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RECOBA

Cross-sectorial real-time sensing, advanced control and optimisation of batch processes saving energy and raw materials

Total Cost €

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EC-Contrib. €

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Partnership

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Project "RECOBA" data sheet

The following table provides information about the project.

Coordinator
BASF SE 

Organization address
address: CARL BOSCH STRASSE 38
city: LUDWIGSHAFEN AM RHEIN
postcode: 67063
website: www.basf.com

contact info
title: n.a.
name: n.a.
surname: n.a.
function: n.a.
email: n.a.
telephone: n.a.
fax: n.a.

 Coordinator Country Germany [DE]
 Project website http://www.spire2030.eu/recoba
 Total cost 5˙999˙346 €
 EC max contribution 5˙999˙346 € (100%)
 Programme 1. H2020-EU.2.1.5.3. (Sustainable, resource-efficient and low-carbon technologies in energy-intensive process industries)
 Code Call H2020-SPIRE-2014
 Funding Scheme RIA
 Starting year 2015
 Duration (year-month-day) from 2015-01-01   to  2017-12-31

 Partnership

Take a look of project's partnership.

# participants  country  role  EC contrib. [€] 
1    BASF SE DE (LUDWIGSHAFEN AM RHEIN) coordinator 799˙648.00
2    THE CHANCELLOR MASTERS AND SCHOLARSOF THE UNIVERSITY OF CAMBRIDGE UK (CAMBRIDGE) participant 888˙270.00
3    VDEH-BETRIEBSFORSCHUNGSINSTITUT GMBH DE (DUSSELDORF) participant 749˙307.00
4    CYBERNETICA AS NO (TRONDHEIM) participant 714˙012.00
5    ELKEM AS NO (OSLO) participant 610˙397.00
6    UNIVERSIDAD DEL PAIS VASCO/ EUSKAL HERRIKO UNIBERTSITATEA ES (LEIOA) participant 505˙170.00
7    VYSOKA SKOLA CHEMICKO-TECHNOLOGICKA V PRAZE CZ (PRAHA) participant 468˙028.00
8    THYSSENKRUPP STEEL EUROPE AG DE (DUISBURG) participant 449˙738.00
9    MINKON SP ZOO PL (Tarnowskie Gory) participant 413˙522.00
10    RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHEN DE (AACHEN) participant 401˙250.00

Map

 Project objective

In many aspects batch processes are superior to continuous. Therefore it is worthwhile to take advantage of recent progress in sensor technologies, modelling and automation to develop a new paradigm for the design and conduction of batch processes: a) operation at maximum efficiency, b) dynamic, quality driven process trajectories rather than fixed schedules c) detailed analysis and tracking of all relevant process and product parameter. The main objective of the proposed project is the maximization of efficiency (reg. quality, energy, raw materials, and costs) of batch processes. Integrated process control is essential for an efficient operation of industrial batch processes: it tracks the evolution of product properties, detects deviations from the target values for product quality and derives corrective actions at a stage when an automatic compensation of deviations from an optimal trajectory is still possible. This contributes to optimal energy and raw material utilisation, shortens production time and enhanced the product quality. With the ambition to deliver solutions with relevance to all sectors of the process industries, the RECOBA consortium represents a selection of batch processes operating industries and partners across the value chain of batch process control, among them 3 global players from the polymer industry (BASF), the steel industry (TKSE), and the silicon metal industry (ELKEM). Within RECOBA there will be developed and validated: (1) new & innovative solutions for the measurement of different types of quality aspects, (2) new models to realise integrated process control of batch processes & suitable online parameter adaptation technologies to keep these models valid, (3) control modules to realise concepts for real-time, model based & closed loop process control, which are easily adaptable to existing batch processes in various industrial sectors, (4) business models to approach relevant industrial sectors for a future market entry.

 Deliverables

List of deliverables.
Report on performance of FBG fibre optical temperature measurement in refractories Documents, reports 2019-05-30 17:18:54
A report on application of acoustic sensors for real-time properties sensing in different batch processes Documents, reports 2019-03-06 11:11:04
Pilot scale test of ladle refractory temperature monitoring system Other 2019-03-06 11:11:04
Fibre optical temperature sensor for monitoring temperature development of high-temperature fluids during batch processing Demonstrators, pilots, prototypes 2019-03-06 11:11:04
Coverage efficiency sensor to monitor temperature loss of high-temperature fluid by radiation Demonstrators, pilots, prototypes 2019-03-06 11:11:04
New developed sensors applicable for steelmaking processes Demonstrators, pilots, prototypes 2019-03-06 11:11:04
Report about the results of the comparison between conventional practice and new practice Documents, reports 2019-03-06 11:11:04
Press release including a project leaflet Websites, patent fillings, videos etc. 2019-03-06 11:11:03
Kick-off exploitation workshop Websites, patent fillings, videos etc. 2019-03-06 11:11:03
Release of project web-site Websites, patent fillings, videos etc. 2019-03-06 11:11:03
Selection of two automated metal level detection systems (AMLDS) for testing in pilot scale Other 2019-03-06 11:11:03
Pilot-scale/industrial scale test of temperature monitoring of solidification process Other 2019-03-06 11:11:04
Event-triggered through process optimisation methods for the control of a chain of batch processes Other 2019-03-06 11:11:04
Set of evaluation criteria for the technical evaluation of different components and the overall results of the integrated process control Other 2019-03-06 11:11:04
Selection of best technology for automated ladle refractory temperature monitoring Other 2019-03-06 11:11:04
Symposium for process industry with high process temperatures Websites, patent fillings, videos etc. 2019-03-06 11:11:04
Application of imaging methods (using optical and electromagnetic methods) in real-time properties measurements across batch processing methods. A cross-sectorial report Documents, reports 2019-03-06 11:11:04
Midterm dissemination event: exploitation workshop 2 Websites, patent fillings, videos etc. 2019-03-06 11:11:04
Selection of best technology for temperature monitoring of solidification process Other 2019-03-06 11:11:04
Final report about the evaluation of the project Documents, reports 2019-03-06 11:11:04
Final model layout as a guide/tutorial for interested parties outside of RECOBA consortium Documents, reports 2019-03-06 11:11:04
Ecobalance of the real-time controlled polymerisation, steel and silicon alloys process Documents, reports 2019-03-06 11:11:04
Knowledge about temperature development in vacuum degassing batch process Other 2019-03-06 11:11:04
Report about the results of the comparison between conventional practice and new methods Documents, reports 2019-03-06 11:11:04
Pilot scale verification of AMLDS and selection of most suitable system Other 2019-03-06 11:11:04
Report on Raman spectroscopic monitoring of emulsion polymerisation with particle size and morphology information Documents, reports 2019-03-06 11:11:04
Report on cross-sectorial transferability Documents, reports 2019-03-06 11:11:04
Knowledge about temperature development in gas stirred ladle treatment batch process Other 2019-03-06 11:11:04
Acoustic sensor for particle morphology monitoring (for different generation of sensors) Other 2019-03-06 11:11:03
Detailed dynamic process model for both processes Demonstrators, pilots, prototypes 2019-03-06 11:11:04

Take a look to the deliverables list in detail:  detailed list of RECOBA deliverables.

 Publications

year authors and title journal last update
List of publications.
2016 T. Chaloupka, A. Zubov, Juraj Kosek
Real-time hybrid Monte Carlo method for modelling of 4 monomer semi-batch emulsion copolymerization
published pages: , ISSN: , DOI:
CHISA 2016 2019-05-27
2016 Ellen Nordgard-Hansen, Kjetil Hildal
Skull formation in dynamic modelling of silicon refining
published pages: , ISSN: , DOI:
International Federation of Automatic Control (IFAC) 17th 2019-05-27
2016 Noushin Rajabalinia, Shaghayegh Hamzehlou, Jose R Leiza, Jose M Asua
Study the effect of reaction condition on the morphology of structured polymer particles in latexes
published pages: , ISSN: , DOI:
Study the effect of reaction condition on the morphology of structured polymer particles in latexes 2019-05-27
2016 Johannes M.M. Faust, Jun Fu, Benoit Chachuat, Alexander Mitsos
Optimization of dynamic systems with rigorous path constraint satisifaction
published pages: , ISSN: , DOI:
ESCAPE26 2019-05-27
2017 G. Rughoobur, M. DeMiguel-Ramos, J.-M. Escolano, E. Iborra, and A. J. Flewitt
Gravimetric sensors operating at 1.1 GHz based on inclined c -axis ZnO grown on textured Al electrodes
published pages: 1367, ISSN: 2045-2322, DOI:
Scientific Reports 2019-05-27
2015 Martin Kroupa, Michal Vonka, Juraj Kosek
Shear-induced Coagulation in Stabilized Dispersions: Modeling by Discrete Element Method
published pages: , ISSN: , DOI:
IACIS 2019-05-27
2016 L. Å eda, E. Jahns, A. Mhamdi, A. Mitsos, P. Joy, S. Hamzehlou, J. R. Leiza, J. M. Asua, N. Rajabalinia, J. Kosek, T. Chaloupka, M. Kroupa, M. DeMiguel-Ramos, A. J. Flewitt, A. Lapkin, J. Suberu, F. Gjertsen, P. Singstad
Expected impact and an overview about progress in advanced process control of emulsion copolymerization
published pages: , ISSN: , DOI:
CHISA/PRES 2016 2019-05-27
2018 G. Rughoobur, H. Sugime, M. DeMiguel-Ramos, T. Mirea, S. Zheng, J. Robertson, E. Iborra, A. J. Flewitt
Carbon nanotube isolation layer enhancing in-liquid quality-factors of thin film bulk acoustic wave resonators for gravimetric sensing
published pages: , ISSN: 0925-4005, DOI:
Sensors and Actuators B 2019-05-27
2016 G. Rughoobur, M. DeMiguel-Ramos, T. Mirea, M. Clement, J. Olivares, B. Díaz-Durán, J. Sangrador, I. Miele, W. I. Milne, E. Iborra, A. J. Flewitt
Room temperature sputtering of inclined c-axis ZnO for shear mode solidly mounted resonators
published pages: 34103, ISSN: 0003-6951, DOI: 10.1063/1.4940683
Applied Physics Letters 108/3 2019-05-24
2015 Johannes M. M. Faust, Jun Fu, Benoˆıt Chachuat, Alexander Mitsos
Local Optimization of Dynamic Systems with Guaranteed Feasibility of Path Constraints
published pages: , ISSN: , DOI:
AIChE, 2015 2019-05-24
2016 M. Kroupa, M. Vonka, M. Soos, J. Kosek
Coagulation and Fouling in Stabilized Colloidal Dispersions: Building a Predictive Model Based on First Principles
published pages: , ISSN: , DOI:
International Conference on Chemical Technology 2019-05-24
2016 T.Chaloupka, A. Zubov, J. Kosek
Real-time hybrid Monte Carlo method for modelling of 4-monomer semi-batch emulsion copolymerization
published pages: , ISSN: , DOI:
PRE 2016 2019-05-24
2015 A. Zubov, T. Chaloupka, J. Kosek
Use of Hybrid Monte-Carlo Models in Online Control of Product Quality in Emulsion Copolymerization
published pages: , ISSN: , DOI:
MaCKiE workshop 2019-05-24
2016 M. Kroupa, M. Vonka, M. Soos, J. Kosek
Viscosity and Stability of Concentrated Colloidal Latexes Modeled by Discrete Element Method
published pages: , ISSN: , DOI:
PRE 2016 2019-05-24
2016 Shaghayegh Hamzehlou; Jose Ramon Leiza; José M. Asua
A new approach for mathematical modelling of the dynamic development of particle morphology
published pages: , ISSN: , DOI:
PRE 2016 2019-05-24
2015 J. Kosek, A. Zubov, R. Pokorny, T. Chaloupka
On-line optimization and control of emulsion copolymerization reactors
published pages: , ISSN: , DOI:
CHISA 2019-05-24
2016 Shaghayegh Hamzehlou; Jose Ramon Leiza; José M. Asua
A new approach for mathematical modelling of the dynamic development of particle morphology
published pages: , ISSN: 1385-8947, DOI:
Chemical Engineering Journal 2019-05-24
2016 T.Chaloupka, A. Zubov, J. Kosek
Real-time process optimisation by a model based on hybrid Monte Carlo method in semi-batch emulsion copolymerization
published pages: , ISSN: , DOI:
International Conference of Slovak Society of Chem. Eng. 2019-05-24
2015 Johannes M. M. Faust, Jun Fu, Benoˆıt Chachuat, Alexander Mitsos
Optimization with Dynamic Systems Embedded with Guaranteed Satisfaction of Path Constraints
published pages: , ISSN: , DOI:
AC.CES 2015 June 15 2019-05-24
2016 T.Chaloupka, A. Zubov, J. Kosek
Real-time hybrid Monte Carlo method for modelling of 4-monomer semi-batch emulsion copolymerization
published pages: , ISSN: , DOI:
WPPRE 2016 2019-05-24
2015 A. Zubov, R. Pokorny, P. Matuska, J. Kosek
On-line control and optimization for intensification of emulsion copolymerization reactors
published pages: , ISSN: , DOI:
International Conference on Chemical Technology 2019-05-24
2015 T.Chaloupka, A. Zubov, J. Kosek
Dynamic model for on-line control of 4-monomer semi-batch emulsion copolymerization
published pages: , ISSN: , DOI:
Danube Vltava Sava Polymer Meeting 2019-05-27
2016 Martin Kroupa, Michal Vonka, Miroslav Soos, Juraj Kosek
Utilizing the Discrete Element Method for the Modeling of Viscosity in Concentrated Suspensions
published pages: , ISSN: 0743-7463, DOI:
Langmuir 2019-03-06
2015 M. Kroupa, M. Vonka, M. Soos, J. Kosek
\"\"\"Modeling the size and structure of clusters producedby shear-induced coagulation\"\"\"
published pages: , ISSN: , DOI:
ESCRE 2019-05-24
2016 M. Kroupa, M. Vonka, M. Soos, J. Kosek
Modelling of concentrated colloidal dispersions using Discrete Element Method: stability, rheology and size of clusters
published pages: , ISSN: , DOI:
6th International Colloids Conference 2019-05-24

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