De- and Remanufacturing

Transcription

1 Brussels, 13/12/2017 ESM Plenary Meeting ESM Demo-cases presentation De- and Remanufacturing Regions: Lombardy, Scotland, Saxony, Tampere, Flanders, Basque Country, Norte, Emilia Romagna Marcello Colledani Politecnico di Milano, AFIL, ITIA-CNR

2 1. Thematic domain of the demo-case De- and Remanufacturing includes the set of technologies, tools and knowledge-based methods to recover, re-use and upgrade functions and materials from industrial waste and post-consumer high-tech products, under a new producer-centric Circular Economy perspective. Example: Benefits of Remanufacturing in the automotive industry (Electronic Air Control unit). [Source Kohler: D., Mechatronic Remanufacturing at Knorr-Bremse Commercial Vehicles Systems (CVS)]. EU Towards a circular economy, a zero waste programme for Europe, COM (2014) 398 final

3 1. Thematic domain of the demo-case Shifting toward a circular economy model would deliver better outcomes for the European economy and yield annual benefits of up to 1.8 trillion by Annual total cost of producing and using primary resources, EU-27, euros trillion Source: Europe s circular-economy opportunity McKinsey Center for Business and Environment September 2015

4 1. Thematic domain of the demo-case G7 Summit Declaration June 2015: The G7 Alliance on Resource Efficiency promotes Circular Economy, Remanufacturing and Recycling as strategic actions. At European level, the Commission has launched in December 2015 the strategic initiative Closing the loop - An EU action plan for the Circular Economy. H2020 R&I projects under the Focus Area Industry 2020 in the Circular Economy, calls CIRC, Spire and FOF, at TRL 6-7. Lack of infrastructures that can demonstrate to industry integrated circular economy solutions and business models, de-risking the private investment. These Innovation Hubs should act as technology gateways" that any business sector can use. De-and Reman pilot network Applied Research - Techn. Validation - Demonstration - Ready to market

5 1. Thematic domain of the demo-case The main objective of the De-and Remanufacturing pilot network is to integrate a multidisciplinary set of advanced and innovative enabling technologies and digital innovations (TRL 7-8) and to exploit the regional Smart Specializations in synergic way to offer services to European end-users, mainly manufacturing companies, to solve specific sustainability-oriented problems related to their products. The pilot network nodes will act as Innovation Hubs for Circular Economy, being a network of competence and technology centers and supporting future producer-driven replication at industrial scale (TRL 9).

6 2.1 Use-cases (or industrial applications) addressed in the demo-case The Pilot Network is seen as a One-stop-shop for delivering innovation services to the industrial end-users with a multi-regional approach. Industrial Innovation Service Portfolio Reverse logistics optimization. Product Life-cycle information management. Environmental sustainability assessment and LCA. Patent and technology IPR searches. Market analysis and business models. Legislation review and innovation deals. Product and process certification. Business case validation and scenario analysis. Circular economy training. Technical feasibility assessment. De-and Remanufacturing Process-chain design and demonstration. System integration and control. Product design/re-design for circular economy. Prototyping and product testing. Production of pre-series. Process chain optimization, simulation, and analytics. Value-chain integration. Support to Environmental Technology Verification (ETV) applications.

7 2.1 Use-cases (or industrial applications) addressed in the demo-case A detailed analysis of identified sectorial Use Cases, with industrial partners associated, has been performed, where more regions are involved. For each Use Case, a business case has been detailed including a business plan for the industrial take-up of the solutions. Regional/Cross-Regional Use Case Composite Recovery from Wind Energy System Heavy machinery components remanufacturing Automotive parts remanufacturing High-value TLC systems and Electronics Recovery Metal components reprocessing Remanufacturing of e-motors Plastics recycling from WEEE Involved Regions Basque Countries, Saxony, Lombardy, Tampere, Scotland Tampere, Basque Countries, Lombardy, Saxony Scotland, Lombardy, Saxony, Norte Lombardy, Tampere Saxony, Tampere, Lombardy Saxony, Lombardy, Norte Flanders, Lombardy E- mobilty batteries remanufacturing for re-use Lombardy, Saxony Photovoltaic panels de-manufacturing Remanufacturing and retrofit of machine tools Flanders, Lombardy Emilia Romagna, Lombardy

8 2.2 Who is working at the use cases? Use-case 1: Composite Recovery from Wind Energy System Regions participating to the use case: Basque Country (lead), Saxony, Lombardy, Tampere, Scotland. Reason for the Regions to work in the use case: Basque Country: production of wind turbines; thermal recovery of glass and carbon fibers. Output market: automotive. Saxony: re-design and remanufacturing of composite parts. Output market: automotive. Lombardy: mechanical demanufacturing processes and composite reprocessing. ICT for value-chain integration. Output market: furniture, sanitary and construction. Tampere: composite material re-formulation and characterization and coating processes for composite materials. Scotland: inspection for composite parts repair. Value-chain integration, market scouting.

9 2.2 Who is working at the use cases? FiberEUse Project Large scale demonstration of new circular economy value-chains based on the reuse of end-of-life fiber reinforced composites. Topic: Systemic, eco-innovative approaches for the circular economy: large-scale demonstration projects (CIRC ) The FiberEUse project aims at integrating in a holistic approach different innovation actions aimed at enhancing the profitability of composite recycling and reuse in value-added products. Duration: 48 months, starting on June Consortium: 21 partners, from 7 EU countries. Coordinator partner: Politecnico di Milano EC Funding: ca. 10 mln.

10 2.2 Who is working at the use cases? More than 60 European companies, with a cumulative turnover of 32 B and with some 175,000 employees, and 69 universities and RTOs distributed among the involved regions are involved. TECforce Candy Italtel CEG Barco Worldilne Turner Aviation Cargotec Finland Oy Sandvik Mining and Construction Oy Metso Minerals Oy Valmet Power Oy John Deere Forestry Oy Bronto Skylift Oy Ab Avant Tecno Oy Hambleside Danelaw Arup Fastems Tenova Maier Indeva DMG Mori Filartex Spa Gafitex Pass Maglia Samatex PTMT PANTER Rivierasca Brianza Plastica S.p.A. Sintostamp S.r.l. Magniplast S.p.A. OCV Owenscorning Covestro Campine Galloo Plastics Kokkola LCC Oy A2A Ambiente Relight Fincoat OY Telatek Oy Siae Batz Ki-lab Weir Group Gamesa Siemens Xnext Lot Quantum Design MH Systems Holonix Idealtech Cosberg Vibram AERNNOVA ITP Galloo Van Gansewinkel TKM TTT Finland Oy IRIZAR Meleghy Automotive GKN Enginsoft MCT Reman Cobat ASPIRE Eng. The stakeholders have signed Letters of Intent to participate to the definition of this Pilot Network and, in the case of future end-users, to access the pilot network and to carry on industrial take-up, in case of positive evaluation of the developed solution.

11 3 Envisaged inter-regional nodes configuration Totally new pilot site (or connection) Upgraded existing pilot site (or connection) Existing pilot site (or connection) Scotland Key Issue: integrated pilot plant solutions, needed by industry to validate high-risk investments in circular economy businesses before the industrial implementation.

12 3 Envisaged inter-regional nodes configuration Lombardy Infrastructure: new infrastructure: 400m2 ca.; 12,5M Integration of advanced and innovative technologies and digital innovations (TRL7-8) Modular and reconfigurable Pilot Plant for different use-case. High degree of integration, automation and control. Remanufacturing ICT tools & Simulation DIGITAL Business Model, Reverse Logistic and LCA Inspection, Materials Analysis, Certification VIRTUAL FITMAN DyVisual SMART Big Data FROM TREATMENT CENTERS IN THE REGION FITMAN Collab. Asset Management Application Mashup TO DE- AND RE-MANUFACTURING PLANTS LOCALIZATION AND ASSIGNMENT OF FLOWS. SPECTRUM ENERGYENERGY SPECTRUM FITMAN Dynamic CEP WATER XSPECTRA DETECTOR WATER + AMMONIA 2,476 IoT & M2M Applications Enterprise Applications Publish/Subscribe Context Broker Information Systems IoT Device Management IoT Broker 35 Secure Gateway Shopfloor IoT Device IoT Device Smart Disassembly Manual Semi-automated 130 1,955 IoT Discovery IoT Device IoT Device IoT Data Handling , IoT Protoco Adapter(s) Smart System IoT Device Mechanical Processes Chemical Processes

13 5 Intra-regional investment plan Business Model of the Pilot Network This pilot network is designed to be a generator of new industrial plants for European circular economy solutions. Pilot Network Revenues: The User will pay a daily fee for each access. The User will share with the pilot network a portion of the revenues obtained by selling the product/service demonstrated by the business case developed by the platform (IPR exploitation). The core partners of the pilot (companies, universities and RTOs) will pay a yearly fee to be part of the pilot network and to access the generated knowledge and best practices. Pilot Network Costs: Each demonstration project will have a specific duration and will requires a group of full-time dedicated persons (hired and paid by the pilot network). Maintenance and upgrade costs of the pilot network facilities will be covered yearly by the pilot. A cost of customization of the platform for each new project will be incurred (paid by the pilot).

14 6 Inter-regional investment plan Business Model of the Pilot Network Year after installation Accesses to the pilot network (n ) Pilot total revenues (mln ) Total costs (mln ) Installation & Launch costs co-funding (mln ) 12 / / / / Installation & Launch costs funding (mln ) 28 / / / / Annual margin (mln ) Cumulative margin (mln ) The installation and launch investments will be paid back in 5 years if 4 demonstration projects are attracted per year (on average) by each regional pilot. Considering a successful industrial replication rate of the developed solutions of 25%, about 35 new industrial installations will be originated by the pilot network in these 5 years. The cumulative revenue for the involved companies of about 215 million Euros. The 35 new installations will mobilize private resources for 535 million Euros. Leverage factor for the public investment of about 19 in five years from the pilot network installation.

15 6 Inter-regional investment plan Implementation & Investment Plans Integration of existing, new and upgraded facilities Phase 1 Concept & Business Plan 2 Detailed Design 3 Installation & Commissioning 4 Marketing & Launch Funding Co-funding Total Total Schedule Achieved 2015 M1-M9 M6-M21 M18-M24

16 7 Demo-case positioning with respect to other EU and regional relevant initiatives The Demo-case is well aligned with the most recent actions of the European Commission to boost circular economy, technology transfer in advanced manufacturing and industrial investments in innovation, with the objectives to achieve re-industrialization of Europe, job creation and sustainable growth. Initiative EIT KIC Raw Materials Digital Innovation Hubs Circular Economy Financial Support Platform European Circular Economy Stakeholders Platform Launched H2020 projects Current Existing Synergies Benefit from enforced synergies involvement Operational synergies with the concepts of CLC Extend the network to emerging regions. Exploit the (Colocation Centers) and the KIC instrument called KIC instruments for supporting industrial uptake of Network of Infrastructures. demonstrated solutions. EC Communication on Digitalizing European industry The De-and Remanufacturing network can act as defining the strategic objective of mainstreaming digital digital innovation hub for circular economy, innovation across all sectors by setting up a Pan- showcasing solutions for data analytics, material flow European network of Digital Innovation Hubs. traceability, process and product simulation. Launched to enhance the link between existing Identify feasible mechanisms to support the upscale of instruments, (EFSI, InnovFin), and develop new financial the network infrastructure as well as to the industrial instruments for circular economy projects. uptake of demonstrated solutions. The EC have setup this platform to facilitate the exchange of good practices in Europe. Provide best practices for dissemination. Being linked with the FiberEUse project and the Screen Establish agreements with existing projects aiming at project, the pilot can be actively involved in the creation integrating demonstrators into the pilot facilities for of clusters with ongoing H2020 projects. post-project exploitation.

17 7 Demo-case positioning with respect to other EU and regional relevant initiatives Initiative INTERREG INNOSUP New Skills Agenda - Blueprint for Sectoral Cooperation EIP Raw Materials Future H2020 programs (SPIRE, FoF, ICT, NMBP) Current involvement Existing Synergies Synergies with the Greenomed, CIRCe and S34Growth projects. Program to develop the ecosystem of innovation support to SMEs in Europe. Benefit from enforced synergies Exchange results for a common methodology for cross-regional value-chain integration and platform operations. Support accesses to the network of infrastructure by SMEs through INNOSUP (e.g. KET4CleanProduction project). Initiative designed to improve the quality and relevance Support filling the gaps in skills on circular economy, of skills to meet the need of a rapidly changing defining new curricula and training modules to create European labour market. new knowledge-intensive jobs in Europe. Watify, Reconfirm Initiatives launched to promote match-making. Standardisation and certification for Circular Economy Strategic platform that brings together representatives Contribution to the EIP Strategic Implementation Plan from industry, public services, academia and NGOs. and to the definition of future targets and roadmaps. Calls are issued in different H2020 programs, addressing Possibility to support the implementation of specific specific value-chains of the De-and remanufacturing use-cases through projects, thus increasing the pilot (e.g. plastics, batteries) and specific enabling inventory of technological capabilities in the mediumlong term. technologies (e.g. ICT platforms) Events in emerging regions extending the pilot footprint. The pilot network is actively promoting new (de facto) The De-and Remanufacturing network can be an standards for product design, in line with the CE experimental space for developing new standards and Package. deliver support services for certification of new (See Ecodesign Working Plan ) advanced manufacturing practices.

18 SCREEN Synergic Circular Economy Across European Regions SCREEN H2020 aims at the definition of a replicable and scalable approach, to support European Regions in the transition to new Circular Economy crossregional value-chains. This will be done through the identification and implementation of operative synergies between R&I investments of H2020 program and EU structural funds. The methodology developed within the project will be replicable in all the European Union, thus creating an interregional framework for financing Circular Economy value chains.

19 8 Main activities and achievements in 2017 Pilot Network Meetings: 10 intra-regional meetings 5 inter-regional meetings (web calls) De- and Remanufacturing Plenary Meeting: Palazzo Regione Lombardia, 5 th May, Milan. 62 Participants from 8 Countries. Smart Regions 2.0: Prof. Colledani was invited to take part to the panel discussion in June 2017, Helsinki. ECFIN: Prof. Colledani was invited to take part the the knowledge cafè at the platform meeting in Brussels. Memorandum of Understanding: Signed during the Vanguard Plenary Event in November Expression of Interest DG Regio: Submitted on time. Three H2020 Proposal Project started form the pilot use cases has been approved: FiberEUSE, SCREEN, CarEService (CIRC ).

20 De-and Remanufacturing EC Workshop on Investment Platform

21 9 Current challenges and actions planned in 2018 Challenges. The platform is very advanced. However, barriers still exist, and thus significant improvements are possible, in the Demonstrate and Upscale phases. Definition of IPR exploitation and related documentation. Definition of service delivery contracts and description of legal obligations towards users. Definition of funding instruments for supporting further infrastructure upscales (Layer 1) (e.g. mix of regional, national and EU subsides and/or loans). Definition of feasible financial routes and channels to facilitate the industrial exploitation of the results demonstrated by the network (Layer 3).

22 9 Current challenges and actions planned in 2018 ID Specific action 1 Definition of the financial sources combining regional, national and European support. Continue the interaction with EIB and regional financial stakeholders. 2 Continue the collection of Letters of Intent (LoI) from the stakeholders and achieve 100 letters of intent (60 currently signed). 3 Formalize the participation of interested regions (Wallonia, South Netherlands, Trentino, Catalunya, Pays de la Loire, East Netherlands). 4 Involve more potential users and technology providers from emerging European regions (Organization of matchmaking events in emerging regions) 5 Finalize the formats for IPR agreements during users accesses, by interacting with the EC IPR helpdesk. 6 Promote proposals in H2020 and regional programs to bring new enabling technologies into the pilot plants (Large Equipment Remanufacturing, ICT Platform for Circular Economy, Plastics recycling and re-use). 7 To contribute to the definition of new cross-regional circular economy value chains (Screen CSA). 8 Prepare specific material to further promote Dissemination, Communication and Awareness. 9 Overcome the identified barriers through the support of the Expression of interest from the DG Regio (if approved). 10 Start designing the platform for connecting the existing facilities and be ready for the pilot network service delivery.

23 9 Current challenges and actions planned in 2018 Marketing and Dissemination Actions

24 Business Model doc Pilot Summary Investment Plan Thank you for attention 63 pages 4 pages 34 pages De- and Remanufacturing Pilot Network Region Technical contact Organization Lombardy Marcello Colledani Politecnico di Milano marcello.colledani@polimi.it Tampere Minna Lanz Tampere University of Technology Minna.lanz@tut.fi Norte Luis Carneiro INESC Porto / PRODUTECH Cluster luis.carneiro@inescporto.pt Scotland Winifred Ijomah Scottish Institute for Remanufacture - Strathclyde w.l.ijomah@strath.ac.uk Saxony Katja Haferburg Fraunhofer Institute for Machine Tools katja.haferburg@iwu.fraunhofer.de and Forming Technology Basque Country Ane Irazustabarrena Tecnalia ane.irazustabarrena@tecnalia.com Flanders Joost Duflou Ku Leuven joost.duflou@kuleuven.be

25 Thanks for attention Marcello Colledani

26 3 Envisaged inter-regional nodes configuration Composite recovery from wind energy systems Remanufacturing of e-motor Automotive parts remanufacturing Pilot inter-regional nodes configuration Tampere Metal components reprocessing High value TLC systems and electronics recovery Heavy machinery components remanufacturing Plastic recycling from WEEE E-mobility batteries remanufacturing for re-use Photovoltaic panels demanufacturing Remanufacturing and retrofit of machine tools Norte Basque Country Flanders Scotland Saxony Lombardy Emilia-Romagna

27 9 Current challenges and actions planned in 2018 Actions planned in Involve more potential users and technology providers from emerging European regions. (Required support for the organization of match-making events in emerging regions). Preparation of professional communication/marketing material. Investigate funding/loan mix to support the pilot upscale towards processchain integration, by exploring existing channels and innovative instruments. Interaction with financial stakeholders (e.g. EIB) in supporting private industrial upscale, once de-risked by the pilot network demonstration in the framework of investment pipelines for new European value chains (new Industrial Policy Strategy).