Notice

Industrial Energy Efficiency Accelerator: Phase 2 projects (funded under EIP)

Updated 2 August 2024

1. Ultrasonic technology to reduce the energy required for plastics manufacturing

Led by Matrix Moulding Systems with industrial demonstration partner Barkley Plastics.

A retrofit solution using ultrasonic technology to enhance the flow of polymer liquid into a mould that reduces the energy required to heat the molten polymer in use, hold at pressure and then to cool after moulding. The project expects to demonstrate more than 13% electrical energy savings and reduced cycle times (increasing productivity) for typical injection moulding processes.

2. Low thermal mass technology for polymer manufacturing

Led by Surface Generation with industrial partner Tiflex.

This innovative development of the Production to Functional Specifications (PtFS) process eliminates conventional steam heating from traditional polymer production techniques, reducing electricity consumption by 70% and cycle times by 75% while delivering increased product quality. These combined efficiencies provide an 80% saving in carbon emissions. Once proven, the technology will lower the cost of entry beyond high value aerospace, automotive, medical, energy and consumer electronics applications.

3. A novel magnetically-geared motor for increased efficiency in waste processing

Led by Magnomatics with industrial partners DonXtra (Donasonic), ELLGIA and ATB Group UK (Laurence-Scott).

A magnetically-geared motor applied to a shredder, processing waste to create solid recovered fuel, intended to displace inefficient gearboxes and pulley systems commonly used by industry. The demonstration will test the motor in a harsh operating environment, with high torque, speed fluctuations and vibration. It is hoped to demonstrate savings of approximately 16% compared with currently used IE3 (International Efficiency class 3) motors equipped with gearboxes and pulleys.

4. A highly efficient cooling technology for data centres

Led by University of Hull with industrial partners AIRCO and NPS Humber.

Demonstrating an innovative evaporative (dew point) cooler with highly enhanced coefficient of performance in data centres, intended to deliver substantial electricity savings. The project aims to save over 270 MWh per year of electricity energy at the demonstration site, amounting to an overall electrical energy savings of over 90%.

5. An industrial waste water filtration system to allow recycling of heated wastewater in the industrial laundry sector

Led by G2O Water Technologies with industrial partners Hydrasyst and Johnsons Textile Services.

Installation of a NanoPulse system - an advanced filtration system using graphene-oxide coated ceramic membranes, which increases separation performance. The system delivers clean warm water back to the washfloor. This reduces the need for heating between wash cycles, reduces water consumption and reduces chemical additions. It is estimated that a typical laundry could generate energy savings of over 2,700 MWh per year and reduce water consumption by 31,000 m3 per year.

6. Low temperature animal by-product processing technology

Led by Agritec with industrial partner Edge Close Green Energy.

Demonstration of a low temperature separation and processing technology at an animal by-product facility, compared to traditionally used high temperature energy intensive processes. The project hopes to demonstrate a 40% thermal energy reduction compared to traditional high temperature rendering processes, alongside an electrical energy reduction of nearly two-thirds.

7. An integrated advanced process control technology for the pulp, paper and board sector

Led by the Paper Industry Technical Association (PITA) and CF Procsim with industrial partners Smurfit Kappa Townsend Hook, AutomationX, and Perceptive Engineering.

Demonstration of a novel ‘Simulation Aided Enhanced Advanced Process Control’ software in the drying section of a paper mill through simulation, and applied at a major UK paper-making operation. By anticipating process variations, the technology reduces the energy required by predicting more quickly and accurately what the end product moisture content will be, optimising control variables within the plant. It is anticipated that an energy saving of 5% or more of current consumption can be made at the demonstration site.

8. Low energy fertiliser production from wastewater

Led by CCm Technologies with industrial partner Severn Trent Water.

A new method of extracting nutrients from wastewater (ammonia) to create fertiliser with a number of recovery processes including CO2 and waste heat from a combined heat and power plant. The project plans to demonstrate a 90% reduction in electrical energy compared to traditional nitrification processes at waste water treatment works, as well as producing fertiliser with a low specific energy requirement. This project has the potential for use in multiple sectors that use anaerobic digestion.

9. A multi-disc dewatering process based on a screw press design, operating at 2 revolutions per minute (rpm) for sludge treatment

Led by Evergreen Water Solutions with industrial partner United Utilities.

This mechanical dewatering process is a more efficient alternative to the current energy intensive centrifugal systems currently in use by industry, while also being easier to install and lower in cost. The main benefit from the demonstration is expected to be an energy saving of 70% to 90% compared to existing centrifugal solutions. This process can also be replicated in other sectors.