The annual Smart Process Manufacturing Congress in Würzburg, Germany, has established itself as one of the top addresses for all experts in the German process industry for whom Digitalization is not just a buzzword. This year, on September 24 and 25, 2024, the congress took place at the Vogel Convention Center (VCC) in Würzburg under the guiding theme Decarbonization, energy efficiency, circular economy – digitalization brings together what belongs together.
Like in the previous year, INOSIM again has supported the SPMK with an eye-opening talk and by hosting a meeting of the process simulation working group (AKPS) in Würzburg in connection with the congress.
How digital twins can create added value across the entire life cycle
Together with experts from CSL Behring and ZETA, INOSIM’s Head Of Innovation, Dr. Christian Sonntag, presented a talk about how simulation models can be used in engineering and operations, with the following title:
Bridging the Engineering-Operations Continuum: How digital twins can create added value across the entire life cycle
In the face of climate change and the current economic and political situation, the process industry is facing unprecedented challenges. Due to energy scarcity, rising prices, shorter time–to–market and increasing competitive pressure, speed, flexibility and maximum efficiency are more important than ever. These goals can only be achieved by fully digital data storage and seamless integration of digital tools over the entire life cycle of a plant.
The new 400 M€ plasma fractionation plant of CSL Behring was recently put into operation in Marburg, Germany. It serves as an ideal case study for the benefits of a consistent use of digital twins. Already during the feasibility study, the first digital twin was generated with the help of INOSIM Simulation Software. Throughout the following phases, it was systematically refined to answer specific questions: In the early phases, process alternatives were compared quantitatively, capacities estimated or apparatus sizes determined. In later phases, the simulation supported the design of cleaning systems, utilities, buffers preparation by precise prediction of dynamic resources demands. It also ensured process robustness under uncertainties, and was used to determine optimal operating modes. Simulation was also reported as extremely helpful for the automation and production planning team.
In addition, the participants learned in Christian’s talk:
- How ZETA‘s integrated methodology for end–to–end engineering and operation of batch production plants made planning more efficient and faster.
- How INOSIM Digital Twins enabled minute–to–minute predictions of all production processes at all stages (from feasibility study, concept, basic, and detail engineering to manufacturing and qualification to operation).
- How the Digital Twin generated during the feasibility study could be systematically refined over all phases using engineering data from a digital smart-engineering platform.
- What added value the Digital Twin created in all phases.
- Why the Digital Twin displayed its greatest advantage after commissioning and what role our innovative software for predictive production support, INOSIM Foresight, played in this process.
An illustrated review of the Smart Process Manufacturing Congress 2024 is available on the event‘s homepage.
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