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Find out how AVEVA customers are putting industrial intelligence to work
- Covestro
- Elkem
- Coromandel
When an idea becomes innovation
Covestro decision makers made a bold move. They committed to reducing both the direct emissions they produce, and the indirect emissions associated with the energy they use, to achieve net-zero emissions by 2035.
Achieving this would undeniably make the polymers producer a sustainability leader in the industry.
To meet this ambitious goal, the team planned to:
- Innovate new ways to close energy and material cycles
- Reinvent and redesign chemical processes towards circularity
- Design revolutionary green polymers with renewable, bio-based raw materials
Covestro’s experienced engineers had a lot of ideas for how to reach these objectives, but not a lot of time. This is where AVEVA's software enabled them to make a step change.
To determine the environmental, technological, and economic feasibility of their new process ideas, they needed to deploy rigorous theoretical models to test efficiency.
We needed a tool to quickly and efficiently assess how real the impact of a new process would be, economically, technically, and in terms of environmental impact.
Easy-to-customize means easy-to-visualize
Typically, new and advanced processes are notoriously difficult to model, but Covestro was already using AVEVA process simulation technology. This enabled the team to easily adapt existing models and create new ones. Applying this approach in a new area of the business gave Covestro engineers an edge in the race for viability and eventually, deployment.
Also, by leveraging the AVEVA software’s open architecture, Covestro’s teams easily integrated additional code to customize the models. With all three tools connected, it was easy to generate the required mass and energy balances and simple to update the outputs when required, reducing effort. Covestro’s teams avoided copying and pasting values and manual data entry, saving valuable time in the company’s race to market.
Flexibility, agility, scalability: Choose three
As the circular economy continues to develop at breakneck speeds, enterprises in chemical, oil and gas, and related industries are looking to gain market share quickly. The flexibility, agility, and scalability AVEVA software delivers are a gamechanger. And by putting industrial intelligence to work, Covestro gains an early competitive edge.
We have a really close development partnership with AVEVA, and together, we make AVEVA Process Simulation a living software that evolves as new needs arise.
When centralization becomes realization
Elkem is leading the way in advanced silicone production, with a bold mission to shape a better, more sustainable future. But it faced a challenge.
With 11 different control rooms across its Norway site, operations monitoring was fragmented and hampering real-time collaboration among teams.
It was time to rethink. Elkem needed to accelerate its progress towards sustainable product development, so the team turned to AVEVA.
We needed to see things differently. Instead of taking what we had and stripping it down, we needed to build something new. It was clear that the UOC could be the product for this.
A thousand insights, one unified perspective
AVEVA’s Unified Operations Center (UOC) gives Elkem a single, centralized platform to visualize operations. One that aggregates and visualizes data in real-time and where large-scale screens display a holistic view of the entire value chain.
Unifying control rooms into a single pane-of-glass view provides a visualization of the performance of all monitoring and control systems. Elkem’s team makes decisions more quickly and is enabled to focus on more important tasks.
Improvements were immediate: start-ups, shutdowns, changeovers, and safety procedures all ran more efficiently. Downtime decreased and operational efficiency increased.
Operators from different departments now sit together, learning from one another and building their knowledge. Moreover, when other stakeholders view the UOC, they too can gain operational insights without distracting technicians.
Meanwhile, the UOC's “wow” factor inspires employee pride and serves as a powerful recruitment tool that attracts talent to the remote Norwegian location.
Ready for everything
By putting industrial intelligence to work, Elkem has significantly elevated operator readiness and situational awareness, boosting product quality and stability across its supply chain.
With Elkem's critical role in supplying materials for smartphones, cars, and even NASA, maintaining operational excellence is critical. The UOC swiftly highlights operational issues, thereby enhancing safety and minimizing downtime.
By ensuring safe and cost-effective production processes, Elkem not only safeguards its reputation as a trusted supplier, but also upholds the integrity of consumer goods and critical industries worldwide.
The operators see where the work is in the now. This boosts confidence in handling processes. Operators are really in charge, and they have much better control.
When connection becomes expansion
A leading player in agrochemicals, Coromandel faced a significant challenge in managing and analyzing vast amounts of operational data.
The team was grappling with optimizing disparate data sources across 15 manufacturing plants. There was no centralized system for data management and analysis, making it difficult to extract actionable insights and make effective decisions. Integrating third-party tools was also challenging.
Coromandel’s engineers were struggling to optimize processes, enhance productivity, and ultimately maximize profits. To resolve these issues, Coromandel needed a technology partner who could help them drive a step change in delivery.
The Coromandel team were considering various platforms. Together, we went through a rigorous process, qualifying each and every criterion. The AVEVA PI System fulfilled all of them.
Elevating efficiency elevates performance
To address these challenges, Coromandel selected the AVEVA PI System, to help them centralize data management and analysis. The templatized structure of the software simplified the integration of different plants and data sources, providing a holistic view of the entire value chain and enhancing operational efficiency.
Coromandel created a unified platform enabling seamless data integration and establishing a basis for advanced analytics and machine learning. The centralized information infrastructure facilitated real-time production monitoring, asset reliability, and digital maintenance. As a result, the team could increase operational throughput.
Moreover, the team identified three distinct dashboards, tailored to drive differentiated value for plant operators, operator supervisors, and central office operators. These enabled comprehensive analysis by each team, comparing all plants across the network, ensuring optimal efficiency and output.
Use cases such as evaporator predictive maintenance and nutrient prediction were implemented, leading to significant improvements in yields. The wide range of applications managed through the platform, from raw material movement automation to digital twin production, underscores its versatility and effectiveness.
The transformative power of innovative technologies
As industries increasingly embrace digitalization, Coromandel's success story serves as a testament to the immense value strategic investments in digital solutions can deliver.
Leveraging AVEVA software, Coromandel’s team overcame its data management challenges, unlocking new opportunities for efficiency gains, profitability, and enhanced competitiveness. And by putting industrial intelligence to work, Coromandel grew profitability and achieved a substantial return on investment.
Leveraging the AVEVA PI [System] interfaces was key. The out-of-box functionality allowed us to do this with an extreme amount of velocity.
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