Under-the-Radar Innovations in Chemistry, Part 3: Digital Twins – Transforming Operations from Design to Maintenance

What Are Digital Twins?
Digital twins are virtual replicas (dynamic simulations) of physical assets, processes, or even entire plants. These models ingest real-time operational data—temperature, pressure, flow rates, equipment status—to mirror what’s happening on the plant floor. Engineers can then run hypothetical scenarios and “what-if” analyses without risking actual downtime.

Why It’s Important

1.    Risk-Free Experimentation: Want to try a new catalyst concentration or adjust operating temperatures? Test it in the digital twin first.

2.    Predictive Maintenance: By continuously comparing the virtual model to real-world data, potential failures are flagged before they happen.

3.    Training and Upskilling: Digital twins serve as training grounds for new operators, allowing them to interact with real-world simulations safely.

Real-World Example: Emerson & BASF

·       Implementation: Emerson, a global technology and engineering company, has documented working with BASF to create digital twins for improved operational efficiency and process reliability.

·       Impact: According to industry reports, these digital replicas help identify process bottlenecks, schedule maintenance proactively, and potentially save millions in annual costs.

·       Verification: Emerson’s case studies highlight quantifiable improvements in reliability and reduced unplanned downtime.

Illustrative Example
Consider an ethylene oxide plant with multiple reactors, each prone to hotspot formation. A digital twin can simulate various feed compositions and temperature profiles, revealing exactly when and where hotspots might occur—thus guiding operators to tweak process variables in real time, long before a safety threshold is reached.

Key Takeaway
Digital twins are powerful allies in today’s data-rich environment. Their ability to fuse real-time analytics with predictive modeling not only boosts efficiency but also fosters a culture of continuous improvement—from design to daily operations and beyond.