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3 ENERGY-EFFICIENT PROCESSES EEMANAGEMENT veloped by Bayer and is now being used by Covestro (previously Bayer Mate- rialScience) [1]. In many ways, the concept behind STRUCTese® goes beyond existing conventional approaches and beyond the requirements stipulated in the standards in that it attempts to make energy efficiency measurable and to separate the major factors affecting energy consumption in industri- al plants and integrated production sites. This maximises transparency and enables ever more ambitious energy savings targets to be set based on quan- tified potentials (distance to the ideal energetically optimised process). Objectively determining the minimum energy consumption targets and the associated process design needed to achieve them are therefore central ele- ments of the STRUCTese® system. The lack of methodological tools available means that industry currently relies on empirical approaches that draw on expert knowledge and simulation studies. Academic research in the field has produced a number of innovative approaches for designing optimised pro- cesses, including heuristics, shortcut methods and rigorous optimisation. A heuristics-based approach uses process knowledge and data from expe- rience to distinguish between feasible and unfeasible process designs. This approach is particularly useful in restricting the theoretically infinite search space. Shortcut methods, in contrast, make use of simple process models to estimate the feasibility and minimum energy requirements of chemical pro- cesses without the need for detailed process specifications. Detailed rigor- ous models that simulate chemical and biotechnological processes take into account all of the transport effects occurring within the apparatus or plant equipment and can therefore be used to evaluate the accuracy of shortcut methods. The modelling of conventional thermal separation techniques such as rectification, absorption and extraction has already been extensively researched. In the case of membrane separation processes, whose low ener- gy requirements make them promising candidates for achieving more ener- gy-efficient processes, process modelling is still a challenge due to the com- plex interactions between the components and membrane materials. 3.10.2 Project description The goal of this collaborative project was to develop a standardised energy efficiency management and benchmarking system that would be globally applicable, i.e. not restricted to specific companies, operations or processes, that would achieve a sustainable reduction in the energy requirements of process industries of more than 20% and that would reflect the most effi- cient technologies recognised by both the academic and industrial commu- nities. Other key areas addressed in the project were the transfer of methods to life science processes and the development and improvement of the avail- 250PDF Image | Chemical Processes and Use of CO2
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