Welcome to the web site of project EFENIS (2012-2015)
ENER/FP7/296003/EFENIS project Efficient Energy Integrated Solutions for Manufacturing Industries (EFENIS) started 01/08/2012. It is a demonstration oriented project which consists of sixteen partners including five big industrial companies, two SMEs and nine universities and research organisations from eleven countries.
Nearly one-third of the world’s energy consumption and 36% of its carbon dioxide (CO2) emissions are attributable to manufacturing industries. The adoption of advanced technologies could provide technical energy savings in industry of 27–41 exajoules (EJ), along with a reduction in CO2 emissions of 2.2–3.2 gigatonnes (Gt) per year, about 7–12% of today’s global CO2 emissions . However, the emergence of step-change innovation of integrative energy management concepts and research-driven technology advancements with respect to supply side measures such as fuel switching and CO2 capture means that even more significant savings can be attained in the future. Within this context, the specific point of departure of the EFENIS project is the mounting energy and Greenhouse Gas (GHG) efficiency opportunities – and the related innovation imperatives. The consortium involves a number of distinguished industrial partners within the highly GHG and energy-intensive industries of, chemicals and refinery, directly targeted by the call. In combination with a cross-disciplinary team of leading European scientists as well as a group of enabling technology providers and EMS specialists – the group of energy-intensive industrial end-users wishes to address the major scientific potential and economic opportunity in achieving significant and tangible improvements in energy and CO2 management through industrial scale demonstration of highly innovative and high-impact total site integration design methods and associated optimisation techniques for energy-intensive process industries.
The overall objective of EFENIS is to facilitate and accelerate a move to low carbon manufacturing processes and site management by deployment and demonstration of innovative energy management systems and enabling efficiency technologies, which extend the scope of energy management outside the boundaries of a single plant to total site and then beyond the total site to district heating/cooling systems. The potential is demonstrated across a selection of the EU’s most energy-intensive sectors – thereby enabling integration across industries and processes while at the same time ensuring wide-spread deployment post-project. The EFENIS project will significantly advance the state-of-the-art with regards to site optimisation and Energy Management Systems. Currently, no deployed solution with a similar holistic scope exists. The major novelty of the project will be the creation of the required foundation for comprehensive, high-impact industrial deployment of energy systems based on Total Site Integration approach in the target industries and subsequent commercial exploitation. The project is focused on allowing integration of the developed technologies and solutions to both new designs and as retrofits to existing sites to ensure fast, widespread and cost-efficient industrial deployment. Until now, both technical and non-technical barriers have prevented the exploitation of this potential.
To enable demonstration of the proposed solutions, targeted pre-demonstration research is necessary to generate deeper knowledge about conceptual targeting and design methods with the aim of systematically integrating energy profiles of a total site and identifying realistic and achievable energy savings, subject to carbon footprint. In addition, the project aims to build a detailed scientific understanding of viable systematic frameworks for multi-objective optimisation under uncertainty and variability of demands and supplies in order to empower and enable optimal decision on structures and operating conditions of site energy infrastructure and to perform rigorous economic trade-offs.
In meeting the key objectives, the preparatory research and demonstration activities will attain high impact on a number of dimensions. At the level of technology end-users within and beyond the consortium of energy-intensive industries, the significantly reduced consumption of fossil fuels and maximized utilization of renewable resources will be the major tangible benefits. Improved poly-generation and energy integration of about 15-40% in particular would translate into up to 20% reduction in their overall operation costs  – thus significantly improving the competitiveness of the European manufacturing industry. The potential energy and GHG savings of the consortium’s industrial partners alone, based on 2008 figures and a 50% uptake at group level, represents about 30 PJ/y and 0.6-1Mt/y CO2 for the participating companies alone. At the industrial level, working and economically viable tools for deploying overall process integration and “beyond-plant-boundary” site integration will mean the establishment of a strong value chain consisting of globally leading European representatives of the energy-intensive manufacturing industry, exploiting very promising economic, energy and GHG efficiency opportunities to the benefit of the environment, regions and citizens. This potential will be growing in the coming years due to the fluctuating energy prices and regulatory pressure. The inclusion in the consortium of major providers of enabling technology, a group of highly specialised SMEs and a market-leading and globally active ESCO, will finally enable high impact and rapid commercial deployment beyond the consortium partners.
In short, EFENIS directly addresses the objectives of the topic (ENERGY.2011.8.1-2), as it demonstrates “innovative industrial processes and/or their substitution or redesign, with substantial potential for actual energy savings and aiming at processes and products with low carbon footprint…. Demonstration will need to be carried out at a scale, that makes it possible to estimate operating conditions at full commercial scale with confidence.” and entail application “of innovative Energy Management System tools” thus enabling “Significant CO2 reduction component attributed to the improved processes, with the development of technology-led processes to make breakthrough CO2 cuts possible“.
 Tracking Industrial Energy Use and CO2 Emissions. (IEA/OECD, Paris, 2007).
 This estimate is convincingly supported by a publicly available report about a production site in the United States – the 3M Hutchinson production site, where from 7 MM$/y initial energy expenses, only the applied energy recovery from the RTO units brings savings of approximately 0.7 MM$/y. This is 10% cost reduction only from heat integration.