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Industrial Park 4.0Cairo, Egypt
Hannes Utikal, Provadis, Frankfurt/Germany
15.03.2018 Inernational SIA Conference, Cairo, Egypt 1
15.03.2018 Inernational SIA Conference, Cairo, Egypt 2
1. Introduction
2. Industry 4.0: The big picture
3. Industry park 4.0: Selected use cases
4. Industry 4.0 and the circular economy: Be Circle
5. Summary
Prof. Dr. Hannes Utikal
Focus: Strategic Management andSustainability
Lead of the Center for Industry andSustainability at Provadis/Frankfurt
Lead of Climate KIC Frankfurt/Hessen
Editor of the Journal of Business Chemistry –the academic journal for management issuesin the chemical industry
Ambition:
Develop and establish a management sciencefor the chemical and pharmaceutical industry
- 3 -
Our project groups:debating events
Industrie 2030
Provadis Center for Industry and Sustainability
We support the industry in their sustainable development
Clean-tech start-up support; Professional education; Applied research
Provadis CampusIndustrial Park Höchst
Industriepark Höchstat a glance.
7
Total area:
460 ha
2016 investment in the site:
€ 341 mn
Rental buildings:
980
Available area:
50 ha
Companies:
90Employees:
22,000
12
Optimization
software:
emissions
compliance
Remote monitoring
secure surveillance of all plant
processes
Integrated asset
management:
improved capacity and
availability
Digital valves:
detect process
abnormalities
Planning & control
system provides reliable,
precise plant control.
24/7
Monitoring of machines:
early detection and diagnosis of
production problems
Industry 4.0 - The physical and the virtual worlds intertwined
Industrial park 4.0 – Selected use cases
15.03.2018 Inernational SIA Conference, Cairo, Egypt 18
Focus Planning
Digital Plant
Predictive Maintenance
Focus Coordinating
Digital Check-In/Out
E-Platforms
Focus Producing:
3D-printing
Focus Qualifying:
Training/Consultancy
A digital distribution platform for match-making between producers and customers
15.03.2018 Inernational SIA Conference, Cairo, Egypt 19
Industrial park Frankfurt-Höchst:
Companies on site communicate
their estimated electricity and
steam demand
Infraserv consolidates the
information and gives feedback
on energy sources (coal, gas,
renewables), availability and
prices
Companies may shift their
production for some minutes /
hours to avoid peak power prices
Effects:
Reduced costs
Reduced
environmental
footprint
Industrial park 4.0 – Use Case - E-Platform
15.03.2018 Inernational SIA Conference, Cairo, Egypt 20
Anticipate defects and predict the best time for maintenance to allow maximum productivity
Predictive maintenance requires the
collaboration of multiple stakeholders:
Producing industry for process
know-how
Asset & component vendor :
Asset expertise; benchmark
Software providers:
Predictive asset models
Maintenance Provider:
Maintenance history; operative
maintenance planning
Effects:
Reduced costs
Reduced
environmental
footprint
Industrial park 4.0 – Use Case - Predictive Maintenance
Estimated benefit:reduce downtime
up to 50%
15.03.2018 Inernational SIA Conference, Cairo, Egypt 21
Training
Provadis 4.0
• Test of digital support for workers
on the shopfloor level (e.g. via
augmented reality)
• Blended learning concept for
supporting startups (9 European
countries)Effects:
Reduced costs
Increased quality
and flexibility
Focus on
sustainability
Industrial park 4.0 – Use Case Training
We make the circular economy work for you!
OBJECTIVE
24
To develop an operational set of
services for industrial businesses and
their ecosystem in order to facilitate
their transition to a circular economy.
The services consists in a personalized
approach to answer economic and
environmental performance issues.
It is based on an advanced modeling
platform that helps to:
DEVELOP WIN-WIN SYNERGIES
WITHIN THE INDUSTRIAL
ECOSYSTEM BASED ON
POTENTIALS FOR SAVINGS AND
NEW SOURCES OF INCOME
DECARBONIZE THE INDUSTRIAL
ACTIVITIES
OPTIMIZE LAND MANAGEMENT
PROJECT KEY FIGURES
25
7 European
partners
1.7 million euros
invested
1.1million euros
EU funded 2 years project
2+ beta-testers
30 + working
community
TWO VALUES
26
An enhanced representation
of industrial territories based
on a multilevel modeling
• Geographical characteristics and
infrastructures (networks, hubs…)
• Economic assets (companies,
resources flows circulating)
Analysis:
• Level of dependency regarding the
resources consumed
• Level of intra-connectivity
• Level of accessibility of vacant plots
• Potentials for mutualization of
imports/exports means
• Potentials for resources exchanges
A simulation tool for
assessing the performance of
alternative scenarios
• Modeling of the industrial site’s
components (plant model), accuracy
depending on the clients’ needs
• Modeling of the utilities equipment
• Modeling of the exchanges with
neighboring industrial sites
• Simulation of current and alternative
scenarios about resources and
technologies choice and use, with
technical ratios
• Integration of seasonality
• Assessment of economic and
environmental KPIs
• Optimization of technologies choice
and sizing
ILLUSTRATION #1: VISUALIZE THE LEVELS OF ACCESSIBILITY OF LAND PLOTS
27
Visualization of plots’ levels of
accessibility regarding transportation
networks (rail, waterways, road) and
other networks and pipes (energy,
water, gaz, H2…)
Identification of the best plots
regarding a prospect’s specific needs
in terms of:
- Volumes
- Imports/exports frequency
- Type of products
imported/exported
- Minimum area
ILLUSTRATION #2: ASSESSING A CONNECTION TO HYDROGEN NETWORK
28
Drawing of a H2 network extension
to answer new / prospective needs
First estimation of feasibility thanks
to technical ratios
Evaluation of economic and
environmental KPIs
If necessary : suggestion of an
optimized layout according to
prioritized KPI and estimated
technical feasibility
Scope: upstream and strategic-level
discussions with key partners, prior to
feasibility/engineering studies
Run of simulation scenarioH2
H2
PROGRESS
29
Today (sprint 1)Shell for web app and
administrator app
End 2017First functionalities operational
Summer 2018Integration of time series and
optimization
Spring 2018Most of « static »
functionalities operational
End 2018Ready to go to market
15.03.2018 Inernational SIA Conference, Cairo, Egypt 30
Industry 4.0 and industry park 4.0 – Summary
Industry 4.0 is a long term vision. The vision focusses on the benefits of cyber-physical systems. These systems are interconnected via the internet of things and supported by cloud computing/ artificial intelligence.
Benefits of Industry 4.0 can be significant: Reduced costs, increased quality, higher flexibility, new business models, reconfiguration of value networks.
The effect of Industry 4.0 varies by industry sectors: While some sectors are confronted with disruptive developments (e.g. media), other industries like chemicals are on a more evolutionary path.
The effect of industry 4.0 on industry parks depends on the prevailing production structure (process vs. discrete production) and the integration of the industry park into global value creation networks.
Individual use cases highlight how industry 4.0 may support not only production planning and steering, but the physical production as well.
Individual use cases highlight the barriers of a fast industry 4.0 revolution: data availability, data compatability, IT security and the need to protect IP.
Industry 4.0 can support sustainability goals: environmental and social criteria may be integrated in all optimization efforts. The circular economy can be enabled by identifying and optimising relevant resource flows – within and beyond the individual industrial park.
