IGNITE: Optimization of the efficiency of industrial combustion heaters using HPC (high performance computing).
Line: Technological innovation.
Execution period: 2017-2020
Scope of work:
– High temperature
Division:
– Energy – Industrial starting heaters
Participants:
– KALFRISA
– BIFI- University of Zaragoza
– NOBLADOT
Summary: Optimization of the performance of industrial preheaters through the use of high performance computing (HPC) technology, digital twins and advanced simulations. It is possible to predict the thermal behavior of the equipment before manufacturing, which reduces costs, improves energy efficiency and reduces emissions, contributing to a more sustainable industrial production.
Expected results: It is expected to obtain a digital twin of the starting industrial preheaters, digitize them for remote monitoring and tracking, develop predictive maintenance technologies applied to this equipment and perform CFD simulations using HPC technologies.
FORTISSIMO PLUS PROJECT
Program: FFplus_OC1_T1_1310
High-temperature radiation recovery technology for melting furnaces
Line: Sustainable Energy Projects
Execution period: 2017-2020
Scope of work:
– Renewable Energy
– High Temperature
Division:
– Energy – heat recovery units
Participants: KALFRISA
Abstract: Research on technologies to recover high temperature radiation in melting furnaces, in order to improve energy efficiency and reduce the environmental impact of these industrial processes. This project seeks to improve high temperature heat recovery in industrial furnaces and reduce their energy consumption.
Results: The project led to the development of a new product, the high efficiency double jacketed recuperator.
CDTI PROJECT
File: IDI-20170798
DT4RAF: Digital twin of high-efficiency recuperators
Line: Technological Innovation Projects
Execution period: 2020-2021
Scope of work:
– Energy recovery
– Digitization
Division: Energy – heat recovery units
Participants:
– KALFRISA
– CLENAR – Clúster de la Energía de Aragón
– NOBLADOT
– AIMEN
Summary: Creation of a digital twin to optimize the processes of high efficiency recuperators, improving the performance and energy management of these industrial systems. This system seeks to improve the efficiency of industrial equipment through simulation and real-time monitoring, reducing energy consumption and pollutant emissions.
Results: The digitization of the heat recovery units and the creation of digital twins that allow monitoring and optimizing their operation were achieved.
AEI PROJECT MINISTRY OF INDUSTRY, COMMERCE AND TOURISM
Dossier: AEI-010500-2020-83
RAFeRTO: Predictive maintenance of industrial gas treatment plants
Line: Technological Innovation Projects
Execution period: 2022
Scope of work:
– Energy recovery
– Digitization
Divisions:
– Energy – heat recovery
– Environment – gas cleaning
Participants:
– KALFRISA
– CLENAR – Clúster de la Energía de Aragón
– ELECTROINGENIUM
Abstract: Implementation of digital technologies and predictive techniques to optimize the operation and maintenance of industrial equipment (regenerative thermal oxidizers and heat recuperators).
Result: The heat recovery and regenerative thermal oxidizers (RTO) were digitized, digital twins were created to monitor and optimize their operation, and data analysis and predictive maintenance tools applicable to both industrial equipment were developed.
AEI PROJECT MINISTRY OF INDUSTRY, COMMERCE AND TOURISM
Dossier: AEI-010500-2022-22
Design and development of new solutions for digital and efficient cremations.
Line: Technological Innovation Projects
Execution period: 2020-2023
Scope of work:
– Digitization
Divisions:
– Environment – waste recovery
– Cremation
Participants: KALFRISA
Abstract: Design and development of new efficient and digital cremation ovens with improvements in combustion, heat transfer, instrumentation, connectivity and data management.
Result: A new product was developed: the KM range of cremation ovens. In addition, the cremation ovens were digitized for remote monitoring and tracking, digital twins of waste recovery ovens were created, and the operability of both the cremation ovens and the waste recovery plants was optimized.
CDTI PROJECT – Ministry of Science and Innovation
Expediente: IDI-20210513
Digital technologies and industry 4.0
Line: Industrial Innovation Projects
Execution period: 2020-2023
Field of work:
– Industry 4.0
– Technological Innovation
Participants: KALFRSA
Summary: Implementation of solutions based on Industry 4.0 technologies to improve the efficiency and competitiveness of companies in the industrial sector. The project focuses on digitization, automation and the integration of technologies such as artificial intelligence and big data to optimize production processes and production management.
Result: KALFRISA’s strategic digitalization plan was developed, applicable to both products and internal processes.
CDTI PROJECT – Ministry of Science and Innovation
Expediente:
DESCARB-e: Decarbonization of a crematorium furnace through the application of electrification solutions.
Line: Industrial Decarbonization Projects
Execution period: 2024-2026
Scope of work:
– Industrial Electrification
– Decarbonization
Divisions: Cremation
Participants: KALFRISA
Abstract: Research for the decarbonization of a crematorium furnace by means of electrification solutions, in order to reduce CO2 emissions and optimize energy consumption in this type of industrial processes. The project seeks to explore and develop technological solutions to replace conventional combustion systems with more sustainable electrified alternatives.
Result: A new range of cremation products, the e-KM cremation ovens, is being developed and our know-how in industrial process electrification is increasing.
Expediente: IDI-20240659
HIGH2-FURNACES: Industrial furnace hybridization for high H2 substitution rates
Line: Digital Technologies Projects – Industrial Research Activities
Execution period: May 2023 – April 2024
Scope of work:
– Digital technology
– Resilient infrastructures
Divisions:
– Environment – waste recovery
– Cremation
Participants:
– KALFRISA S.A.
– FHa – Foundation for the Development of New Hydrogen Technologies in Aragon
– CLENAR – Energy Cluster of Aragon
Abstract: Development of hybrid hydrogen furnaces with high substitution rates in industrial environments for the reduction of CO2 emissions. Different H2 substitution rates up to 80% will be tested in three different types of furnaces, integrating digitalization and automation of the combustion process.
Result: A new range of KM-H2 cremation furnaces was developed and know-how in the decarbonization of industrial processes by using 100% hydrogen was increased. In addition, the combustion of gas mixtures with up to 100% hydrogen was achieved under real industrial conditions.
File: AEI-01500-2023-157
EDPIC: Electrification and digitalization of an afterburner for the circularity of photovoltaic recycling
Line: Digital Technologies Projects – Industrial Research Activities
Execution period: May 2023 – April 2024
Scope of work:
– Digital technology
– Resilient infrastructures
Divisions:
– Environment – waste valorization
Participants:
– KALFRISA
– IBER Sostenibilidad y Desarrollo SL
– FUNDACIÓN CIRCE
– CLENAR – Energy Cluster of Aragón
Abstract: Research for the design of an electric afterburner for the purification of gases generated in photovoltaic recycling by pyrolysis. Development of a digital twin of the process and evaluation of environmental impacts through LCA studies.
Result: An electric afterburner was designed for the recycling of photovoltaic panels, making progress in its digitalization and thus increasing our know-how in the electrification of industrial processes.
Docket: AEI-010500-2023-159
LIFE ABATE: High-performance compact technologies for VOC reduction in waste treatment plants
Line: Industrial Decarbonization Projects
Execution period: 2023 – 2028
Scope of work:
– Industrial decarbonization
Divisions:
– Environment – gas purification
Participants:
– KALFRISA
– University of Valladolid / FUNGE
– Barcelona Metropolitan Area (AMB)
– AERIS Environmental Technologies
– FCC-Environment
– Polytechnic University of Catalonia (UPC)
Abstract: Development of innovative technology for the reduction of non-methane volatile organic compounds (NMVOCs) and CO2 in mechanical biological treatment plants (MBT), using a rotoconcentrator and thermal or biological degradation. The aim is to minimize emissions and energy consumption through the use of biogas and the reuse of CO2 in greenhouses.
Result: Emission purification technologies were implemented and validated in real conditions, developing solutions such as biological filtration and pollutant concentration. In addition, progress was made in the digitalization and automation of the associated industrial processes.
Program: LIFE22 ENV/EN/1011113838
e-RTO: Electrification and digitization of the regenerative thermal oxidizer
Line: Technological Innovation Projects
Execution period: 2021-2022
Scope of work:
– Industrial decarbonization
Divisions:
– Environment – gas purification
Participants:
– KALFRISA
Abstract: Development of a digital model for electrification and advanced RTO control by digital twin.
Result: A digital twin of the regenerative thermal oxidizers (RTO) was developed, progress was made in their digitalization to allow remote monitoring and follow-up, and know-how in the electrification of industrial processes was increased.
AEI Call – Ministry of Industry, Commerce and Tourism.
Expediente: AEI-010500-2021b-37
3H2: Hybrid hydrogen furnace
Line: Technological Innovation Projects
Execution period: 2022
Scope of work:
– Industrial decarbonization
Divisions:
– Environment – gas purification
Participants:
– KALFRISA
Abstract: Research on the use of green hydrogen and natural gas mixtures in industrial burners, analyzing the digitalization and automation of the process.
Result: Know-how in the decarbonization of industrial processes through the use of hydrogen was increased, combustion tests were carried out with mixtures of up to 50% H₂ in real industrial conditions, and progress was made in the digitalization of the combustion processes of such mixtures.
AEI Call – Ministry of Industry, Commerce and Tourism.
Expediente: AEI-010500-2022-23
