digitalization of industrial plants –“industry 4.0” · lng tank digital twin software set for...

ENGIE LAB CRIGEN & Singapore ENGIE Research and Innovation Centers for Energy transition

Digitalization of Industrial plants – “Industry 4.0”:Perspectives and Contribution to Energy Efficiency & Energy transition

October 2018

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Chapter 1 ENGIE & ENGIE Research

Chapter 2 New challenges for industry & digitalization

Chapter 3

Industry & Digitalization – Examples & Case studies: From

energy efficiency to Energy revolution1. Advanced modelling

2. Digital twin

3. DT + BIM + Drones

4. Drones & robots + AI for inspection

5. Data analytics + IoT sensors

6. Digital solution for operation

7. Augmented reality for maintenance

8. Digital platforms for sustainable factory

Chapter 4 Conclusions

Agenda

1- ENGIE the Global Energy and Innovation Leader

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LARGE INDUSTRIALEXPERTISE

STRONGINNOVATION CULTURE

• 153,090 employees

• Operations in 70+ countries

• No.1 energy efficiency services provider

• EPCs ranging from <€50k - €50 million

• No.1 independent power producer with 115 GW of installed power capacity

• 21.5 GW installed in renewables

• 850+ MW Solar PV from ground-mounted to rooftop solutions

• 60+ MWh Battery Storage installed behind the meter

WORLD ENERGYLEADER

UNIQUE BUYING POWER POSITION

• €1 billion growth investments over 2016-2018 in innovation and digital

• €115 million fund to invest in innovative companies

• 1,000 researchers and experts at 11 R&D centres

• Collaboration with 100+ universities and competitiveness clusters

• Joint calls for projects with our clients and partners

• Events organisation to engage with innovators

• Work with external incubators

• €19 billion External spend (Excluding energy)

• 110 Purchase categories

• +110,000 Active suppliers

• PV, LED and other energy equipment's Global Procurement agreements

• More than 100 Innovative partnerships each years

• Leader in Energy services into industrial markets

• Partner of several international industrial groups for Energy transition and decarbonization

• Many references and patents on disruptive technologies

1- The International Network of ENGIE Labs and their Ecosystems

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Singapore

ENGIE Lab Singapore

NTU (Joint lab)

Schneider Electric

Sigfox

Fraunhofer

Japan

Tokyo GasOsaka GasMHI, Toshiba, Panasonic

Chile

ENGIE Lab LATAM

SERC Chile

E.Cl

Fraunhofer Chile

Middle East

ENGIE Lab Middle East

Masdar Institute

AD Little, Netra

Brasil

ENGIE Lab Brazil

Coppe Rio

GE (Global R&D)

China

ENGIE Lab China

Tongki, Tsingha

BGG, Fosun, Disney Lab

USA

ENGIE Lab USA

MIT, Stanford

Lightsail,Nanoptech…

Europe : Several ENGIE Labs

Laborelec B, NL, G Electricity

Crigen F Gas & new Energies

TractebelEngineering

F Engineering, simulation

Cylergie F Energy efficiency

CEEME B Economic modelling

ENGIE INEO R&D F Digital

1- ENGIE Research Preparing the Future Examples of Collaborative Projects & Demonstrators

Biogas – pyro-gasificationtechnology

Hydrogen: Power to Gas

and Solar production

Smart grids : advances tools for

Elec. grids

Industry - Low temperature waste heat recovery & storage

Internet of Things low energy

sensors

REIDS: Distributed off-

grid energy systems

for islands, including innovative

multi- energy and storage solutions

(renewable electricity, biogas,

battery or hydrogen energy storage,

innovative multi-fluid EMS

MMO anode

Cathode

Photoanode

Gas separators

Energy data platform

MAPPED: coordinatingmethanation units at regional level

Renewable Energy

New Uses of Energy

Digital and Enabling

Technologies

LiLiBox: Liquefying biogas and biomethane on site

ENE.FIELD field tests of

FuelCells in

social

housing

ACCENT: a European project

to develop a software tool for

energy

planning in

cities and

districts

BE CIRCLEA digital service for helping industrial parks to achieve a circular economy

POWERZEEA serious game on energy efficiency

for university campuses

Provide competitive advantage to energy

performance contracts for

university campuses

involving users

Mars 2018 - ENGIE Lab CRIGEN5

REIDS_short.mp4

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Academic and

Institutional

1- ENGIE Lab Ecosystems & Partnerships

Competence

Project development

Start-up

http://www.bing.com/images/search?q=RATP+logo&id=64210831C5F0D89A6EB61B371653AC08A6099EC9&FORM=IQFRBA



Chapter 3



2. Digital twin








Agenda

2 – Context : Industrials have to deal with new Energy Revolution The 6 Key Game Changers of Future Energy Mix

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2 - Energy Transition/Revolution : The 6 key Game Changers of future energy mix

Decentralization

Energy Systems are becoming smaller

and get closer to the end customer

Size divided by 1000

Fuel Cell

Interpenetration of gas and electricity

systems plus energy storage gains

importance

Electrolyser

Water O2

H2Electricity

Heat

New energy Gas chains are raising :

Renewables / H2-Biogas / Mobility /

Biomass / New Energy uses / uses

as feedstocks .

H2

CH4

Méthane

C2H6O

Ethanol

Decarbonization

They are looking for the right balance

between energy price and environment,

which leads to a strong interest in CO2

valorization technologies.

Digitalization

Digital spreads though the energy

chain at all levels (assets / clients)

to better monitor / control / optimize

Access to Large range of energy

sources

Stakeholders are interested by having

the largest possible panel of primary

(green) energy sources

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2- Challenges for Industries for the Future

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00/00/2015 9

2- Challenges for Industries for the Future

Industrial sector continues to account for the largest

share of energy consumption (and CO2 emissions)

through 2040 (1) Drastic effort to reduce its

contribution to fossil Energy consumption & GHG

emissions

15 %(2) to 50% (3) of jobs in industries will likely be

automated within 20 years. “Industry 4.0” requires a

paradigm to shift manufacturing strategies

(1) https://www.eia.gov/outlooks/ieo/pdf/0484(2017).pdf(2) Rolland Berger & (3) France Stratégie cited in http://www.emploiparlonsnet.pole-emploi.org/prospective/le-livre-de-la-semaine-lindustrie-40-nouvelle-donne-industrielle-nouveau-modele

This context will need integration of 5 simultaneous transitions requiring disruptive technologies

Energy transition: Better use of energy, high energy efficient technologies , Smart operation…

Reduction of environmental impacts: low CO2 processes, high Energy & environmental efficiency, use

of green Feedstocks, use of renewable energies , Complete range of Assessment/Control tools …

Digital transformation: Big-data use , IoT sensors, Digital Twin ; augmented reality…

Organizational changes: Flexible factories/production, short production lead time enabling new business

models…

Societal evolutions: Flexible work organization, remote work permanent connectivity of Staff;

operators and workers…



Chapter 3

Industry 4.0 & “Digitalization” – Examples & Case studies: From


2. Digital twin








Agenda

3.1 – Process modelling /Advanced modellingDigital Tools for Design and Optimization Process

Yesterday : Use Process modelling software, like the market-leading process optimization software suite (ASPEN) to:

• Improve technical performance of processing operations

• Optimize CAPEX & OPEX

• Ensure safe and profitable operations

Today: “Tailor-made” design & modelling including:

• Steady state and dynamic models

• On line treatment of Data coming from on-site

tests and measurements (sampling – Data base)

• Expanding models to include innovative concepts

(Big data, AI models…)

• Advanced model for design processing , coupling

with external databases & model fitting with

experience Digital Twin

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Digital twin available applications : • Optimum design &/or Eco- design of process lines• Energy optimization of processes or workshops (Energy

Consumption; Heat recovery or CO2 Emissions ; pollutants emissions, one line fuel switching … )

• Advanced Control command of industrial processes• Tools for operators training or on line support

• Energy efficiency & reduction of NOx emissions in Glass industries: Combustion, thermal and CFD modelling :

Energy consumption reduction

Production & quality assessment

Environmental impact vs Combustion system & Fuel used

..

3.2 - Advanced Modelling to Improve Energy Efficiency

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Furnace & glass meltingbath temperature

Integration of Heat recovery system with Heat

pump into Chemical industry :

Assess potential of heat recovery on fatal heat losses

(Pinch analyze digital tools…)

Evaluation of best solutions (Process modelling )

Assess performance of the system (Specific HP models

to assess HP COP, global efficiency)

Financial impacts ..

3.3 – Tools for Operation optimization of LNG plants including Digital Twin & AI : ENGIE’s Set of Tools - An LNG expertise encapsulated in a whole set of software

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BUNKERING SOFTWARE ®

Helping LNG operators in the design and operation of bunkering facilities

LNG MASTER ®

Management of LNG stored inside on-shore tanks CARGO ®

CARGO ONBOARD ®

LNG ageing on-boardLNG carriers / BOG saving

STAGE®

Supply chain &storage capacitydesign

OPTIRETAIL®

Supply chainoptimizationSMART GAUGE®

Prediction of holding time and assessmentof energy content in LNG tank

Digital Twin software set for decision support: • Optimization of LNG storage operations• Better control of quality of LNG gas • Advanced Control of LNG & Small scale LNG supplying processes• Optimization of supply chain for SSLNG Up to 15% Energy saving and cost savings • …

Appliance : Coupling Outdoor + indoor 3D reconstructions of industrial facility with drone imagery + CFD or thermal modelling to : reduce fatal heat losses or improve production layout, Quality of workers post, quality of indoor air ….

3.3 – Use of Drones, Digital Twin model & BIM for Performance Improvement of Industrial Plants /buildings

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3.4 – Use of Drones & Robots + Artificial Intelligence to improve or facilitate Maintenance

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Applications & interests: • Assessment of heat losses or

insulation defaults• Detection of oxidation points (rust –

energy or water grids) • Detection of breaking points,

damages & malfunctions with automatic (AI) diagnosis and alarms (PV panels or Wind mills blades )

• Advanced Control of industrial processes (Vibrations of Steam or gas turbine; Quality defaults, safety control…..)

• Reliability of maintenance operations & High reduction of manpower costs

Coupling Artificial Intelligence + Drones for Industrial Inspection + Big data software From data collect to added value diagnosis

Challenges• Improve performance indicators (KPI)

• Find the best techno-economic ratio for your facility and achieve it

• Build from existing process data an energy action plan & Energy dashboard

• Define and enforce the best operating practices for production

Constraints : Need of many process datas

3.5 - BIG DATA ANALYSIS/DATA ANALYTICSOn line Energy Optimization for Process / Combine Big Data and Process Expert Skills

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Big data tools:

• Content: Automatic collect of existing data , multi-criteria continuous big data analyze ; elaboration of

optimized correlation (KPI) and production of best recipes for operator or control command system

• Target : Energy dashboard, production dashboard , performance indicator(s) KPI.

• Prescribe : select the most efficient settings points by combining influential variables.

• Energy efficiency in industrial plant: up to 5-6% of energy savings or costs savings

3.5.b – Advanced Energy Dashboard using IOT Sensors + Big Data + AI sofwares Key factors for Rational Energy Consumption

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Energy flux measurements & metering plan with IoT or wireless

sensors

Energy balance

Big data analyse Trends

Advanced control/Optimized recipes & KPI :• Better & continuous control of production

(quality, costs…)• Energy & cost savings• Reliable operation• Increase of flexibility…

Monitoring & Bigdata analyze

3.6 – Digital Solutions for “Industries 4.0”

Development of Advanced Digital Solutions, Augmented Reality Tools and Digital Platforms

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3.6 – Augmented Reality : Development of Advanced Tools and Methodologies for Remote Assistance to Operators for IEE and Maintenance

• Next generation of remote assistance appliances fro: Maintenance diagnosis/ energy audits/ maintenance or inspection tasks• Better efficiency: Faster

communication of expertise or with expertise , enlarge time to exchange with local operators and/or technician’s needs

• Cost savings: Avoid or limit business trip costs/time (Experts spend much of their time in transit, data collection, unable to attend to the situation at hand)

• Increase operator’s skills: Mentoring, clearing up questions, personalized training

• Reliability: Online critical information for maintenance operations

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3.7 – Digital Platform for Sustainable Industry : Digital expert Tools to Assess CO2 Free Roadmap: Example of Food industry – ENGIE ”Green.e solution”

The challenge: Find the path toward low carbon foot print or zero GHG emission in 2030

Deliver a roadmap for carbon neutrality of food factory in 2030 including Energy & Water savings

Different path ways to RE 100 or Science Based Target scenario (SBT) or Zero emissions could assessed

Today Industrial food and health sectors are significantly advanced on the neutral carbon path

Methodology : Energy & Environmental Audit on site + Advanced modelling of Carbon footprint (Scopes 1 ; 2 &3)



Chapter 3



2. Digital twin








Agenda

Major Challenges of industry in next 20 years will be :• Energy efficiency & Decarbonisation : Reduce drastically the “CO2 footprint” and shift to more

Sustainable Operation of industrial plants ;• Digitalisation of process lines & operation - « Industry 4.0 » - Massive introduction of digital

technologies, IoT sensors, Big data & artificial intelligence software , Robots & Drones for maintenance & operations of production lines.

To meet these challenges, stay competitive and move to a sustainable industry:

Should industry remain attentive to the development of these digital technologies or be proactive in implementing their development ?

To face these challenges, because of the very fast development of these digital technologies carried by new actors (start-up, GAFA), the industrials must clearly be involve proactively in:

• The development and industrialization of technologies and tools to adapt them to industrial constraints (ATEX; ...) ;

• Integration into industrial solutions and into their implementation in order that meet their real needs.

• Review and Strengthen internal skills (engineers, technicians) on these new subjects and production piloting modes.

The best answer is : Yes Be proactive in !

The ENGIE group have decided it!

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THANK YOU

Philippe BUCHET

Director of Research ProgramsSenior Key Expert in Energy & Environmental Efficiency in Industry

ENGIE Lab [email protected]

Yee Wah TANG

Program Manager, Future IndustryENGIE Lab Singapore

[email protected]

mailto:[email protected]

mailto:[email protected]

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