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Initial research into polymer nanocomposites and their formation took place at Strathclyde from 2000 - 2010. This was followed by a collaboration with the world's largest manufacturer of composite kitchen sinks, Carron Phoenix Limited, through a 6-year Knowledge Transfer Partnership (KTP) which resulted in a successful new production process of its high-end synthetic granite kitchen sinks. This led to £4 million of capital investment in new production facilities at their Falkirk site, enabling the company to sustain its leading position in the designer kitchen sink market and retain its workforce of over 400 employees in central Scotland, including the 170 workers in the composite sink division in Falkirk. Within the REF period, the research has led to the manufacture and sale of in excess of one million kitchen sinks, generating sales revenue in excess of over £50M and supporting the UK economy.
Significant economic impact was achieved as a result of research into polymer nanocomposites and their formation, conducted at WestCHEM from 2000 to 2010. Collaboration over the six-year period 2004-2010 with Carron Phoenix Ltd, the world's largest manufacturer of composite `granite' kitchen sinks, led to nanocomposite technology being incorporated into over one million sinks, generating income for the company in excess of £50M from 2007 to the present day. Considerable production efficiency gains saved in excess of £1M annually through the reduction in manufacturing time, the reduction of raw materials wastage, and the reduction in landfill costs (and commensurate environmental benefit) for failed and out-of-spec products. In addition, a £4M capital investment by the company at the Falkirk plant was secured, enabling the company to sustain its leading position in the designer kitchen sink market. With the site consequently designated as the parent company's competency centre for composite sink technology, employment for 170 workers was secured.
Carbon8 Systems (C8S) was founded on joint research between UCL and the University of Greenwich. The company has since developed a technology known as Accelerated Carbonation, which helps to reduce carbon dioxide (CO2) emissions by using carbon dioxide gas to treat waste materials and form artificial aggregate. In January 2013, C8S completed the first commercial plant for treating municipal solid waste incinerator (MSWI) fly ashes, designed to produce 1,000 tonnes per day of aggregate. Masonry products company Lignacite has also benefited commercially. It has used C8S's aggregate to develop an award-winning building block that captures more carbon dioxide than is emitted during its manufacture. Carbon8 Systems and its offshoot company Carbon8 Aggregates currently employ 11 people.
Research conducted at the University of Cambridge under an EPSRC grant between 1999 and 2002 established the viability of using microwave induced pyrolysis as a process for recovering clean, elemental aluminium and hydrocarbon liquids and gases from waste laminate packaging, thus preventing the need to send this material to landfill. The research has been commercialised by Enval Limited — a multi-award-winning University spin-off founded in 2006 that has attracted approximately £2M funding during the REF period and employs 7 people. A pilot scale unit has been operational since 2011, and the first commercial-scale unit has been constructed and has operated since April 2013.
The demand for biofuels and alternative energies is increasing globally as a sustainable source of energy is sought for the future. Energy from crops is no longer a viable option due to the increase in wheat prices. Scientists at the BEST Research Institute have managed to bridge the gap by using novel and unique microwave systems for converting waste (biomass, food, animal) into energy. Our advances in this area have generated considerable interest from both national (e.g., United Utilities PLC, Balfour Beatty PLC, Biofuels Wales Ltd, Stopford Projects Ltd, Longma Clean Energy Ltd) and international (e.g., RIKEN-Japan, Fraunhofer-Germany, Sairem-France, Acondaqua-Spain, Ashleigh Farms-Ireland) companies. This has resulted in several collaborative, funded projects leading to industrial adoption of our microwave technologies.
The impact presented is the use of research carried out in the School of Chemical Engineering by a range of multinational food industries (inc. Unilever, Cargill, PepsiCo) to engineer a series of fat-reduced foods such as low fat spreads (LFS), dressings, margarine, sauces and mayonnaise. This has allowed them to build up a portfolio of novel low fat products; this portfolio would be much reduced or in some cases non-existent without the research contribution and capability generated by the Birmingham group as stated by Peter Lillford5.1 (former Chief Scientist, Unilever) and John Casey, (Vice President Biological Sciences, Unilever)5.2. These products are a significant and growing market segment e.g. LFS now outsell margarine/butter in a number of countries and are estimated to be worth globally 10 Billion Euros per year between 2008-13. Thus these products are having a significant impact on the industries' profitability. In addition, consumption of low fat foods act to tackle obesity with knock on effects for government (health service, lost GDP etc.) and the community as a whole.
The anærobic production of gas from waste — or biogas — is an important renewable energy source and means to prevent the release of methane, which is a powerful greenhouse gas. Exploitation of biogas is hampered by traces of siloxanes and H2S, which damage engines through the formation of SiO2, SO2 and H2SO4 during combustion. Research at Sussex in collaboration with PpTek Ltd (engineers of purification technology) has expanded the scope of current purification technology, meaning that biogas systems can be installed in a range of new sites. This has led to a strong increase in the commercial activity of the company, with turnover increasing from £910,000 in 2008 to £1.95m in 2012-13 and half year figures suggest turnover of at least £3m 2013-14 with £4.3m predicted for 2014-15.
Accelerated Carbonation Technology (ACT) is an innovative solution to several key environmental issues - CO2 emissions to the atmosphere, sustainable use of resources and the reliance on use of virgin stone for construction. ACT rapidly stabilises industrial waste recycling it into valuable aggregate, thereby reducing the amount going to landfill. ACT simultaneously captures the greenhouse gas CO2, via the rapid production of carbonate, which solidifies the waste into a hardened product. ACT has been commercialised through two spin-out companies leading to the first commercial production of carbon negative concrete blocks, taking hazardous waste from the bottom to the top of the waste hierarchy.
This case study describes the impact of the research work relating to anaerobic process technology undertaken within the Sustainable Environment Research Centre (SERC) and its industrial interfacing arm, the Wales Centre of Excellence for Anaerobic Digestion (AD). Anaerobic process technology is used globally to produce renewable energy, and other resources from wastes and low value biomasses. These impacts can be grouped into the following areas:
Powder handling research at the Centre for Numerical Modelling and Process Analysis (CNMPA) enables industries to reduce the risk in new powder processes and to troubleshoot existing ones. The study focuses on two closely-related projects that have resulted in a series of instruments, analysis techniques, training and spin-out research that has found application in a large number of companies all over the world, in a wide range of industries. The case is typical of the influence that the CNMPA has had on industry awareness and practice in the UK and globally.