公司责任

为什么数字双胞胎应该成为可持续发展计划的组成部分

作者:Aspentech的化学工业Paige Morse博士

In today’s volatile chemicals marketplace, managing the complexity of tradeoffs between profitability and sustainability is daunting, given the volume of information to be analyzed and the need for agility and scenario development. Implementing a digital twin strategy as part of an overall digitalization plan is key. A digital twin has greatest value when aligned with business and sustainability strategy, aiding decision-making and helping to enable the achievement of important corporate goals.

如今,在可持续性方面,化学公司正在朝着考虑排放和资源使用的特定过程指标迈进。这些解决方案提供了应对可持续性目标固有的挑战所需的可见性,分析和见解。成功首先要利用运营可用的大量数据(应用新技术,例如人工智能(AI))来获得洞察力和控制操作;并授权运营商做出将为客户提供绩效的决策,同时还解决社会可持续性和业务利润。

Using a digital simulation of operational processes, companies can select the best process scheme and equipment to maximize energy efficiency and reduce emissions. Design engineers can weigh the best options, selecting process steps and equipment that deliver the best outcome. After construction, these same models are used to optimize operations by adjusting them in accordance with feedstock and operational variations to ensure efficient resource and energy use.

此外,工程师可以提高工艺产量,并最大程度地减少从生产单元中排出的废物,并通过数字解决方案提高效率。他们正在探索具有较低碳足迹的新能源。Digital Twins可以深入了解这些选择,从而使公司可以将现有运营与未来的替代方案进行比较。

Charting progress on sustainability is important to success, a process made easier with visibility gained through digital dashboards. Process simulation technology tracks and optimizes CO2and other pollutant emissions and effluents; the same tools, combined with other technologies such as planning solutions and enterprise visualization tools, provide the basis for emissions reporting for chemical plants.

类型的数字双

Digital simulations, typically referred to as digital twins, can be classified according to three main use cases: asset-focused as the plant digital twin; process optimization through the operational excellence digital twin; and reliability with the operational integrity digital twin.

植物数字双胞胎

These models simulate the process plant using rigorous engineering simulations, enhanced by AI capabilities. They can also include embedded cost and risk models enabling alternative investment and business scenarios to be explored using a range of market views. They can be deployed offline or online and are often calibrated to plant operating conditions through autonomous model tuning.

该概念可以跨越广泛的范围:从反应堆等单个设备到单元操作(蒸汽饼干),植物范围(能源和公用事业系统)或企业范围内(整个复合物或区域操作)。

在可持续性的背景下,工厂数字双胞胎帮助工程师整合了流程的安全需求,同时还考虑了其​​环境影响。从项目开始,工艺工程师可以设计为过程安全,包括压力缓解和耀斑系统,提供符合行业安全标准的最佳计划以及更有效的设计,以减少碳足迹。

卓越运营数字双胞胎

从业务层面到控制层的工厂运营可以被建模并实际上视为规划,调度,控制和公用事业分析工具。卓越运营数字双胞胎为供应链规划等业务决策提供了信息,还可以帮助技术决策,例如优化质量,能源使用,排放合规性和安全性。

供应链的数字双胞胎在全球化学工业中发现了特别的价值,在全球化学品行业中,长而复杂的供应线可能会破坏和不确定。网站或集成业务部门的生产计划的模型有助于确定整个计划过程中的效率机会,例如最佳生产顺序,该顺序可最大程度地减少等级之间的质量降低。

操作完整性数字双胞胎

该数字双胞胎可以在规定维护方面就战术和战略决策提供指导,从而提供实时建议以最大化正常运行时间。这种洞察力用于调整生产以管理故障设备,最大程度地减少环境影响,减轻生产损失并确定安全性。此外,质量和风险评估还提供了对设备健康,风险概况的未来视图,以及未能改善正常运行时间和运营完整性的根本原因。根据每个生产系统的挑战,运营完整性数字双胞胎的范围从单个设备(单个工艺单元)到整个植物或企业范围的双胞胎的范围。

支持AI的解决方案使用机器学习来识别具有高精度的精确故障模式,以预测设备在数周甚至几个月内降级,以便采取行动以准备并避免潜在的环境或安全事件,并最大程度地减少业务破坏。该技术从现有的设计和操作数据中学习,然后集成过程知识以执行规范性维护并优化资产绩效。

Looking ahead

Global efforts to move towards new energy sources and the circular economy will drive a strategic shift in business metrics and the practices that will enable future success. Digital twins are key to this, enabling improved process design, greater manufacturing insight, and better operational integrity.

对于化学公司而言,将可持续性目标与业务目标的整合将是转型的,尤其是当大型机构投资者和媒体在股东会议中提出这些主题时。这项活动还将企业定位为长期业务成功。

Achieving the fragile balance of sustainability goals — equally considering people, planet and profit — is a challenge, but one that must be addressed to be competitive in the chemicals markets of today and tomorrow.