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BRITEST is a global leader in the development of innovative process solutions for the chemical processing sector with > £500m of value being realized since 2008. Research in Manchester (1997-2000) generated a set of novel tools and methodologies which analyse chemical processes to identify where and how process improvements could be made. BRITEST was established in 2001 as a not-for-profit company to manage the technology transfer and effective deployment of these tools and methodologies into industry. Manchester holds the IP arising from the underpinning research and has granted an exclusive license to BRITEST for use and exploitation of the toolkit.
Publically and industrially funded research at Loughborough University into the simulation, monitoring and control of electronics soldering has had significant impact in the development of new software and hardware technologies, which have delivered substantial commercial and economic benefits, with examples cited for at least two leading companies. One key commercial product is a modelling tool that optimizes reflow oven settings quickly, easily and accurately. It optimises oven settings each time a new product or solder paste is introduced, reducing set up times and scrap levels. More than 700 systems per year continue to be sold, with 90% exported.
Research at the University of Manchester, focusing on process systems in advanced architecture for large systems, has enabled the development and successful implementation of the Salford Process Reengineering Involving New Technology (SPRINT) method within Salford City Council. SPRINT is a change and innovation method tailored to the needs of the public sector. Having been adopted as the standard for all Local Authorities in 2004, the SPRINT methodology aided Salford City Council in achieving savings of £20M by 2011. It has been further used in projects in Education and Housing where it has delivered cost savings of £0.5M.
The field of conceptual chemical process design as practiced industrially has been influenced significantly by the outputs from the Centre for Process Integration (CPI) at Manchester. Process Integration Ltd (PIL) was spun-out from Manchester and currently employs over 50 staff globally, who have conducted projects that have resulted in annual cost savings of hundreds of millions of US dollars. The application of CPI technology has led to significant reductions in both energy costs and emissions of greenhouse gases. Since 2008 ca. US$350m of savings have been realized through the exploitation of CPI technology with US$1.4m generated from software sales.
Fluid modelling approaches devised by the Materials and Engineering Research Institute's (MERI's) materials and fluid flow modelling group have impacted on industrial partners, research professionals and outreach recipients. This case study focuses on economic impacts arising from improved understanding which this modelling work has given of commercial products and processes. These include: metal particulate decontamination methods developed by the UK small company Fluid Maintenance Solutions; liquid crystal devices (LCDs) manufactured by the UK SME ZBD Displays; and an ink-droplet dispenser module originally invented at the multinational Kodak. Additionally, the modelling group's computer simulation algorithms have been adopted by industrial research professionals and made available via STFC Daresbury's internationally distributed software package DL_MESO. Finally, the group has developed, presented and disseminated simulation-based materials and visualisations at major public understanding of science (PUS) events.
The vulnerability of both military and civilian infrastructure to the threat of terrorist activity has highlighted the need to improve its survivability, and this poses a significant design challenge to engineers. Research work at Imperial has led to the development of novel constitutive relationships for polymeric materials coupled to novel analysis procedures; software algorithms for effective simulations of blast and impact events; and enhanced experimental testing methods allowing a fundamental understanding of the structures. According to Dstl, this body of research has `unquestionably improved the security and effectiveness of the UK armed forces operating in hostile environments abroad as well as the safety of citizens using metropolitan infrastructure within the UK'. The techniques have been applied to vehicles and UK infrastructure, including for high profile events, such as the 2012 Olympics.
This case study describes the creation and use of advanced simulation technology by international mining corporations to optimise high value metal recovery. The technology involved the development of advanced novel computational methods and software tools to model industrial scale heap leach processes for large scale industrial application at major mining operations. This focus on the development of optimised operational strategies has produced considerable economic benefits measured in the $multi-millions to industrial sponsors, including $58 million dollars in additional revenue for one multi-national corporation over one year following the adoption of engineered heaps based upon the advanced simulation tools from Swansea.
Multinational companies [text removed for publication] have saved more than 20,000 tonnes of plastic and $10M in less than 4 years, using QUB technology to develop their innovative lightweight plastic bottles.
This has created both economic and environmental impact through the savings in material, transport and energy costs and a reduction in CO2 usage. For example the [text removed for publication] showed savings per year of €3M and 1800 tonnes of plastic and a reduction of CO2 of 800 tonnes/year.
A spin-out company, built on this technology, was created in 2012 and is actively selling process instrumentation (THERMOscan) to both USA and EU customers enabling them to make further reductions in material and energy usage. The product won a clean energy award in 2011.
UCL research has been instrumental in creating critically needed new biocatalysts and bioprocess technologies for industrial biocatalytic process development. These have impact across the UK chemical and pharmaceutical sectors. BiCE enzyme technologies have been exploited through the formation of a spin-out company, Synthace, generating investment of £1.8m and creation of 7 new jobs. Commercial utilisation of BiCE enzymes by company partners has led to environmental benefits through sustainable syntheses and reduced waste generation. BiCE high-throughput bioprocess technologies have also been adopted to speed biocatalytic process development. UCL established a parallel miniature stirred bioreactor system as a new product line for HEL Ltd. [text removed for publication]. Related knowledge transfer activities have also benefited some 157 industrial employees from over 50 companies since 2008.
Automotive design analysis software based on qualitative reasoning research in the Advanced Reasoning Group at Aberystwyth is deployed at more than 200 automotive and aeronautic OEMs and Tier 1 suppliers world-wide. The software necessitates companies changing their process for performing design analysis, and companies are willing to do this because of the attendant benefits.
The major benefits of use of the software are early feedback on potential problems with the design of automotive systems, and improved safety of automotive designs. Related benefits are improved product time to market, and cost savings. A representative example of production savings of $2.5 million has been given for use of the software on a single product design, as well as Ford Motor Company's estimate of $20M per year saved in just their company.