Digital Twin Technology for Operational Excellence : Use of Aspen Plus Software for Digitalization
In modern industry, staying ahead demands both innovation and strategic use of cutting-edge tech. Digital twins, virtual replicas of physical assets and processes, are a game-changer. They mimic real-world behavior, allowing for analysis, prediction, and optimization. For example, in optimizing benzene-toluene separation, a company used digital twins to reduce costs and enhance efficiency. This technology is reshaping industries by offering insights and solutions that were once unimaginable.
What is a Digital Twin?
A digital twin is a virtual representation of a physical object or system, leveraging real-time data and simulations to mimic its behavior, performance, and interactions. It essentially creates a digital counterpart that mirrors the physical entity, allowing for analysis, prediction, and optimization in a virtual environment.
How Digital Twins Work ?
Digital twins operate on the principle of data integration and advanced analytics. They are fed with real-time data from sensors, IoT devices, and other sources, creating a dynamic model that reflects the actual state of the asset or process. Advanced simulations and algorithms then analyze this data to simulate scenarios, predict outcomes, and optimize performance.
Case Study : Study of Benzene-Toluene Separation Plant and its optimization
Consider a company grappling with suboptimal benzene-toluene separation, leading to costly offsite processing and operational disruptions. Embracing digital twin technology, they constructed a virtual model using tools like Aspen Plus and hydraulic modeling. This digital replica not only identified inefficiencies but also charted a path to enhanced performance.
Through rigorous simulation and analysis, the company pinpointed a redundant column as a potential solution. Validating this within the digital twin environment, they achieved the desired separation locally, saving $2.4 million annually and streamlining operations. This success wasn’t just about cost savings; it empowered continuous improvement, fine-tuning processes, and optimizing controls for sustained efficiency gains.
In essence, digital twins are more than virtual mirrors; they are catalysts for innovation and informed decision-making. They enable companies to navigate complexities with agility, drive operational excellence, and pave the way for sustainable growth in today’s dynamic business environment.
Use of Aspen HYSYS and Aspen Plus, for creating robust virtual replicas of physical assets.
Aspen Plus and Aspen HYSYS, with their capabilities in steady state and dynamic simulation, are indispensable tools in the creation of robust digital twins for industrial processes.
Aspen Plus excels in steady state simulation, allowing engineers to model and optimize chemical processes under constant conditions. This includes detailed thermodynamic calculations, equipment sizing, and material balance analysis. By accurately representing the steady state behavior of a system, Aspen Plus forms the foundation for a reliable digital twin.
On the other hand, Aspen HYSYS specializes in dynamic simulation, capturing the transient behavior and response of processes to changing conditions. This includes startup/shutdown sequences, process disturbances, and control system dynamics. Aspen HYSYS’s dynamic simulation capabilities enhance the digital twin by providing insights into process dynamics, control strategies, and performance under varying scenarios.
How we will help ?
A key aspect of staying competitive in dynamic industries like refining, petrochemicals, and textiles. Adapting to technological advancements and changes in materials and specifications is crucial for maintaining market leadership. Tools like Aspen Plus and the aspenONE Engineering suite play a vital role in predicting, validating, and optimizing plant performance under varying conditions. This adaptability ensures that organizations can stay ahead in an ever-evolving market landscape. ChemKlub is a top choice for digitalization in the chemical industry because of its expertise in process simulation tools like Aspen Plus and HYSYS, enabling accurate digital twins for enhanced operational efficiency and decision-making.