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CoPro: Intexc Suite – Seamless integration of model-based real-time solutions into production IT environments

The Problem Model based applications provide an important contribution to optimised plant operations. It is still a challenge to integrate model-based real-time solutions with the existing heterogenous IT-systems in the plants. Time and effort to integrate real-time model-based applications into IT-System environments must be reduced. The Solution The Intexc Suite – an integration platform for real-time data orchestration of distributed model-based applications in the process industries....
Type:
Case study, Other, Software, Poster

CoPro: Optimisation of the operation of heat exchangers

The Problem Heat exchangers are crucial elements for the reduction of the energy demand of the processing industry. Heat exchangers often suffer from fouling, which decreases the heat transfer and thus the efficiency of the process. Cleaning is needed to recover nominal efficiencies. The optimal time for cleaning depends on the usage of the heat exchangers. Overall, these are many operation decisions difficult to take for the plant personnel. The Solution A methodology for monitoring the...
Type:
Case study, Software

CoPro: Optimum operation of an evaporator network in viscose fiber production

The Problem Recovery of the spinbath is the process with the highest energy demand in viscose production. An evaporator network with 29 different evaporators is used for the reconcentration of the solution in different product cycles. The efficiency of the evaporators depends on the type, volume flow rate, temperature and fouling effects. The Solution A decision-support system (DSS) for the assignment of evaporators to different product cycles was developed in a cooperation of Lenzing AG and TU...
Type:
Case study

CoPro: Large-scale production scheduling in the food industry

The Problem Food process industries are typically characterised by the production of multiple products using flexible multi-stage facilities under tight operating and design constraints. The optimal production scheduling of such a complex facility is a very challenging and demanding task, and existing solutions cannot generate schedules in computational times that are acceptable in industrial practice. This complexity forces production engineers to derive production schedules that underutilise...
Type:
Case study, Other, Software, Poster

CoPro: Optimal operation of sterilisation processes in food production

The Problem Sterilisation is a crucial process in order to fulfill sanitary constraints in the food industries. At Frinsa, the sterilisation process is performed  in a set of parallel batch sterilisation units that are placed between continuous processing lines. Being an energy-intense process, steam is a limited common resource for the sterilisers, and its availability influences their processing times. Due to food safety constraints, there is a maxi mum waiting time for every sterilisation...
Type:
Case study, Software, Poster

CoPro: Optimisation of the production and procurement of technical gases

The Problem At the ChemPark in Dormagen, Covestro operates several networks for technical gases, which connect Covestro’s internal consumers as well as external clients with the internal production. Due to changes in plant operation, the demand within the networks can change several times per day. Contracts with multiple suppliers are in place. These contracts are tiered and coupled. The optimal procurement of the gases is a complex task.

 

The Solution An advisory tool for the...
Type:
Case study, Software, Poster

CoPro: Optimisation of the operation of an industrial power plant under demand uncertainty

The Problem INEOS in Köln operates a power plant that incinerates off-gases of the production plants and produces steam and a part of the electricity that is required for plant operation. The steam demand of the site depends on the operation of the plants which is exposed to uncertainties. An imbalance in the steam network results in inefficient operation of the power plant. The Solution A framework for the optimal operation planning of the power plant considering uncertainties in the steam...
Type:
Case study, Software, Poster

CoPro: Large-scale optimisation of production and logistics in chemical plants

The Problem INEOS in Köln operates a large number of production plants that are linked by streams of intermediates and carriers of energy. The overall performance and efficiency of the site depends on the coordination of the individual plants and the coordination of external logistics via barges, trains and pipelines. An example of such site-wide integrated optimisation is the ammonia network of INEOS  in Köln. The Solution A site-wide optimisation model composed of modules for plants and...
Type:
Case study, Software, Poster

CoPro: Anomaly detection in polyethylene production

The Problem Unforeseen plant failures cause production  shut-downs and may lead to damages. Early predictions of such failures enable corrective actions and ensure resource efficient and sustainable production. Decompositions in polyethylene plants are major upsets that should be avoided.

The Solution

Application of machine learning algorithms for anomaly detection and prediction. Prediction of plant failures in polyethylene production using those algorithms. Integration into divis’...
Type:
Case study, Software, Poster

CoPro: Operator support for improving energy and material efficiency

The Problem The process industry continuously searches for options to move towards a more energy and resource-efficient production. Chemical production plants are complex systems, and the most resource-efficient operation is not easy to identify under varying conditions. INEOS in Köln has been looking for a solution in between full automation operation at standard constant reference values to improve the resource efficiency of their production plants. The Solution A data-based surrogate...
Type:
Case study, Poster

CoPro: Cross-company site-wide optimisation without sharing of sensitive data

The Problem Large chemical sites consist of several independently managed production plants. There is a high degree of integration and coupling via streams of energy and material. Site-wide optimisation is difficult due to the problem size and confidentiality reasons. There is a large unexploited economic and ecologic potential. The Solution Coordination by a neutral coordinator to improve the efficiency of the site. Consumption and production of shared resources is charged at certain prices....
Type:
Case study, Software, Poster

CoPro: Planning and scheduling of make and pack processes

The Problem Scheduling optimisation for companies from the consumer goods industries, such as P&G, is a challenging task due to the continuously increasing demand, tight operating constraints and the large variety of similar products. Efficient models are missing to derive nearly optimal solutions that minimise the changeover times, which causes production down times and an unnecessary use of resources. The Solution Optimisation-based solutions were developed for the scheduling problem of...
Type:
Case study, Other, Software, Poster