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The Leicester Variwave project, in relation to electrostatic dust precipitation, utilises a novel high voltage, high frequency, high power transformer within the power supply, which has enabled cuts in industrial emissions of ~50 per cent and considerable cost savings. Most new-build power stations and many other industrial sites now use technology based on that developed in Leicester. As well as fly ash and dust, the technology has the ability to trap sub-micron particulates thought to be partly responsible for the increase in the number of asthma cases during the past few decades. The MD of [text removed for publication] states `Through publications made by ...Leicester ...we were interested to learn how the team designed their high voltage transformer, and how that transformer operated with the high frequency, high power switched-mode electronics. They achieved that `Holy Grail' combination [of high voltage, frequency, high power] in a 70 kW switched-mode power supply (SMPS) running at 20 KHz and at 50 kV. The publication in the IEEE Transactions on Power Delivery was very helpful, and enabled us to choose the direction when pushing the design boundaries in developing our own high power, high voltage technology for electrostatic precipitators'. Dr Devine, a key member of the Leicester team between 1995 and 2000, was employed by [text removed for publication] in 2001 purely on the basis of his knowledge of Variwave. [text removed for publication] now have 200 units in operation. In 2002 Dr Devine was head-hunted for his knowledge of Variwave and moved to [text removed for publication], who also developed commercial units. The uptake of the technology has been growing steadily since 2001. Exemplar data from one company on the associated reduction in emissions shows 195 switched mode power units installed in boiler plants worldwide by 2004 gave a reduction of around 60%. A 60% reduction in emissions is equivalent to a reduction from 40 mg.m-3 to 16 mg.m-3 of flue gas particulates. Since 2004 to date there are now estimated to be at least 5000 units installed worldwide.
Research at the University of Strathclyde between 2003 and 2008 directly produced the following impacts from 2008 onwards: 10 wind farms (17 MW aggregate capacity) connected to the Orkney power network from 2009 to 2013 with accompanying economic and environmental benefits; Orkney power network reinforcement deferral saving of £30M from 2009 with repeat deployments of Active Network Management (ANM) technology in other UK power networks; spin-out company formed in September 2008 with total revenues to date of £6.1M, equity investment totalling £3.5M and 35 FTE jobs created; provision of new power system options for long term network plans impacting the 2013 investment decisions in distribution network companies; contribution to the emerging Smart Grid business sector in the UK and overseas from 2008.
University of Huddersfield research into the optimal design of flow-handling systems has been credited with "transforming" the development strategies and global market sales of an industrial partner. Weir Valves and Control Ltd has enjoyed a 75% saving in design lead time and a 1,800% increase in annual sales - from several thousand before its collaboration to millions in 2013 - through the structured integration of researchers' computational fluid dynamics expertise in its design process. The success of this collaboration, which has been described as an exemplar of a Knowledge Transfer Partnership, has also led to further research contracts.
Research conducted since July 2008 by the University of East London in collaboration with Control Techniques Dynamics (CTD), a leading manufacturer of Permanent Magnet Synchronous Motors (PMSMs), has led to the development of a software tool called the PMSM analyser. This tool has helped CTD to improve its motor design methodology by incorporating electromagnetic, thermal and cost models, together with genetic algorithms. In turn, the design optimisation allowed CTD to enhance motor performance and reduce manufacturing time by 30-40%, leading to an increase of 20% in company sales between 2008 and 2013. During the same period the company was able to cut materials usage by 15%.
A unified design methodology for tuning gas turbine engine controllers, developed by researchers in the Department of Automatic Control and Systems Engineering (ACSE), is being used by Rolls- Royce across its latest fleet of Civil Aero Trent engines. Trent engines are used to power, for example, Boeing 787 Dreamliner and Airbus A350 aircraft that have been adopted by the world's leading airlines.
This new methodology has made economic impact through the introduction of a new process for tuning gas turbine engine controllers leading to the adoption of a significantly changed technology. Indicators of impact are:
i) a new control law and design practice, resulting in a unified approach for different projects;
ii) reduced development effort by shortening and simplifying the design exercise and rendering it suitable for modular insertion; and
iii) streamlined verification requirements.
Our research has been key to the development of investor confidence in an emerging UK tidal stream industry. We have contributed to the development and validation of commercial and open- source software for tidal stream system design and our expertise has been instrumental to the successful delivery of major objectives of two national industry-academia marine energy projects commissioned by the Energy Technologies Institute (ETI). Taken together, these outcomes have reduced engineering risks that had been of concern to potential investors. Investor confidence in tidal energy has been increased, as highlighted by Alstom's £65m acquisition of a turbine developer following a key outcome of the ETI ReDAPT project.
Coal fired power stations will be a major element of global power generation for the foreseeable future. Measurement, and hence control, of pulverised fuel flow is a vital technology for the efficient and green operation of coal fired power stations. Balancing fuel delivery and combustion stoichiometry increases boiler efficiency and reduces emissions. Research in this area carried out at Teesside University was adopted by ABB Ltd and led to the commercial development of new powder flow measurement systems (PfMaster technology) installed in power stations around the world. Quantifiable economic benefits of the installations to date amount to >£3.4 M with concomitant environmental benefits of significant reduction in CO2 and NOxemissions and solid waste disposal burdens.
Newcastle University has a substantial background in researching novel control methods for electric motors. This case study concerns the impact that our work on sensorless control systems has had upon Dyson consumer products.
One of our sensorless control schemes has been adopted by Dyson for their vacuum cleaner drive systems offering benefits of ruggedness, flexibility and being inexpensive to implement, leading to reduced production costs and improved ergonomics derived from the ability to eliminate bulky sensor components and separate control electronics from the motor.
Dyson has invested £5M in a new production line for products using this sensorless control system which have production volumes of around 5 million units per annum. The Company estimates the cost savings accruing from the use of our designs at around £2M per annum.
The development of a novel 3D inverse design method for turbomachinery aerodynamic design at UCL has led to important design breakthroughs for pump and compressor applications. The resulting IP and software has been commercialised by a UCL spinout company Advanced Design Technology Ltd (ADT), which is now considered a global leader in advanced turbomachinery design software. Since 2008, the 3D inverse design codes embedded within ADT's TURBOdesign™ suite of software have been adopted by many of the leading turbomachinery equipment manufacturers in Europe, Japan and the US. These companies are using the TURBOdesign suite to achieve significant improvements in the time taken to design their turbomachinery components. It has also helped them unlock major efficiency gains and hence achieve a reduction in CO2 emissions. [text removed for publication]
A step change reduction in tidal energy costs has been achieved through the development of the novel Contra Rotating Marine Turbine `CoRMaT' tidal energy technology. The internationally patent-protected CoRMaT system reduces capital, operational and maintenance costs while increasing the extractable tidal energy resource by harnessing flows in deeper waters and from less energetic sites, which were previously considered to be uneconomic. A University spin-out company, Nautricity Ltd, was formed in 2010 to commercialise this technology. The development of this technology has changed both Scottish and UK Government policy via their introduction of programmes which demonstrate a step change reduction in the costs of marine renewables.