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Energy Reduction and Emissions Savings through Digitalization and Collective Participation

This ARC report discusses the implementation of digitalization and collective participation in Prayon production facilities to achieve energy reductions and emissions savings. The report highlights the approaches, workshops, and advanced analytics used to identify and address variability and improve operational efficiency. Case studies on sodium-phosphate salts, steam network optimization, and purified phosphoric acid demonstrate substantial cost savings without capital investments.

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Energy Reduction and Emissions Savings through Digitalization and Collective Participation

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  1. ARC 2016 03

  2. Des réductions d’énergie et d’émissions grâce à la « digitalisation » et … à la participation collective

  3. Prayon – production facilities Engis Head office Belgium Puurs Belgium Les Roches de Condrieu France Augusta Prayon Inc. USA 3

  4. Prayon - Products Prayon - Products 4

  5. Energy Target : 12 % reduction

  6. Emissions CO2

  7. SAVINGS THROUGH OPERATIONAL MANAGEMENT Procurement Investments Operations

  8. Workshops Diagnostic analysis Deployment Gap Analysis Follow-up Training Approach Roadmap ENERGYmaestro APPROACH FLASH Monthly 2-3 weeks 1-2 weeks 6 weeks 4 weeks 1-2 weeks

  9. APPROACH:Gap analysis Gap analysis Implementation Training & follow-up Advanced analytics Workshops • Define initial KPIs • Analyse and quantify historical variability against baseline target of initial KPIs. Nb of hours Specific energy Period where much higher that target Potential Savings Period where on/lower that target Time

  10. APPROACH:Workshops:Profits tree indentification Gap analysis Implementation Training & follow-up Advanced analytics Workshops • Workshops with operators and plant staff • Brainstomring root causes of variability and process improvement ideas • Objective to engage operators in the project • Ideas presented on a cause tree • Cause tree communicated to operators

  11. Reporting structure at PRAYON Gap analysis Implementation Training & follow-up Advanced analytics Workshops CORPORATE LEVEL SITE LEVEL PLANT LEVEL LINE LEVEL

  12. ENERGY DASHBOARD AT CORPORATE LEVEL Gap analysis Implementation Training & follow-up Advanced analytics Workshops

  13. APPROACH:Advanced Analytics:Root Causes Analysis model Gap analysis Implementation Training & follow-up Advanced analytics Workshops Decision trees machine learning to map impact of top parameters on efficiency

  14. Gap analysis Implementation Training & follow-up Advanced analytics Workshops • Develop useful indicators in control screen • Developor update daily/weekly/monthly reporting • Tracking of root causes for loss of performance

  15. APPROACH:Training plant staff Gap analysis Implementation Training & follow-up Advanced analytics Workshops • Training of plant staff and operators on control screens, reports and regular monitoring

  16. APPROACH:Follow-up and KPI/KPE updates Gap analysis Implementation Training & follow-up Advanced analytics Workshops A. DCS – real time B. Production report daily C. Monthly reviews Evaluate and update dynamic target models for continuous improvement

  17. Sodium - phosphate salts– Roches (FR) METHODOLOGY • Methodology and advancedanalyticssupported by PEPITe sa • 20 kEur/yearwithin 6 monthswithoutcapex SAVINGS : 20 kEur/Year ADVANCED ANALYTICS

  18. Steam network optimization – Engis (BE) METHODOLOGY • Methodology and advancedanalyticssupported by PEPITe sa • 400 kEur/yearwithoutcapexsince 2012 SAVINGS : 400 kEur/Year ADVANCED ANALYTICS

  19. Purified phosphoric acid – Puurs (BE) METHODOLOGY • Methodology and advancedanalyticssupported by PEPITe sa • 300 kEur/yearwithin 6 monthswithoutcapex SAVINGS : 300 kEur/Year ADVANCED ANALYTICS

  20. KPI for all decision levels Integrated project team Data availability and quality Management and operator involvement Advanced analytics capabilities Facteurs clés de succès

  21. Conclusions • Participation des personnes clés • Support de la hiérarchie • Distribuer les bonnes informations, aux bons destinataires, au bon moment. • Communication • Utiliser les technologies de l’information

  22. Vos questions ?

  23. Merci pour votre attention

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