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PROCESS AUTOMATION
SUSTAINABILITY IS AT THE HEART OF INDUSTRY 5.0
Paige Marie Morse, Sustainability Advisor, AspenTech, explains how Industry 5.0 can elevate sustainability across the process industries
companies must target energy efficiency, waste reduction and water conservation to ensure they operate with a focus towards sustainability goals. The emerging fifth industrial revolution, or Industry 5.0, takes the existing Industry 4.0 paradigm one step further by highlighting operational excellence, research and innovation as drivers for a transition to a sustainable, human-centric and resilient approach. Industry 5.0 technologies will help drive
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sustainable movements and make reaching sustainability goals a reality for many industrial organisations. Application of advanced technology such as machine learning, industrial internet of things (IIoT), and artificial intelligence (AI) will help industrial operations increase efficiencies. Here, we consider the challenges asset-
intensive companies face in cutting the environmental footprint of their production process and the role digital technology can play in addressing these. We look at how to redesign processes and technologies to reduce materials waste, and the benefits that digitalisation can bring, before considering how solutions will evolve over time. How technology reduces energy usage in
industrial processes Many industrial processes demand high
temperature operations and high-energy input. Process simulation helps process engineers optimise CO2 and other pollutant emissions throughout the process, providing enterprise visualisation and planning solutions. One oil company, Abu Dhabi National Oil
Co. (ADNOC) was successful in using a digital twin of existing oil and gas operations in the Middle East to capture efficiency opportunities and optimise implementation, cutting water use by 10%. Others report benefits including optimising energy usage and improving resource use. For example, Kuwait National Petroleum company (KNPC) used simulation of its processes to reduce its carbon footprint and cut energy usage, resulting in annual savings of $15 million. Operational instability can also contribute
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he industrial world is under pressure to reduce the impact of their operations on the environment. Asset-intensive
to energy waste and can lead to product (or feedstock) waste. Using advanced process control technology, operators can better control manufacturing processes to keep energy use to a minimum and ensure that feedstock is not wasted making off-spec product. Artificial intelligence (AI) and machine-
learning can detect anomalies in equipment behaviour and use historical and contextual data to determine patterns leading to failure. AI provides organisations with visibility into the health of their operations by predicting malfunctions in advance and prescribing solutions to address issues. Warnings about unplanned disruptions helps companies avoid incidents that can lead to potential safety hazards and environmental releases to land and waterways. Key role of simulation Digital technology helps improve energy
savings through simulation and process modelling. This type of technology enables organisations to evaluate and measure the greenhouse gases generated by processes and develop alternatives with lower environmental impact. Simulation technology also helps
organisations model process alternatives early in development and identify alternate process routes and steps to optimise overall energy usage and waste generation. Through simulation technology, companies can reduce emissions, and get better at optimising energy and resource use. Effectively managing waste Material waste from plant activities can also
have negative consequences for the environment, especially when viewed in the context of raw materials, wasted energy, and
disposal issues. In plastics manufacturing, supply-chain scheduling technology helps reduce waste by enabling data-backed decisions that optimise the order of production. This reduces the amount of transition material waste produced between preferred polymer batches and helps cut energy output by more effectively transitioning between processes. Outside of precise production planning,
intelligent technology also makes it possible to analyse controlled and uncontrolled process variables in real time. This can identify errors as they happen and provide guidance on how to best mitigate or correct the process to recover the product and avoid waste. Managing waste effectively requires a
holistic view of the entire plant and its end-to- end operations. Multivariate analysis helps identify issues in manufacturing processes, such as drifting temperatures, or feedstock quality, allowing corrections that improve product quality and reduce off-spec product waste. Intelligent technology can provide insight on small variances that are often hidden deep within production layers, to correct issues and recover the product. How Industry 5.0 could evolve The fast-emerging concept of Industry 5.0
can help companies progress toward important sustainability targets. It’s real, and the technology advancements it is producing are pivotal to the industrial world, particularly in the area of operational efficiency. Technologies that make strides in sustainability efforts today will continue to offer more innovative solutions in the future.
AspenTech
www.aspentech.com
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