INDUSTRIAL AND
TERRITORIAL ECOLOGY
HOW TO DEVELOP SMART FACTORIES ?
19 - 20/11/2014
CAFFEET 2014
Session 2 – Smart Factory @ the scale of the plant/site
Panel 2: How does smart factory improve plant Energy
Management ?
Sokha LEANG - EDF R&D
PRESENTATION OVERVIEW
INTRODUCTION
What is industrial and territorial ecology ?
Interest for EDF
METHODS AND TOOLS
APPLICATIONS
A large industrial harbor area in France : le Havre
A medium sized industrial area in France : Vitry le François
CONCLUSION
LEANG - EDF R&D - CAFFEET 2014 2
IT JUST MAKES SENSE
LEANG - EDF R&D - CAFFEET 2014
.
Natural ressources scarcer
Price increase
Waste management
difficulties
Yesterday
Tomorrow
Reduce waste generation and
waste management cost
Reduce non renewable
ressources utilization
Ressources cycling
= cradle to cradle
Cradle to grave
Robert Frosh, Nicholas Gallopoulosz
(General Motors),1989, Scientific American
The traditional model of industrial activity in
which individual manufacturing processes take
in raw materials and generate […] waste to be
disposed of should be transformed into a more
integrated model: an industrial ecosystem.
In such a system the consumption of
energy and materials is optimized, waste
generation is minimized and the effluents of
one process […] serve as the raw material
for another process.
Braden Allendy, 90s
Young ecosystem: few species, low competition
for ressources
Intermediary: interdependance between
individuals and species
Mature and sustainable: low consumption of
ressources, recycling
3
FROM SMART FACTORY TO SMART FACTORIES
LEANG - EDF R&D - CAFFEET 2014
1
2
3
1
23
Substitution
Common
supply
Common waste
management
INDUSTRIAL
AND
TERRITORIAL
ECOLOGY
4
WHAT IS THE INTEREST FOR EDF?
LEANG - EDF R&D - CAFFEET 2014
New valuable services for our
customers
Bettermanagement of EDF power
plants
Waste heat use
Territorial integration
Substitution synergies
Expertise and tool
for an
automatization of
synergies
identification
5
METHODS AND TOOL
LEANG - EDF R&D - CAFFEET 2014 6
STEP 1: DATA ACQUISITION
LEANG - EDF R&D - CAFFEET 2014
Surveys and interwiews with local industrial actors
Inputs and outputs Energy
Other :
Transport
Storage infrastructure
Services (Laundery,
Restauration,
Accounting… )
Name Temperature, usage
Quantity
Regularity
Supply and managament cost
Needed or waste
heat?
Potential synergies identification
Feasibility study
Implementation
New territorial dynamic :
multistakeholders gathering7
LEANG - EDF R&D - CAFFEET 2014
Companies
GPS location
Heat flux and matter flux
Inputs and outputs
Pooling supply and waste
management synergies
Substitution synergies :
heat and matter
New activities development
STEP 2: AUTOMATIZATION OF SYNERGIES IDENTIFICATION
8
Real data from surveys
on the field
Data by
business sector
LEANG - EDF R&D - CAFFEET 2014
Surveys and interwiews with
local industrial actors
Potential synergies identification
Implementation
New territorial dynamic :
multistakeholders gathering
STEP 3 : FEASIBILITY STUDY
Component
(waste)
Potential synergy 1
(valorization)
Potential synergy 2
(valorization)
Classic management
(elimination)
Input criteria Output criteriaTo characterize a
component, a solid
knowledge of
acceptation criteria is
necessary.
Feasibility study
F THERY, EDF R&D
9
CASE STUDIES
LEANG - EDF R&D - CAFFEET 2014 10
2 CASES = 2 DIFFERENT METHODS
LEANG - EDF R&D - CAFFEET 2014
LE HAVRE HARBOR
(France)
VITRY LE FRANCOIS ASSOCIATION OF LOCAL
AUTHORITIES
(France)
Interviews and surveys of
interested industrials via local
community
Sectorial dataReal data and sectorial data
RECYTER
Identification of potential
synergies
Manual data comparison
Heat Matter
Heat Matter
Identification of potential
synergies
11
CASE STUDY 1 : LE HAVRE
LEANG - EDF R&D - CAFFEET 2014
Le Havre harbor
Large industrial area
Energy production sites
2nd harbor in France (67 Mt in 2011)
Objective
Identify industrial synergies to develop an ecopark
Contrainst : no data available
12
NO DATA FROM THE FIELD
LEANG - EDF R&D - CAFFEET 2014
Selection of industrial business sectors at stake
Selection of representants of each business sector
75 companies of the studied territory
13
Business sector of the 75 studied companies
Energy
Services
Water treatment, waste managementConstruction
Other industries
Capital goods
Fine chemistry
Metallurgy
Non metallic minerals
Industrial chemistry (heavy)Food and beverage
DEMO
LEANG - EDF R&D - CAFFEET 2014
What are the synergies between the companies of the territory?
?
14
RESULTS: WASTE HEAT RECOVERY
LEANG - EDF R&D - CAFFEET 2014
Heat flux comparison matrix
On site waste heat recovery
Heating network supply and utilization
< 40 °C 40 – 60 °C … > 500 °C
A Producer
B Producer and
consummer
C Consummer Consummer
15
2 CASES = 2 DIFFERENT METHODS
LEANG - EDF R&D - CAFFEET 2014
LE HAVRE HARBOR
(France)
VITRY LE FRANCOIS ASSOCIATION OF LOCAL
AUTHORITIES
(France)
Interviews and surveys of
interested industrials via local
community
Sectorial dataReal data and sectorial data
RECYTER
Identification of potential
synergies
Manual data comparison
Heat Matter
Heat Matter
Identification of potential
synergies
16
CASE STUDY 2 : VITRY LE FRANÇOIS
LEANG - EDF R&D - CAFFEET 2014
Vitry le François
Rural territory
Medium sized industrial area with big
players
Contract between local authorities
(municipalities association) and
DNSAE, EDF
Objective
Implement a decentralized energy system
17
A CIRCULAR MODEL
Heat production
Malting plant
Cement plant
Slaughterhouse
Methanization
Greenhouse
Steel tube
production plant
Corn processing
plantMalting plant
Electronic
compounds
production
Raffineriy
LEANG - EDF R&D - CAFFEET 2014
network
Tiles factory
Algae production
Heat
MatterArea 1 Area 3
Area 2 Area 4
New activity
Plastics industry
18
ALTERNATE FUEL AND RAW MATERIAL IN CEMENT PLANT
LEANG - EDF R&D - CAFFEET 2014
Cement plants are key players for industrial and territorial ecology. In 2013, Lafarge used
17,4% of alternate fuel and 4,4 million tons of alternate raw material (ashes…)
Biomass plant ASHES
Cement plant CEMENTLIMESTONE CLAY +
GYPSUM, OXYDES …
FUEL
Slaughterhouse
BIOMASSENERGY
CATTLE MEATBLOOD AND OTHER PARTS WITH HEALTH HAZARD
Biomass plant
LIMESTONE CLAY +
GYPSUM , OXYDES…
FUEL
Cement plant
Slaughterhouse
BIOMASS ENERGY
CATTLE MEAT
BLOOD AND OTHER PARTS WITH HEALTH HAZARD
ASHES
CEMENT
19
GREENHOUSES DEVELOPMENT
LEANG - EDF R&D - CAFFEET 2014
Heat production site HEAT
Greenhouse
EXCEDENT HEAT
LOCAL VEGETABLES PRODUCTION
kilometers
Malting plant
Heat production site HEAT
Fallow
Heat production equipment is oversized. heat sale
Fallow fields asset valorization
Local food production and consumption new business
20
Malting plant
CONCLUSION
Industrial & territorial ecology aims at developing a smart
organization between plants and save ressources & energy.
Methods and tools can help, but each project is unique.
But remember, industrial ecology is only a part of the solution! Energy savings and energy efficiency, ecoconception, longer product shelf lives, etc.
LEANG - EDF R&D - CAFFEET 2014
Companies’ competitivenessIndustry’s environmental
impact reduction
New local relationships
Keys to success
• Motivation and involvment
• Animation and communication
• Quick wins
21