Industry 4.0

The integration of industrial production with modern information and communication technologies is essential for the optimization of the value chain. On the way to a self-organized and fully automated production, people, machines, plants, logistics and products must communicate and cooperate.
Our goal is to develop the automated production of the first phase of digitization into an intelligent and digitally networked system of Industry 4.0 (second phase of digitization). The steps to this process are:
  • Digitization of your production processes into a simulation model
  • Connection of the digital factory model to the programmable logic control system (PLC)
  • Implementation of early-warning and assistance systems: soft sensors for the monitoring of difficult to measure or critical values ​​(e.g. concentrations, heat flows or fouling factors)
  • Development of an online optimization

 How it works

As a first step, a validated process simulation model is developed as a digital image of the plant. This is then connected to the existing process control system via the CHEMCAD internal OPC interface, through which the data exchange takes place.
Goals:
  • Networking
  • Technical Assistance
  • Decentralized decision making mechanism
  • Transparency
  • Increased efficiency
  • Flexibility
  • Safety
  • Soft sensors
  • Online optimization
 
OPC interface to build an online training system for plant operators
OPC (OLE for Process Control) is a standardized interface for the transmission of data. CHEMCAD can be connected to any other OPC-compatible program, including current process control systems (e.g. Siemens, ABB) through this interface.
OPC interface can also be utilized for the development of an online training system (OTS) for the education of system operators. The basis for the OTS is a dynamic simulation of the production plant, which is operated via the OPC interface.
Digitization of the production plant
On the basis of a digital image of the production plant, all processes as a whole can be examined. Through the process simulation, operators and engineers receive details on the interaction of the equipment and piping networks, including an overview of all current data information:
  • Temperature
  • Pressure
  • Compositions
  • Enthalpy
  • Physical state
  • Viscosity
  • Heat capacity
  • Density
Together with the simulation model, this information builds the basis for optimization.During the optimization equipment and process data is modified in order to increase energy and resource efficiency and optimize economic feasibility.
Goals:
  • Inspecting the entire system
  • Stream data provides important insight into the process
  • Analyzing the improvement possibilities
  • Check plant design for errors
  • Impact of new equipment and process conditions

Our other consulting services:

PROCESS OPTIMIZATION
FEASIBILITY STUDY
EQUIPMENT DESIGN
ENERGY CONSULTING
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