the water efficiency of the European chemical industry, the E4Water project aimed to demonstrate the benefits of integrated, cost and energy efficient water management. Including 19 partners across nine EU countries, and with six pilot sites the total project investment was € 19 million and the project ran from 2012 to 2016.

“Although the European chemical industry is a standard-bearer for eco-friendly measures like cutting greenhouse gas and increasing energy efficiency, this project identifies important new potential for increased water efficiency. This not only helps safeguard the planet by saving water and energy but also costs for industry”, said William Garcia, Cefic Executive Director. “We hope to see the model this project demonstrates scaled up in other industries to make important gains for the climate.”

Pilot examples
Six pilot cases were conducted to demonstrate what is possible if the recommendations from this project are taken up by other industry stakeholders and integrated into their processes. The potential benefits shown in the pilot studies included:

• Reduction of 3 million m3 of freshwater per year
• Reduction of 2.5 million m3 of produced wastewater per year
• Reduced wastewater discharge by 4 million m3 per year
• Reduced resource use through more efficient processes
• 20% less energy used by implementing low energy technology
• A drop in operating expenditure of 30% for every m3 of saved freshwater/year
• Eliminating need for incineration (5,000 tonnes/annum/plant)

More information on the project and its outcomes can be found in the E4Water brochure with a more detailed report available on the project's website.

Water efficiency is a huge part of tackling climate change. The EU chemical industry – Europe’s fifth largest manufacturing sector – relies on water for many industrial processes. For example, processing, washing, heating, cooling and transporting products. To cut the amount of water required for these processes, the E4 Water project applied new research and development concepts to boost its eco-efficiency and sustainability.

Background
The ‘Economically and Ecologically Efficient Water Management in the European Chemical Industry’ (E4Water) project addressed crucial process industry needs to overcome bottlenecks and barriers for an integrated and energy efficient water management. The main objective was to enable more efficient and sustainable management of water in chemical industry sector and identify possibilities to share the models developed with other industrial sectors.

The E4Water project consortium united large chemical industries, leading European water sector companies and innovative RTD centres and universities active in the area of water management with and collaborators from national and regional water authorities. The project received funding from the European Union Seventh Framework Programme (FP7).

'SusChem Inspired' Project Package Published

CORDIS (the Community Research and Development Information Service) has just published a package of 13 summaries of “SusChem-inspired” FP7 projects. The projects cover a range of subjects within the overall theme of ‘Energy efficient process industries: Furthering Europe’s ambitious environmental targets’. Greater energy efficiency in Europe’s process industries contributes to Europe’s long-term competitiveness and helps to meet highly ambitious environmental objectives.

Over 450 000 enterprises and around 6.8 million jobs are dependent on Europe’s process sector, which includes chemicals, engineering, minerals and ore, non-ferrous metals, steel and water. The process industries, which generate more than EUR 1.6 billion in annual turnover and represent 20% of the EU’s total industrial production, are absolutely vital to Europe’s economy and long-term industrial competitiveness.

However, these vital industries have to face the key challenge of reducing their high dependency on resources. Although energy efficiency in industry across the EU has gradually improved (by an average of 1.8% per year up until 2009), there is still much work to do to encourage the uptake of cleaner technologies, more efficient methods and better industrial procedures to reduce environmental impact.

Achieving a better environmental footprint for the process industries is now even more pressing due to the EU’s target to cut its emissions to at least 40% of 1990 levels as a part of its comprehensive 2030 climate and energy framework. In April 2016, the EU also formally signed the Paris Agreement on Climate Change (COP21), formally committing the Union to fully embracing the transition to a low-carbon economy.

The CORDIS Results Pack showcases some SusChem-inspired and EU-funded projects that have taken up the challenge of developing the novel methods and enabling technologies that will increase energy efficiency in industrial processes.

Project examples

Examples include the implementation of more sustainable and less-resource dependent manufacturing methods, the design and optimisation of new and accurate computational frameworks and software, and the cultivation of better international cooperation.

The full list of projects described in the package is:

• MORE developed new tools to help large plants achieve resource efficiencies including new resource efficiency indicators and software that can be easily integrated into large processing plants in order to achieve optimal daily performance.
• TOP-REF worked on novel resource indicators and tools for competitive and sustainable continuous processing that will lead to the substantial improvement of resource efficiency in energy intensive industrial processes within the agro-chemical, chemical and petrochemical industries.
• MAPSYN researched new techniques to energise the EU chemical industry through new energy sources and catalysts that can achieve cost efficient, high yield chemical production and boost competitiveness.
• CYCLICCO2 was one of the first project to investigate conversion of carbon dioxide into commercially viable chemicals in a sustainable way that could be scaled-up for energy efficient industrial use.
• ALTEREGO helped to ‘green-up’ the chemical industry with efficient alternative energy sources including ultrasound, microwave and non-thermal plasma technologies to power chemical processes, replacing fossil fuels and achieving higher levels of energy efficiency.
• R4R used stronger regional cooperation to drive innovation in energy and resource efficiency forward in Europe’s chemical and processing industries.
• InnoREX looked to accelerate the production of ‘green’ biobased plastic polymers in an environmentally-friendly, energy efficient and commercially viable process. 
• COOPOL produced new monitoring tools for more efficient polymer processing in the chemicals sector that will improve polymerisation reaction quality and provide new continuous production methods.
• E4WATER helped to cut water use in the European chemical industry by creating novel systems and processes and make the European chemical sector more competitive.
• OPTICO developed an adaptive and integrated computational framework for intensified processes in the chemical and biochemical industries consisting of multi-scale, multi-phase phenomena-based modelling technologies, and advanced process analytical tools.

SPIRE Project Brochures Online

The Sustainable Process Industry through Resource and Energy Efficiency (SPIRE) PPP has just published two brochures cataloguing the research and innovation projects established under its calls in 2014 and 2015. The two brochures concisely outline the aims of each project and the concepts being used to implement it. A link to each project’s website is also included. 

The 2014 Project Brochure covers the following calls and associated projects:

SPIRE 1 – 2014 on ‘Integrated Process Control’

• RECOBA - Cross-sectorial real-time sensing, advanced control and optimisation of batch processes saving energy and raw materials 
• DISIRE - Integrated Process Control based on Distributed In-Situ Sensors into Raw Material and Energy Feedstock   
• PROPAT - Robust and affordable process control technologies for improving standards and optimising industrial operations 
• CONSENS - Integrated Control and Sensing for Sustainable Operation of Flexible Intensified Processes 
• ICSPEC - In-line Cascade laser spectrometer for process control 

SPIRE 2 – ‘2014 on Adaptable industrial processes allowing the use of renewables as flexible feedstock for chemical and energy applications’

• STEAMBIO - Flexible Superheated Steam Torrefaction and Grinding of Indigenous Biomass from Remote Rural Sources to Produce Stable Densified Feedstocks for Chemical and Energy Applications 
• MEFCO2 - Methanol fuel from CO2 - Synthesis of methanol from captured carbon dioxide using surplus electricity 
• MOBILE FLIP - Mobile and Flexible Industrial Processing of Biomass 

SPIRE 3 – 2014 on ‘Improved downstream processing of mixtures in process industries’

• PRODIAS - PROcessing Diluted Aqueous Systems 

SPIRE 4 – 2014 on ‘Methodologies, tools and indicators for cross-sectorial sustainability assessment of energy and resource efficient solutions in the process industry’

• STYLE - Sustainability Toolkit for easY Life-cycle Evaluation 
• SAMT - Sustainability assessment methods and tools to support decision-making in the process industries 
• MEASURE - Metrics for Sustainability Assessment in European Process Industries 

EE 18 – 2014 on ‘New technologies for utilisation of heat recovery in large industrial systems, considering the whole energy cycle from heat production to transformation, delivery and end use’

• TASIO - Waste Heat Recovery for Power Valorisation with Organic Rankine Cycle Technology in Energy Intensive Industries 

Waste 1 – 2014 on ‘Moving towards a circular economy through industrial symbiosis’

• RESLAG - Turning waste from steel industry into a valuable low cost feedstock for energy intensive industry 
• CABRISS - Implementation of a CirculAr economy Based on Recycled, reused and recovered Indium, Silicon and Silver materials for photovoltaic and other applications 
• FISSAC - Fostering industrial symbiosis for a sustainable resource intensive industry across the extended construction value chain
• BAMB - Buildings as Material Banks: Integrating Materials Passports with Reversible Building Design to Optimise Circular Industrial Value Chains 
• RESYNTEX - A new circular economy concept: from textile waste towards chemical and textile industries feedstock  

The 2015 Project Brochure covers the following calls and associated projects:

SPIRE 5 – 2015 on ‘New adaptable catalytic reactor methodologies for Process Intensification’ 

• ADREM - Adaptable Reactors for Resource- and Energy-Efficient Methane Valorisation 
• MEMERE - MEthane activation via integrated MEmbrane Reactors 
• PRINTCR3DIT - Process Intensification through Adaptable Catalytic Reactors made by 3D Printing 
• ROMEO - Reactor Optimisation by Membrane Enhanced Operation 
• TERRA - Tandem Electrocatalytic Reactor for Energy Resource Efficiency and Process Intensification 

SPIRE 6 – 2015 on ‘Energy and resource management systems for improved efficiency in the process industries’

• EPOS - Enhanced energy and resource Efficiency and Performance in process industry Operations via onsite and cross-sectorial Symbiosis 
• MAESTRI - Total resource and energy efficiency management system for process industries 
• SHAREBOX - Secure Management Platform for Shared Process Resources 
• SYMBIOPTIMA - Human-mimetic approach to the integrated monitoring, management and optimisation of a symbiotic cluster of smart production units 

SPIRE 7 – 2015 on ‘Recovery technologies for metals and other minerals’

• ADIR - Next generation urban mining - Automated disassembly, separation and recovery of valuable materials from electronic equipment 
• REE4EU - Integrated high temperature electrolysis and Ionic Liquid Extraction for a strong and independent European Rare Earth Elements Supply Chain 
• REMAGHIC - New Recovery Processes to produce Rare Earth -Magnesium Alloys of High Performance and Low Cost  

SPIRE 8 – 2015 on ‘Solids handling for intensified process technology’

• IBD - Intensified by Design® for the intensification of processes involving solids handling 

EE 18 – 2015 on ‘New technologies for utilisation of heat recovery in large industrial systems, considering the whole energy cycle from heat production to transformation, delivery and end use’

• INDUS3ES - Industrial Energy and Environment Efficiency 
• I-THERM - Industrial Thermal Energy Recovery Conversion and Management 
• SUSPIRE - Sustainable Production of Industrial Recovered Energy using energy dissipative and storage technologies  

About SPIRE
The Sustainable Process Industry through Resource and Energy Efficiency (SPIRE) is a contractual Public-Private Partnership (PPP) dedicated to innovation in resource and energy efficiency enabled by the process sector in Europe. The SPIRE Partnership is based on Article 19 of the EU Research and Innovation Framework Programme Horizon 2020 regulation and has been established through a contractual arrangement between the European Commission and A.SPIRE aisbl. SPIRE will be implemented through competitive calls included in the Horizon 2020 work programme. The objective of SPIRE is to develop the enabling technologies and value chain solutions required to reach long-term sustainability for Europe in terms of global competitiveness, ecology and employment.

For more information visit the SPIRE website.

SusChem Stakeholder 2016: Materials focus

This year’s SusChem stakeholder event takes place on 16 June in Brussels. One of the areas for discussion at the stakeholder event will be Materials. In this blog Anne Chloe Devic (pictured below right), Cefic Innovation Manager responsible for this SusChem priority area, outlines the field, its many areas of innovation for sustainable chemistry and how you can participate in the discussion at #suschem16.

Materials is one of the five SusChem priority areas for innovation. There are at least two European Commission policy areas that relate closely to materials. One is ‘Closing the loop - An EU action plan for the Circular Economy’ and the second is the Energy Union with its Strategic Energy Technology (SET) plan. SusChem has defined its priority areas for research and innovation in materials as materials for energy efficiency, materials for low carbon electricity production, and materials for energy storage.

However, these three application areas remain very wide and SusChem wants to narrow down the priorities in order to maximise impact. Therefore SusChem is looking to engage its stakeholders to support and contribute to refining and defining the top priorities for sustainable chemistry in the materials domain.

In the next few month a SusChem working group, currently being formed, will discuss and propose the priorities that SusChem will put forward for inclusion in future calls of Horizon 2020 (and beyond) and other European and National collaborative research and innovation programmes.

Materials and Energy
The chemical industry is a key solution provider for many value chains and other industry sectors that are aligned with the priorities outlined in the fifth pillar (research and innovation) of the Energy Union.

Sustainable chemistry provides technologies and advanced materials for:

• Enabling the EU to be a world leader in renewable energy. This includes providing advanced materials 
• for sustainable production of renewable electricity, for example new composites for wind turbine blades and materials for photovoltaic technologies that include the recycling of these materials, 
• for energy storage, for example: electrical energy storage - materials for advanced batteries; chemical energy storage - advanced materials and process technologies such as H2 and CO2 based energy carriers via power-to-gas and power-to-liquid technologies; and thermal energy storage - phase change materials or reversible thermochemical reactions.
• Efficient energy conservation solutions to make the future and existing building stock energy neutral. This includes: advanced materials for thermal insulation, efficient lighting, and phase change materials amongst others.
• More sustainable transport systems through the use of lightweight materials as a solution to enable lower carbon transport. This includes innovation in ‘light-weighting’ technologies in terms of both materials and process technologies that can play a vital role to improve fuel efficiency and reduce CO2 emissions in transport. Composite materials, such as fibre reinforced plastics (FRP that can be carbon or glass reinforced) have a significant potential for weight reduction in vehicles. They can offer light weight benefits in comparison to other structural metallic materials, while maintaining high mechanical properties. In addition hybrid materials, combining composites and metals, with appropriate joining technologies, can reduce vehicle weight. Materials development for more fuel efficient tyres and advanced battery technologies are also important.

Materials and the Circular Economy 
The development of innovative advanced materials by the chemical sector is essential to enable a better use of existing resources along the whole life cycle of products and services, and to develop new production and recycling process paths.

The development of materials enabling ‘eco-design’ of products is required to address very demanding requirements in terms of performance in downstream applications, including better recyclability. New technological development of materials is often carried out by the chemical industry in collaboration with its value chain partners to provide improved / desired material characteristics and to enable more recyclable end-use products.

For this design and development process to be effective, sustainability assessment over the whole life cycle of the product needs to be considered. The evaluation of environmental impact should consider all environmental aspects including energy and water.

Stakeholder discussions
A highly interactive debate is expected at the Stakeholder event on 16 June and your questions and expectations on the outcomes for the panel debates, in particular on materials for energy, are welcome in advance.

Registration for the 2016 SusChem Stakeholder event is still open, but will be closing soon. This dedicated registration website includes all the information you will need to attend the event.

You are invited to submit your questions and comments and also your expectations for outcomes as part of the registration process. You can submit your questions and comments when you register and there will also be a link for question submission sent with the registration confirmation email.

SusChem Stakeholder 2016: Solutions for the Energy Union

This year’s SusChem stakeholder event takes place on 16 June in Brussels. One of the major areas for discussion at the stakeholder event will be energy and the contribution that sustainable chemistry can make to energy efficiency, new sustainable energy sources and the transition to a low-carbon economy. This article outlines some of the issues that will inform the debate in this area during the stakeholder event and for which we are seeking your input in advance.

The chemical industry needs energy in its processes and has a strong track record in reducing energy consumption through innovation and manufacturing excellence. In fact, since 1990, the chemical sector has effectively decoupled production from greenhouse gas (GHG) emissions.

The European Commission’s Energy Union strategy, adopted in February 2015, dedicates one of its five dimensions to research, innovation and competitiveness. The integrated Strategic Energy Technology (SET) Plan plays a central role in a new European energy Research and Innovation approach designed to accelerate the transformation of our energy system.

Sustainable chemistry solutions

Advances in sustainable chemistry are key elements in achieving the objectives of the European Commission’s Energy Union and SET-Plan. SusChem’s Strategic Innovation and Research Agenda (SIRA) dedicates a chapter to the challenge of, and solutions for, Secure, Clean and Efficient Energy. The chapter covers energy efficiency in chemical processes and proposed solutions that are key to the competitiveness of the chemical industry. It also describes how the industry’s technologies and products contribute to energy efficiency and clean energy productions and storage for the wider society.

Examples of innovations that will contribute to further improving energy and resource efficiency in the chemical sector include:

• Increased energy efficiency of process technologies through advanced high performance catalysis, process intensification, and advanced process modelling and control.
• Better utilisation of alternative sources of carbon such as biomass, waste, and industrial gaseous effluents (including CO₂).
• Industrial symbiosis making connections with and across industries for improved energy and resource  efficiency via better valorisation of heat, improved water management and use of materials from waste and side streams.

Equally important are the solutions provided by the chemical industry to the development of a low carbon economy and energy efficiency in other sectors.

The chemical industry is a key solution provider in virtually all value chains, with technologies and advanced materials that enable Europe to be a world leader in renewable energy such as:

• Advanced materials for sustainable production of renewable electricity including new composites for wind turbine blades and materials for photovoltaic technologies including recyclability of materials.
• Advanced materials and technologies for renewable energy storage including materials for advanced batteries, chemical energy storage through advanced materials and process technologies (hydrogen and CO₂ based energy carriers via power-to-gas and power-to-liquid technologies), and novel thermal storage of energy via phase change materials or via reversible thermochemical reaction.
• In addition sustainable chemistry provides energy efficiency solutions for buildings such as advanced materials for thermal insulation, highly energy efficient lighting, and phase change materials for thermal storage. Chemistry is also key to better energy efficiency in water treatment, for example by development of advanced membranes for water purification.
• Chemistry is also key to more sustainable transport systems by providing lightweight materials, materials for more fuel efficient tyres, advanced materials and process technologies for battery production and sustainable alternative fuels for transport including CO₂ based fuels such as methanol, methane, gasoline and kerosene.

How to sustain success?
In order for the chemical industry to make an effective impact on the development of a low carbon economy, support for technology development (including to achieve breakthroughs) and an appropriate policy framework (to ensure market uptake) will be required.

A sustainability based approach for policy development involving the integration of all aspects of sustainability (environment, economy, social) and integration of lifecycle concept is essential to evaluate the impact of innovative technologies and the development of an effective strategy and policy framework.

Coherence and stability over time for the policy framework is critical to contribute fully to a sustainable economy and address climate goals This means that a variety of policies have to be developed in coordination such as those on energy, primary and secondary resources. Policy coherence in content and timing, as well as policy stability over time, is essential to establish a regulatory framework that enables investment in sustainable, resource efficient and innovative technologies. Uncertainty and extended timelines for policy decisions have negative consequences on the confidence of private investments in new, cleaner technologies. The regulatory framework is an essential element to ensure European leadership in innovation toward a low carbon economy.

Stakeholder discussions
A highly interactive debate is expected at the Stakeholder event on 16 June and your questions and expectations on the outcomes for the panel debates, in particular on energy issues, are welcome in advance.

Registration for the 2016 SusChem Stakeholder event is now open. The event will take place on 16 June 2016 at the Hotel Bloom in Brussels, Belgium. The dedicated registration website includes links to discounted accommodation at the Hotel Bloom.

You are invited to submit your questions and comments and also your expectations for outcomes as part of the registration process. You can submit your questions and comments when you register and there will also be a link for question submission sent with the registration confirmation email.

For more information on registration, please contact the SusChem secretariat.

Energy Fest in Amsterdam

From May 24 to 28 the Startup Fest Europe is taking place in the Netherlands under the patronage of Prince Constantijn van Oranje. This exciting cluster of events is designed to connect innovative talent and their breakthrough technologies with investors and corporate innovators worldwide. As part of this event on Thursday 26 May Shell, DSM, Eneco, Rockstart, Sungevity and Salesforce are hosting an Energy Fest at the Shell Technology Centre in Amsterdam. The event will explore how innovators are tackling the biggest energy transition challenges.

Energy Fest promises to be an exciting day of energy technology innovation featuring breakthrough solutions and disruptive technologies in the start-up ecosystem. Energy Fest will experiment with taking collaboration and creativity to a new level that can tackle our current energy challenges and tap into new opportunities. The event offers accelerated match-making between venture capital investors, corporate innovation programmes and start-up companies to stimulate collaboration as well as ‘bigger picture’ insights from government and thought leaders.

If you are a start-up, corporate, venture capitalist or someone with an interest in energy innovation then you should attend Energy Fest to hear leading experts speak at the Energy Fest conference and panels. The speakers include Maros Sevkovic (Vice President of the European Commission responsible for the Energy Union policy), Bertrand van Ee (CEO of the Climate KIC), and Rob van Leen (Chief Innovation Officer at DSM).

Connect and collaborate
The event will allow delegates to connect and collaborate with great thinkers from Silicon Valley and The Netherlands, to explore our Start-up Village displaying a multitude of exciting energy start-ups and enjoy facilitated matchmaking between start-up companies, venture capitalists, corporates, start-up accelerators and potential customers. You can also discover the corporate innovation support programmes available to innovators and start-ups at Shell, DSM, Salesforce and Eneco.

You can also attend our start-up pitch competitions. Energy Fest will hold an open pitch competition focusing on three areas ripe for innovation:

• Renewable Energy & Storage
• IT in Energy, and
• Oil & Gas

If you are a start-up looking for funding and acceleration then you cannot afford to miss this opportunity to present your ideas to a broad audience of potential investors and an expert jury.

How to register
Attending the Energy Fest is free of charge, but there are only a limited number of places available. To reserve your place, please click on this link to register today!

EFFRA Launches Public Consultation on FoF PPP Work Programme

The European Factories of the Future Research Association (EFFRA) has just launched a public consultation on the ‘Factories of the Future’ (FoF) PPP work programme for 2018 through to 2020. The FoF consultation document contains a wide range of potential call topics that will be of interest to the SusChem community from manufacturing complex and multi-material components to additive manufacturing (3D printing), material and resource efficiency in manufacturing, energy efficiency, new processes, digitisationresouir and circular economy issues.

The public consultation is part of EFFRA’s preparations for strategic discussions with the European Commission concerning the final ‘Factories of the Future’ work programme under Horizon 2020.

The consultation is a unique opportunity to provide your input to this important research and innovation programme. The deadline for consultation feedback is 4 May 2016 (17:00 CET).

EFFRA is looking for input from representatives of industry, research and innovation, and academia to provide their views on priorities for the work programme that will shape the ‘Factories of the Future’ research and innovation call topics in 2018, 2019 and 2020.

EFFRA will use the input received to compile a roadmap document that complements the current ‘Factories of the Future 2020’ roadmap. The new document will be entitled 'Factories 4.0 and Beyond' and will be delivered to the European Commission to provide a key contribution to preparations for the work programme.

How to get involved

The consultation feedback form can be completed online through the EFFRA Innovation Portal. The feedback form does not have to be completed in one sitting and participants may save and return to it as often as they need until the close of the consultation on Wednesday 4 May.

To access the response form you must be registered and logged into the EFFRA Innovation Portal. Instructions on how to participate are available here.

You can access the consultation response form here when logged onto the portal. The consultation document itself is available without logging on here.

For more information, or if you have specific questions on the consultation, please contact Chris DeCubber at EFFRA.

Alternative Energy use highlighted in Horizon 2020 Projects

The results from three Horizon 2020 projects on the use of alternative energy sources for industrial processes will be highlighted at a workshop in Brussels on 2 March 2016. The three projects address process intensification technologies utilising alternative forms of energy, such as microwave, laser or ultrasound, and are very relevant to resource and energy efficiency challenges in chemical processing.

This final industrial workshop is being organised by the InnoREX project and will see also the participation of projects MAPSYN and ALTEREGO.

InnoREX looked at the continuous reactive extrusion of lactide to polyactide (PLA) and online process monitoring of reactive extrusion processes. The project contributes to the fast growing demand for biobased polymers. Current catalysts needed to improve the polymerisation rate of lactones contain metals that pose a hazard to health and the environment.

InnoREX has developed a novel reactor concept using alternative energies for the continuous, highly precise, metal-free polymerisation of PLA in a continuous extrusion line. It has further replaced the metal-containing catalysts by newly developed organic catalysts, and investigated their activity enhancement by use of alternative energy sources laser, ultrasound and microwave. A pilot line including the energy sources and ensuring the polymerization and purification of the polymer from the residual monomer has been built. In addition simulation tools have been developed enabling fast upscaling of the process to industrial scale.

MAPSYN examined chemical reactions like selective hydrogenations and nitrogen fixation, upscaling of microreactors and flow reactors. The project aims to manufacture and scale microreactors and continuous flow reactors in which reactions are carried out assisted by ultrasound, microwaves or plasma energy. MAPSYN focusses on reducing costs and energy consumption of the production, preserving and enhancing high quality, reproducibility and sustainability.

Two different reactions were investigated:

• A novel hydrogenation process incorporating microwave heated microreactors and innovative catalysts has been evaluated
• Use of plasma reactors for nitrogen fixation processes including simulations of this process have been carried out

These reaction systems are important to the pharmaceutical and fertiliser industries. By the end of the project, MAPSYN will build two demonstrators: a plasma reactor for nitrogen fixation and a continuous flow microwave hydrogenation system.

ALTEREGO investigated pharmaceutical, green fuels and bulk chemicals synthesis and development of a generic methodology for upscaling these processes. The project aims for implementation of alternative energy technologies for intensified chemical manufacturing. A new hierarchical methodology to enable highly efficient chemical syntheses with alternative energy forms through reliable process data collection with advanced analytical tools, robust multiscale modelling and design and development of scalable equipment has been established.

The methodology is generic and was demonstrated for three alternative energy technologies: ultrasound, microwave, and non-thermal plasma. These were applied to different industrially relevant case studies in the application areas of advanced pharmaceutical synthesis and green fuels and bulk chemicals synthesis during the project.

More information
The workshop will take place at the Fraunhofer EU office in Brussels. Places at the workshop are limited, but if you are interested in attending, please contact the event organiser Anke Hartmann.

SPiCE3 Energy Efficiency gets Green Light for Phase Two

Today (13 January 2016) the European Chemical Industry Council (Cefic) has announced further support for EU chemical companies to increase their energy efficiency and competitiveness. This fresh investment round supports an innovative project designed to help European chemical companies to improve their energy efficiency: SPiCE3 (Sectoral Platform in Chemicals for Energy Efficiency Excellence). The SPiCE3 initiative provides a wealth of free resources to all chemical companies including workshops, peer-to-peer mentoring, on-site coaching and targeted events promoting best practice.

Europe’s SMEs represent a huge collective potential for driving energy efficiency, but can face challenges such as the lack of tools, expertise or resources. SPiCE3 will continue to provide accessible, hands-on assistance to SMEs, helping them with them to implement concrete measures that boost their energy efficiency.

Over 6 500 European companies have so far been reached through the SPiCE3 programme via:

• 63 SME on-site trainings
• 48 workshops at the local level reaching more than 650 participants
• Three EU-wide events raising awareness of energy management best practices
• The SPiCE3 web portal - a ‘one-stop shop’ for energy efficiency information and resources, including case studies, best practices, funding guides and newsletters

The continued investment by Cefic consolidates an industry-wide commitment to support increasing energy efficiency and competitiveness. As an energy intensive industry, the chemical sector alone consumes around 12% of the EU’s total energy demand, and one-third of EU industrial energy use. In addition, energy can be up to 25% of the total costs of an SME in the EU chemical sector. Therefore increasing energy efficiency is essential to preserving the industry’s competitiveness and to help meet Europe’s climate action goals.

Learn more about the SPiCE3 project in the video below.



For more information on SPiCE3 visit the web portal your one-stop shop for energy efficiency information including 50 case studies, 20 best practice guides and much, much more.

SusChem Position Paper on the Circular Economy

Following approval by the SusChem board, the European Technology Platform for Sustainable Chemistry has published a position paper on the Circular Economy. You can download the paper here. Since its inception in 2004 SusChem has inspired numerous research and innovation activities that address major European societal issues. SusChem’s solutions are based on sustainable enabling technologies developed by the chemical industry and its partners in academia, research and technology organisations, and other industrial players from a wide variety of different value-chains and sectors. Many of these technologies are essential to the implementation of a sustainable circular economy.

The position paper develops SusChem’s vision for a functioning circular economy in Europe (and globally) and provides some concrete examples of the high impact contributions that the platform and its partners can make to achieve this essential objective.

The paper has three main messages.

A sustainability-based approach is needed
The integration of all aspects of sustainability is essential to the development of a circular economy in order to effectively ensure a positive impact on society while minimising environmental impact and maintaining economic growth.

Technology development is required for a sustainable circular economy
A circular economy cannot be achieved only through implementation of new regulations, services and business models.  Advanced technologies are essential to enable a better use of existing resources along the whole life cycle to develop new production and recycling paths – and the expertise of the chemical industry as a material supplier is highly valuable and important here. In particular SusChem believes that the principle technology developments should take place in the following three areas:

• Utilisation of sustainable alternative feedstock including  secondary raw materials, ligno-cellulosic biomass, waste or CO2 from industrial flue gases. 
• Design of sustainable materials enabling eco design of ‘products’ that are easy to recycle while maintaining or improving performance.
• Improved efficiency for production processes to maximise the use of all resources entering the system including primary and secondary raw materials, water, and energy.

These technologies are more fully described in the SusChem’s 2015 Strategic Innovation and Research Agenda (SIRA) and should be supported through the appropriate European funding instruments.

Coherence and stability over time for the policy framework is critical for European leadership
To contribute fully to a sustainable economy, the circular economy policy should be developed in coordination with other related policies such as the Energy Union Package. Policy coherence, as well as policy stability over time, is essential to establish a regulatory framework that enables investment in sustainable, resource efficient and innovative technologies in Europe and ensures European leadership in sustainable/clean technologies.

Case studies
The SusChem position paper concludes with  five case studies that describe a selection of potential contributions by SusChem technology solutions to the circular economy. Each case study describes the potential contribution of the technology to the circular economy, the technology development or deployment required, and the non technology barriers and policy framework aspects that require addressing.

The case studies cover:

• Utilisation of CO2 as an alternative carbon resource 
• New composite materials
• New catalysts 
• Industrial symbiosis 
• Biorefineries

More information
The full position paper can be downloaded here. If you have any questions about the paper, how you or you organisation could work with SusChem in achieving the circular economy, or would like more information on SusChem activities in general, please contact the SusChem secretariat.

RESIDE gets Results

The heating and cooling of buildings contributes around 30% of the gross energy demand in Europe. Although new buildings follow more stringent energy efficiency standards, the existing and extensive estate of old buildings with poor energy rating is significant. Around 35-40% of Europe’s building stock was built before 1960 and 45-50% of the remainder before 1991. The density of old building stock varies extensively by regions, but the vast majority of Europe’s built environment more than 25 years old. In order to meet its emission and energy consumption reduction targets, Europe needs to urgently target and refurbish these older buildings in a cost-effective way.

Launched in December 2013 the SusChem-inspired FP7 project RESIDE aimed at supporting the implementation of EU Strategies to boost demand for innovation in the buildings refurbishment market by:

• Adapting and applying of a promising emerging scientific approach, Technology Innovation Systems (TIS) for an extended localised market assessment
• Defining, implementing and monitoring multi-level strategic roadmaps for Demand Sides Policy Measures (DSPM), based on the TIS market assessments, and
• Proactive engagement of all target groups in the whole process

CEFIC was a partner in RESIDE together with CiaoTech (Italy), Bax & Willems (Spain) and the University of Utrecht (NL)

RESIDE has assessed the market and set up a baseline scenario of the EU refurbishment sector with a focus on three EU regions (Lombardia-Italy, Catalonia-Spain, Noord Brabant-The Netherlands), using the TIS methodology to identify the interactions among different parts of the system.

The main results of RESIDE, in particular from the TIS analysis and confirmed through direct discussions with the regional stakeholders, are that the three regions have clear targets and comprehensive plans for building refurbishment and that the main barriers to implementation are not the existence of financing schemes or refurbishments technologies from construction companies but are more due to:

• Lack of knowledge of existing schemes
• The speed of market formation
• Resource mobilisation issues

Smart cities
The final results of the eighteen-month RESIDE project were presented to the General Assembly of the European Innovation Partnership on Smart Cities and Communities (EIP SCC) at the Metropolitan Solutions conference in Berlin on 21 May 2015.

RESIDE representatives attended the plenary session of the EIP Smart Cities Conference, chaired by European Commissioner for Transport Mrs. Violeta Bulc and European Commissioner for Digital Economy and Society Mr. Günther H. Oettinger. The conference attracted more than 450 representatives of EU organisations and communities including Mayors, CEOs and High-level speakers from all around Europe. The RESIDE project displayed a poster as part of the EIP event within the Berlin “Metropolitan Solutions” fair along with other 20 EU-funded projects on similar topics.

The RESIDE work raised high interest with the stakeholders present. In particular, Commissioner Bulc (see above Commissioner Bulc centre with Laszlo Bax on left from RESIDE) showed high interest in the RESIDE methodology and the three regional case studies, asking for more feedback on project’s results.

In the afternoon sessions, Laszlo Bax, the RESIDE project coordinator, presented the final results of the project to the EIP SCC’s Action Cluster “Sustainable Districts and Built Environment”. The Action cluster, chaired by Mrs. Rinske van Heiningen of Akzo Nobel and the Action Cluster leader, gathered about 40 people, all experts with multidisciplinary background and experience including architects, representatives of various EIP SCC commitments, entrepreneurs, university professors specialising in urban planning and energy efficiency in building, among other disciplines.

Finally, RESIDE partners participated to the break-out sessions on “Business Models for Sustainable Districts” and “District Regeneration” where representatives of the Action Cluster further discussed these topics and links and synergies with the EIP SCC in general, including the next steps for follow up.

RESIDE received several expressions of interest for future collaborations and was included in the list of projects on which the Action Cluster wants to push for a follow up within the EIP SCC community.

Chemistry: Building Energy Efficiency into Smart Cities

SusChem's thinking on chemistry's contribution to energy efficiency in buildings and their contribution to Smart Cities initiatives is featured in the latest Nexus Blog: the American Chemical Society (ACS) blog on Green Chemistry. The article was written by SusChem coordinator Jacques Komornicki and is based on the SusChem report "Innovative chemistry for Energy Efficiency of buildings in Smart Cities". The ACS's Nexus Blog aims to connect and expand the global green chemistry and engineering community.

The Nexus blog article covers a range of key chemistry-enabled solutions for Smart Cities initiatives including:

• High Reflectance Indoor Coatings
• High Reflectance and Durable Outdoor Coatings
• High Performance Insulation Foams
• High Performance Vacuum Insulation Panels
• Phase Change Materials (PCM)

Today, almost 75% of European citizens live in cities and this trend will continue. To succeed in creating sustainable and healthy cities, the Covenant of Mayors was launched in 2008 and is working to to support Europe’s 20-20-20 objectives of 20% reduction in emissions, 20% renewable energies and 20% improvement in energy efficiency by 2020.

You can learn more about these Key Innovations for Smart Cities in the SusChem report: "Innovative chemistry for Energy efficiency of buildings in smart cities." For more information, please contact Jacques Kormornicki at Cefic directly.