Post on 28-May-2020
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
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Academic and
Institutional
1- ENGIE Lab Ecosystems & Partnerships
Competence
Project development
Start-up
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
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 1 ENGIE & ENGIE Research
Chapter 2 New challenges for industry & digitalization
Chapter 3
Industry 4.0 & “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
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 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
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 CRIGENPhilippe.buchet@engie.com
Yee Wah TANG
Program Manager, Future IndustryENGIE Lab Singapore
Yeewah.tang@engie.com