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"Improved energy and resource efficiency by better coordination of production in the process industries" (CoPro) addresses the call SPIRE 02-2016 and will make significant contributions towards
efficiently utilising existing plants by integrated plant-wide scheduling and control;
better coordination of connected units in a site and within a chemical park;
buffering the effects of fluctuating renewable energy production and distribution by integrating demand-side response with plant-wide scheduling and control.
CoPro will provide tools for the plant-wide optimisation of continuous and discrete decisions, will develop technology for balancing production and consumption in industrial parks for industrial symbiosis and will address power plant scheduling and demand-side response.
We will develop online data analytics and novel forms of information presentation that lead to a symbiosis of operators and computer-based control algorithms. The solutions will be integrated into the IT infrastructure of the plants via a neutral integration platform that connects to different IT systems. CoPro will pay special attention to methods for the efficient development of plant models as the basis for advanced control, scheduling, and coordination.
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The goal of the CoPro project is to develop and to demonstrate methods and tools for process monitoring and optimal dynamic planning, scheduling and control of plants, industrial sites and clusters under dynamic market conditions, to provide decision support to operators and managers and to progress to automated closed-loop solutions to achieve an optimally energy and resource efficient production.
The objectives are motivated by challenging and characteristic use cases from different sectors of the process industries:
The technologies that are developed are nonetheless of a generic nature and can be applied to all sectors of the process industries and also to production sites in other sectors. CoPro builds upon results of the MORE www.more-nmp.eu and DYMASOS www.dymasos.eu projects and makes a further step forward to apply and extend them to plant-wide coordination and control, and towards market-based coordination mechanisms for Industrial Parks.
INEOS in Köln (Cologne, Germany) operates an integrated petrochemical complex to produce a large number of important base chemicals. The site consists of more than twenty plants, more than ten utilities networks and a large number of storage tanks.
There is complex interaction between the different INEOS plants, with site logistics and with other plants owned by other companies in the chemical park. Today, daily production (products and energy) is planned for the year ahead using a central planning tool.
The focus of the planned work related to the INEOS site is to achieve an optimal short-term planning and scheduling and operation of large units (crackers) and of the complete site.
INEOS operates two steam crackers offering continuous degrees of freedom in plant operations and discrete degrees of freedom in feedstock planning and furnace decoking scheduling.
Optimal site operation is a combined continuous optimisation and scheduling problem as not all plants are operational all the time. The real-time solutions need to interact with long term planning to provide automatically coordinated site operation for planned and unplanned plant shut-downs and maintenance.
Demand-side management can contribute significantly to the economics of the site as well as to the reduction of the CO2 footprint if more electricity from renewables can be used on average.
Covestro Deutschland AG is among the world’s leading manufacturers of polymers and high-performance plastics. Our innovative developments in polycarbonates, polyurethanes, coating, adhesive and specialty raw materials enhance the design and functionality of products in a wide variety of markets. Key customers include the automotive and construction industries, the electrical and electronics sector, manufacturers of sport and leisure goods, and representatives of the healthcare and medical technology sectors.
At the Dormagen site, Covestro Deutschland AG produces base chemicals as intermediates for polymers. Of these base chemicals production units coupled units will be picked as use cases to find an overall optimum across more than one unit. It will include the planning of partial shutdowns of units due to maintenance or demand fluctuations.
In chemical parks, as in the Dormagen/Köln ChemPark where Covestro and INEOS in Köln are located, companies exchange streams of energy or materials via networks with limited storage capacity. Often such couplings are multiple such that the plants are connected by several flows in both directions. This leads to a coupled allocation problem, because when one company changes its production levels or its product mix this affects the others and may lead to cascading effects. Current practice is to negotiate corridors of flows with associated prices which are both fixed over long horizons. As production demands change quickly and the response to the availability of “green” electric power (demand-side management) asks for flexible production, the need for a more dynamic and semi-automated management of the exchange streams arises. This creates a potential to operate the plants optimally with respect to energy and resource consumption. The benefits of the exchange and the cost of the flexibility must be computed and distributed fairly among the participating companies. Due to confidentiality reasons and anti-trust legislation, the management of the exchange flows of material must be performed with a minimum amount of information about the demands, restrictions, cost structures etc. of the plants and companies involved. Market-based algorithms that have been developed by TUDO in the DYMASOS project can compute the joint optimum on the basis of confidential individual optimisations of the participating companies by adapting the exchange prices. In CoPro, we develop this idea further to include partial shutdowns of units due to maintenance or demand fluctuations as well as the optimal procurement of resources from external providers.
The Lenzing Group operates in Upper Austria the world´s largest fully integrated pulp and Viscose® fiber production site. In the Viscose® fiber production the recovery of the spinbath is a key process step with the highest energy demand. In this recovery process the diluted spinbath liquid gets reconcentrated and the co-product sodium sulphate gets extracted. The recovery is performed by evaporation, crystallisation and calcination process units.
The evaporation unit consists of many different evaporators. To optimally operate this unit the plant supervisor has to schedule the load, the cleaning cycle and the allocation of every single evaporator while taking a number of boundary conditions into account.
River water is used for the cooling of the most evaporators. The river water is limited and has to be distributed optimal to reduce the overall energy consumption. The usage of the river water also creates algae deposits on the surface condensers of the evaporators. To increase the efficiency of the condensers an improved scheduling for the removal of the algae deposits is necessary.
A large number of heat exchangers is used to shift the energy between the different operation units. The efficiency of these exchangers decreases due to fouling. An optimised management of the cleaning cycles will result in a higher overall energy efficiency.
The goal of the application of the technologies developed in CoPro to the Lenzing use case is to achieve a plant-wide coordinated operation of the recovery section, in particular by optimal planning and scheduling of cleaning steps and an optimal choice of the equipment and resources that are used in the operation.
P&G operates one of its largest detergent making plants in Europe where it co-locates with other companies for collaborative production and operates several platforms of products. The site makes hundreds of different complex products, including a range of detergents. Some ingredients are shared but many different formulations are produced combining both continuous and batch processing steps. All products require synchronised packing of bottles, tubs and bags as well as palletisation units. The production needs to be real time demand-driven by retail customers.
The integration is so far mostly manual on the basis of individual process controls and would tremendously from integration.
Specifically, the key challenges that will be addressed in CoPro are:
FRINSA DEL NOROESTE (Ribeira, Spain) is the third largest canning company in Spain. The factory processes more than 500 t/day of 25 different raw materials and produces an average of 3.5 million units per day of more than 3,500 different finished products.
The utility network that supplies thermal energy for cookers, sterilisers and Cleaning in Place includes a cogeneration plant. So far, daily site production is planned for the year ahead using a central plan in SAP and Excel, then planned monthly, and rescheduled manually on a weekly and daily basis in response to product demand (different products and formats), raw material availability (at competitive prices), unpredicted downtimes, CIP and failures.
Typically, more than 40 Process Orders of different products coexist along the plant, even in the same process line. Materials have to pass through batch and continuous processes along their routes, FRINSA's main challenge to be tackled is to optimally plan and schedule equipment operations and processes, continuous (filling and packing) and batch (cooking and sterilisation) in order to minimise waiting times, downtimes, avoiding coupling and queues), reduce lead-time and plant energy consumption.
Different products can coexist in different units and changeovers may happen while the previous Process Order is still running. In particular, the coordination of the operation of cookers and sterilisers is required what may include readjustments of temperature/pressure set-points for the different units. The underlying optimal control problems need to be solved on a real-time basis and must take into account quality and safety specifications (lethality) that must be estimated from the available sensors.
The CoPro Consortium comprises the following 17 partners from 8 European countries, including 5 large industrial companies (end users), 3 academic partners, 2 research institutes and 7 SMEs.
TU Dortmund is a leading German Technical University, located in the Ruhr Region. The CoPro project is coordinated by the Process Dynamics and Operations Group in the Department of Biochemical and Chemical Engineering, headed by Prof. Dr. Sebastian Engell. The focus of the group is on advanced control, plant-wide coordination and scheduling of production units, with an emphasis on robustness against the mismatch between models and reality. The Coordinator is supported by the Reserach Support Services team at TU Dortmund which has considerable experience in managing EU projects from FP6 to Horizon 2020.
INEOS in Köln operates a large petrochemical site where the process plants produce key raw materials for other INEOS businesses and for external customers. INEOS in Köln benefits from economics of scale and close proximity to both feedstock and customers as well as from the high integration with the different plants for derivatives, such as ethylene oxide, propylene oxide, acrylonitriles and others. The highly integrated site at Cologne is focused on high reliability, quality and cost leadership with a strong integration of both the production units and the energy network.
Covestro Deutschland AG is among the world’s leading manufacturers of polymers and high-performance plastics. Our innovative developments in polycarbonates, polyurethanes, coating, adhesive and specialty raw materials enhance the design and functionality of products in a wide variety of markets. Key customers include the automotive and construction industries, the electrical and electronics sector, manufacturers of sport and leisure goods, and representatives of the healthcare and medical technology sectors. Covestro employed a workforce of 15,800 in 2015 and generated sales of EUR 12.1 billion. The company is present around the globe, operating 30 sites in Europe, Asia and the Americas, eight of them being world-scale production facilities with annual capacities exceeding 100,000 metric tons.
Procter & Gamble Services Company NV is a global leader in consumer products with several thousand innovators in development centres and more than 20 plants. The Brussels Innovation Centre consists of the key activities for holistic product innovation for Fabric and Home Care products. These activities include technology development, consumer understanding, product design, package design, process design, industrial and brand design as well as engineering. It is one of the 3 Mega Innovation Hubs in Europe.
The Lenzing Group is a world market leader headquartered in Austria, with production sites in all major markets as well as a worldwide network of sales and marketing offices. Lenzing supplies the global textile and nonwovens industry with high-quality, botanic cellulose fibers. Its portfolio ranges from dissolving wood pulp to standard and specialty cellulose fibers.
Frinsa is one of the largest European manufacturers of canned tuna and seafood. Founded in 1.961 in Ribeira (Galicia - Spain) the company is focused in the obtaining the highest quality responding to customer expectations in a sustainable and environmentally friendly way.
The University of Valladolid is the second oldest in Spain, its origins can be traced back to the XIII century. The Supervision and Process Control research group participates in CoPro, headed by Prof. Cesar de Prada, and focuses its research on advanced process control, process optimisation, process supervision and modelling and simulation. The group tries to combine research on new methods and algorithms with development of software systems and industrial applications oriented to optimal model based operation of large-scale processes.
EPFL is Europe’s most cosmopolitan technical university with students, professors and staff from over 120 nations. With over 350 laboratories and research groups on campus, EPFL is one of Europe’s most innovative and productive scientific institutions. Ranked top 3 in Europe and top 14 worldwide, EPFL has attracted the best researchers in their fields.
The work in CoPro is completed within the group of Industrial Process and Energy Systems Engineering (IPESE), directed by Professor François Maréchal. EPFL and IPESE work together with an extensive network of partners including other universities, institutes of technology, developing and emerging countries, secondary schools and colleges, industry and economy, policitical circles and the general public, to bring about real impact for society.
The Centre for Research and Technology-Hellas (CERTH) is the one of the largest in Greece and carries out fundamental and applied research in Chemical Processes and Alternative Energy Sources systems, among others. The Chemical Process and Energy Resources Institute (CPERI) of CERTH is the leading research institute and has participated in numerous EU and National projects related to energy field acting as a technology and systems integrator and demonstration case provider. CERTH has unique knowledge in system design, engineering and integration of industrial automation systems, supervisory control and optimisation for industrial processes combined with reactive scheduling and planning techniques.
The CSIC is an autonomous, multi-disciplinary public research body affiliated to the Spanish Government, covering most fields of science social sciences and technology. The CSIC has its own legal structure and is represented throughout the Spanish territory with a total of 132 centers/institutes.
LeiKon GmbH is an innovative company working in the area of process control engineering, vertical data communication and MES (Manufacturing Execution Solution). LeiKon was founded in 1999 as a spin off of the University of Technology Aachen (RWTH Aachen). LeiKon is a SME (Small and Medium Enterprise) and acts as consulter and system integrator of industrial automation systems in process industry. LeiKon has also more than 15 years experience in innovation and technology transfer as well as in industrial project management.
A lot of big companies of process industry are customers of LeiKon. Examples of industrial partners and/or clients of LeiKon: Bayer, BASF, Covestro, Evonik, Gaz de France, Ineos, Perstorp, SGL Carbon, Shell, etc. In the past, LeiKon accomplished successfully several R&D projects with industrial partners and/or RTD performers.
LeiKon was part of the past EU NMP project MORE (Real-time Monitoring and Optimization of Resource Efficiency in Integrated Processing Plants). LeiKon is also active in several standardization panels like NAMUR and DIN DKE K931 ‘System aspects in automation and process control’ (German mirror of IEC TC 65).
PSE is the world's leading supplier of Advanced Process Modelling technology and related model-based engineering and innovation services to the process industries. We help our customers to create value in their organisations through the application of advanced process modelling using our gPROMS platform technology.
divis’ core fields of expertise are data analysis, data driven modeling, and optimization for production processes and product development in industry. The main industries served are automotive, chemistry, oil & gas, and consumer goods.
Sabisu is the operational and project intelligence platform of choice for oil & gas, petrochemical and advanced manufacturing for customers such Shell, Sudzucker, Huntsman and SABIC. Sabisu ensures leadership teams deliver on their targets and commitments by providing analytics which anticipate limiting factors and collaboration which eliminates friction in the enterprise.
The goal of ASM is to provide efficient and innovative solutions focused on Business Management, Manufacturing Management and Process Optimisation, and MES-ERP Integration under a holistic approach helping our customers to move towards a flexible and collaborative manufacturing.
ORSOFT is a software provider specialising in Advanced Planning and Scheduling (APS) and Supply Chain Management (SCM) solutions. These solutions extend the planning capabilities of ERP-systems and create optimised production schedules.
inno is an EU-based innovation and technology transfer consultancy practice with its headquarter in Germany (Karlsruhe) and further offices in France (inno TSD), Germany and Sweden, employing approx 60 staff and having more than 20 years experience. inno specialises in innovation and technology transfer, university-industry cooperation, exploitation issues and IPR support, in dissemination and outreach, as well as in evaluation, benchmarking and impact assessment studies, and in project management. inno TSD, a French office of the inno-group and partner in CoPro, is established in 1986. Its track records include over 500 projects, from them about 30+ FP6/FP7/Horizon 2020 projects (IP, STREPs, research and innovation actions, support actions) and three SPIRE-related projects. inno TSD leads the European Cluster Collaboration Platform initiative.
Check out project outcomes in the following sub-sections:
D1.4 Report on model reduction for optimization and control
March 2018 (pdf - 1.8 Mo)
D2.2 Preliminary report on tools for anomaly detection
April 2018 (pdf - 1.8 Mo)
D3.1 Preliminary report on optimisation methods for large plants with discrete and continuous degrees of freedom
April 2018 (pdf - 2.7 Mo)
D3.4 First report on methods for distributed optimisation of plants with shared resources
April 2018 (pdf - 2.2 Mo)
D4.1 First Report on techniques for plant-wide reactive scheduling
March 2018 (pdf - 2.9 Mo)
D5.1 Report on new multi modal HMI concepts
April 2018 (pdf - 2 Mo)
D5.3 Requirement specification and functional design specification of the CoPro integration framework
October 2017 (pdf - 1.61 Mo)
D7.4 First report on standardization activities
April 2018 (pdf - 1.2 Mo)
Volume 110, February 2018
C.G. Palacín, J.L. Pitarch, C. Jasch, C.A. Méndez, C. de Prada, Robust integrated production-maintenance scheduling for an evaporation network Full Paper
C.G.Palacín, J.L. Pitarch C. de Prada, C.A. Méndez, An Efficient Way to Tackle Uncertainty in the Scheduling of a Continuous Evaporation System Abstract
S. Wenzel, V. Yfantis, W. Gao, Comparison of regression data selection strategies for quadratic approximation in RTO Abstract
L. S. Maxeiner, S. Wenzel, S. Engell, Shared resource allocation in the process industries via price-based coordination for systems with discrete decisions Abstract
Full papers are available in the Proceedings of the European Symposium on Computer Aided Process Engineering (ESCAPE27), Oct. 1st – 5th, 2017, Barcelona, Spain, (pp. 1411-1416, pp. 1711-1716 and pp. 1897-1902)
L. S. Maxeiner, S. Engell, Hierarchical MPC of Batch Reactors with Shared Resources Abstract / Full paper
S. Nazari, S. Wenzel, L. S. Maxeiner, C. Sonntag, S. Engell, A Framework for the Simulation and Validation of Distributed Control Architectures for Technical Systems of Systems Abstract / Full Paper
S. Wenzel, R. Paulen, B. Beisheim, S. Krämer, S. Engell, Adaptive Pricing for Optimal Resource Allocation in Industrial Production Sites Abstract / Full paper
3-6 July 2017 - Valletta, Malta
G.C.Palacín, J.L. Pitarch, C. de Prada, C.A. Méndez, Robust Multi-Objective Scheduling in an Evaporation Network
Full Paper: https://doi.org/10.1109/MED.2017.7984194
Kick-Off Meeting (November 2016)
Plenary Meeting in Thessaloniki, Greece (November 2017)
Project Poster (February 2017)
Project Flyer (May 2018)
Prof. Dr. Sebastian Engell
Process Dynamics and Operations Group
Biochemical and Chemical Engineering Department
44227 Dortmund, Germany
Phone: (++49/0) 231 755 5126