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COGNIPLANT optimising production plants in the process industries

COGNIPLANT team

“Horizon 2020 helps us to look 10 years into the future and enables us to tap into the huge R&D capability across Europe.”

Eoin Keane, Energy Specialist, COGNIPLANT Horizon 2020 project

Key Takeouts:

  • Aughinish Alumina (AAL), part of the RUSAL group and one of the world’s major producers of aluminium and alumina, is taking part in a project to develop an innovative approach to the advanced digitization and intelligent management of production plants.
  • The COGNIPLANT project has received €8.5m in funding from the European Union’s Horizon 2020 research and innovation programme.
  • AAL helped to define the requirements for the design of the COGNIPLANT solution and its County Limerick facility is currently testing and demonstrating the solutions identified by the COGNIPLANT consortium.

H2020 Case Study: COGNIPLANT

A global shortage of raw materials, increasing energy prices and environmental concerns have made the goal of improving the performance and energy efficiency of process industries a European imperative.

Among many initiatives tackling the issue is the COGNIPLANT Horizon 2020 project. Using the latest developments in advanced analytics and cognitive reasoning, coupled with the digital twin concept (a computer model that simulates the operation of the plant), it aims to design a monitoring and control solution that will significantly improve the performance of production plants and reduce CO2 emissions.

The COGNIPLANT consortium involves 14 partners from universities and businesses across Europe including four production sites that are testing and demonstrating the technology. One of these is County Limerick company Aughinish Alumina (AAL), part of the RUSAL group and one of the world’s major producers of aluminium and alumina.

The best-in-class company has the reputation of being forward-thinking and innovative and has set itself ambitious carbon reduction targets. Taking part in the COGNIPLANT project was an opportunity to help develop the technology that will contribute to it achieving those targets.

“The COGNIPLANT solution is aligned with the decarbonisation goals of the company where advanced process control techniques are used to minimise energy usage,” explains Eoin Keane, AAL’s Energy Specialist

“Currently there are hundreds of sensors installed on the plant relaying information into a central data storage system. The operations teams and engineers review this information continuously to ensure the process is running smoothly. The goal of COGNIPLANT is to make this intelligence available 24/7 to the control room operator so that they can make informed decisions when the wider team is not available.”

The COGNIPLANT consortium includes expert modellers who are using the data and expertise gathered from the test sites to identify opportunities to optimise the plants. It’s an iterative process, which over the next 12 months should culminate in a packaged solution for process industries.

 

The Horizon advantage

Having been involved in Horizon 2020 projects before, AAL was aware of the benefits of pan- European collaboration.

“We’ve done Horizon 2020 projects in the past and benefitted immensely from them, including building up relationships with experts across many disciplines. When this opportunity arose, which is looking at energy-intensive industries, the co-ordinator of COGNIPLANT, Ibermática, asked us if we wanted to come on board and we were keen to get involved,” says Keane.

“Being part of COGNIPLANT gives us the opportunity to develop detailed and insightful models of the process beyond what is currently available to us. The modellers bring in expertise from many different areas that we would otherwise not be able to access.”

The sharing of knowledge between the partners in the consortium is a valuable aspect of the Horizon experience, even when it does not directly relate to the core project deliverables.

“We’ve been able to share our knowledge and experience of sensors with the lime plant in Italy which was installing a particle-size sensor and we’ve also shared our experience of data handling. We’re building connections with other industries too, for example, the group of researchers in Munich who are working in the field of chemicals in heavy industry. We’re thinking about building on that connection in the future around decarbonization and climate action goals. Horizon Europe will be the route we’ll go down to develop actions in this area,” says Keane.

On a personal level, Keane feels he has greatly benefitted from the opportunity to network with people from other disciplines and backgrounds, to get an insight into what other companies across Europe are working on and see the synergies around climate change.

 

Navigating the Horizon environment with Enterprise Ireland’s support

Identifying the best-fit Horizon project, negotiating the consortium build and keeping on top of pan-European developments can be challenging, but AAL has found Enterprise Ireland’s help to be invaluable.

“Enterprise Ireland helps to identify suitable matchmaking events for us to attend, which help in forming a consortium. They are also available to answer any questions or offer support when needed.” explains Keane

 At the moment they are helping us with the next round of calls for Horizon Europe, pinpointing future projects around climate change and the circular economy. These are areas where you need to think outside the box and that’s why Horizon is so important to us; it allows us to tap into the huge R&D capability across Europe, which is very exciting. Horizon really helps us to look 10 years into the future.”

For advice or further information about applying for Horizon Europe support, please contact HorizonSupport@enterprise-ireland.com or consult www.horizoneurope.ie

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