Notice

Industrial Energy Efficiency Accelerator: Phase 1 projects (funded under EIP)

Updated 2 August 2024

1. Low carbon multi-component cements for UK concrete applications

Led by the Mineral Products Association (MPA) alongside industrial partners Hanson Cement, Forterra Building Products, and Building Research Establishment (BRE).

The MPA has identified that low carbon multi-component cements have the potential to replace traditional cements in some UK construction applications. Using a combination of limestone, waste and by-products, the quantities of these materials can be increased, reducing the need for energy intensive cement clinker production. The project is formulating, developing and testing the new cements ready for the UK market. It is estimated that there could be savings of 8% of carbon emissions across the UK’s cement sector, which currently emits around 7.8MtCO2 annually, but some of these new cements have carbon emission profiles 40% lower than conventional alternatives.

2. Development and trialling of Exergyn DriveTM for low-grade waste heat recovery

Led by Exergyn alongside their industrial partner, a global engine manufacturer.

Globally, we waste almost half of our energy as low-grade heat. The cost-effective recovery of low-grade waste heat has been a long-standing challenge in all energy intensive industries. This ground-breaking project aims to generate electricity from low-grade waste heat streams of up to 100 degrees C. A shape memory alloy (SMA) core is cycled through hot and cold states to produce reciprocating motion, which is used to drive an electrical generator. The technology benefits from having zero emissions and does not require any refrigerants.

3. PRISMA Energy Storage (Peak Reduction by Integrated Storage and Management of Air)

Led by Innovatium alongside industrial partner Aggregate Industries and research partner Birmingham University.

Liquid Air Energy Storage (LAES) has considerable potential for storing energy, which helps increased deployment of intermittent renewable energy sources. PRISMA is a unique new application for LAES in which liquid air is released to provide compressed air to an industrial site. This allows the use of smaller compressors to work more efficiently, operating at times when electricity generation is lower carbon. The project has the potential to deliver estimated electrical energy savings of around 30% via reduced compressor operation, whilst also providing the ability to avoid higher tariff periods.

4. Replacing hot water cleaning with electrolysed cold water

Led by Ozo Innovations.

This project demonstrates the significant energy and cost savings available from substituting hot water for cold electrolysed water in hygiene applications, particularly in the food and drink industry. The use of cold water significantly reduces demand on boilers, as well as providing a significant time saving by eliminating multiple hygiene processes, improving productivity. Replacing hot water cleaning with electrolysed cold water cleaning could save up to 90% of energy consumption and 35% water consumption.

5. Development and demonstration of an automatic steam boiler blowdown system

Led by Spirax Sarco UK.

Steam boilers are widely used in a variety of process industries, with accurate control of total dissolved solids (TDS) required to avoid poor-quality steam, scaling and excessive boiler water blowdown. At present, it is a statutory requirement that TDS levels are monitored within steam boilers, yet commercially available TDS sensors are fraught with unreliability issues and require frequent recalibration. Spirax Sarco, with the University of Nottingham, have developed a reliable new type of boiler TDS measurement probe and controls, hoping to improve boiler efficiency significantly. Potential energy savings have been estimated at 6% of boiler fuel consumption at the demonstration site.

6. Energy efficient leachate treatment

Led by LAT Water alongside industrial partner Viridor Waste Management.

This project will demonstrate a Low Temperature Ambient Pressure Technology (LAT) process in the treatment of a high ammonia content leachate stream on a landfill site. The LAT process utilises heat recovered from hot flue gases from on-site biogas generators to drive the leachate treatment process. The project expects to demonstrate thermal energy savings of greater than 25% compared to existing technologies; coupled with waste heat utilisation there potentially could be a 70% reduction in specific energy consumption on-site. The project also provides a reduction in carbon emissions associated with transportation, where leachates are currently transported off site for treatment.

7. Novel de-watering solutions within corrugated case medium (CCM) manufacture

Led by Innventia alongside industrial partner, DS Smith.

This project aims to demonstrate an enhanced ‘dewatering’ approach to CCM manufacturing in the paper and pulp industry. Contaminants in process water will be identified and removed, leading to improved drying rates following the removal of CCM from paper machines. This will deliver energy savings of approximately 10% when compared to existing drying processes, with potential on-site fuel savings of 80 million kWh annually, and strong potential to scale in the industry more widely.

total dissolved solids *[TDS]: total dissolved solids *[LAT]: Low Temperature Ambient Pressure Technology *[CCM]: corrugated case medium *[kWh]: kilowatt hour