International organizations are increasingly recognizing Industry 4.0 technologies for their potential role in industrial decarbonization. Yet, their contribution to climate change mitigation within the manufacturing industry is uncertain and access is highly uneven globally. This section sheds light on Industry 4.0 progress, beyond the superlatives.
Proven technologies
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4. Industry / Industry 4.0 / Proven technologiesAdditive manufacturing (3D printing) of steel
SLM Solutions
Getty Images /© Marina_SkoropadskayaContinuous casting – the process whereby steel is shaped and solidified without interruption – has become the industry standard. Over 96 percent of steel is produced through this process which has reduced significantly the amount of liquid steel needed to produce steel sheets. Two more recent versions of this process are thin slab casting and near-net-shape casting (NNSC). Near-net-shape casting is a family of techniques where the production process is calibrated to make an object as close to its final shape as possible. Additive manufacturing (or 3D-printing) is one example. This reduces waste and removes several post-process stages, ultimately lowering energy consumption. SLM Solutions produces various machines for additive manufacturing. An example is the selective laser melting system SLM 280 2.0 suitable for medium-to-high volumes of metal additive manufacturing.
- Contracting type: For sale
- Technology level: High
- Country of origin: Germany
- Availability: Worldwide
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4. Industry / Industry 4.0 / Proven technologiesComputer modelling for reduced resource use in construction
Autodesk
© AutodeskAutodesk’s BIM 360 is a cloud-based platform providing building information modeling (BIM) software for the construction industry. BIM is the foundation for digital transformation and allows architects to visualize and plan designs according to various scenarios and parameters. Moreover, it encourages building component reuse. It does so through better design and planning undertaken with a building’s eventual deconstruction in mind. Autodesk’s platform includes tools for 3D modeling, project management and collaboration. This helps reduce over-design and unnecessary use of high-carbon materials such as steel and cement.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: United States
- Availability: Worldwide
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4. Industry / Industry 4.0 / Proven technologiesAutomated control system for electric arc furnaces
AMI Automation
Getty Images /© davit85AMI Automation has developed an automated control system for steelmaking electric arc furnaces. The company’s SmartFurnaceTM technology is centered around artificial intelligence. Its different modules enable key parameters to be measured and controlled, including temperature, off-gas, slag level, arc stability, as well as gas, oxygen and carbon status. Laser technology and off-gas sensors allow best operating points and energy saving to be quickly identified. The system can also control the rate at which steel is input through continuous feeding systems so as to maintain optimal temperature.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: Mexico
- Availability: Worldwide
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4. Industry / Industry 4.0 / Proven technologiesAutomation and control systems for steel and cement
Siemens AG
Getty Images /© WangAnQiSiemens supplies a range of automation solutions for various industries, including steel and cement. Within the steel sector, Siemens offers solutions for automated material handling, such as the Siemens Mechatronic Solution for Material Handling (MSMH). This system uses advanced control algorithms and simulation tools to optimize material flow and reduce energy consumption. It incorportates a range of components – for example, cranes, conveyors and stackers – that can be configured to meet a steel plant’s specific needs. Within the cement sector, Siemens provides the Simine Conveyors system. This uses advanced control algorithms and simulation tools to optimize conveyor belt operation and improve energy efficiency. Similarly, components such as drive systems, pulleys and belt cleaners can be tailored to a cement plant’s specific requirements.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: Germany
- Availability: Worldwide
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4. Industry / Industry 4.0 / Proven technologiesDigital energy management system
Metron
Getty Images /© Terry J AlcornMetron’s digital tool optimizes grinding mill efficiency, saving cement plants both cost and energy. The tool enables production planning according to energy market conditions by collecting data on production, consumption and operation parameters. Thereafter, sequencing rules are built to provide a holistic view of the plant, with personalized dashboards. Comparing data to baselines, real-time alerts are issued when ideal energy consumption is exceeded. Examples of data collected include mill intensity, furnace temperature, emission analysis and energy consumption.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: France
- Availability: Worldwide
Frontier technologies
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4. Industry / Industry 4.0 / FrontierAI platform for control room operators: optimizing steel and cement energy usage
Carbon Re
© Carbon RECarbon Re’s Delta Zero is a software platform that uses artificial intelligence (AI) to optimize steel and cement production processes. Analysis of real-time sensor data generates a high-resolution digital twin of the plant. This twin enables AI “agents” to learn process control through deep reinforcement learning – an AI area that has witnessed a significant breakthrough in recent years. Software then provides operators with clear, actionable recommendations for the various process stages and parameters. According to the company, up to 10 percent energy savings and 20 percent emission reductions can be achieved, while also keeping equipment within a safe operating space and controlling NOx emission limits.
- Contracting type: For collaboration
- Technology level: High
- Country of origin: United Kingdom
- Availability: N/A
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4. Industry / Industry 4.0 / FrontierDistributed ledger technology for product tracking
Siemens AG
© Siemens AGSiemens Insights Hub (former Mindsphere) digital IIoT platform tracks products transparently throughout their entire life-cycle. It is based on distributed ledger technology. The tool assesses all useful information before forwarding relevant data subsets to the distributed ledger. There the data are safely and transparently stored for relevant stakeholder access. This enables a better control of operations and the connection of assets such as products, plants, systems and machines to a central location where sustainability data can be collected, analyzed and acted upon.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: Germany
- Availability: Worldwide
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4. Industry / Industry 4.0 / FrontierMixed reality for manufacturing industries
Microsoft Corporation
© Microsoft CorporationHoloLens 2 is a Microsoft product that enables staff at manufacturing plants and other industries to learn complex tasks and collaborate using mixed reality technology. Through mixed reality applications, the technology aims to make manufacturing processes more lean and efficient, while reducing expert travel time. HoloLens 2 is a head-mounted device that staff can wear on a needs-basis.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: United States
- Availability: Worldwide
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4. Industry / Industry 4.0 / FrontierReal-time cement plant optimization
TITAN Cement Group
Getty Images /© kynnyTITAN Cement Group provides technology for optimizing cement plant production and energy efficiency. Sensors are integrated across plant equipment in order to record large volumes of operational data. Data is then transmitted, analyzed and used for the real-time optimization of production parameters, with the support of artificial intelligence technology.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: Greece
- Availability: Worldwide
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4. Industry / Industry 4.0 / FrontierAI-based cement plant predictive maintenance
CemAI
Getty Images /© Goodvibes PhotoCemAI – part of TITAN Cement Group – supplies artificial intelligence-based predictive maintenance solutions for the cement sector. A specially developed algorithm, supported by sensors, helps predict plant failure. The technology simultaneously monitors the entire plant for anomalies, improving operational efficiency and reducing maintenance needs. Installation of the CemAI application takes approximately three months.
- Contracting type: For sale/service
- Technology level: High
- Country of origin: Greece
- Availability: Worldwide
Horizon technologies
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4. Industry / Industry 4.0 / HorizonDigital modeling for optimized transport routes
Western Digital
Getty Images /© ipopbaWestern Digital develops digital models that optimize supply chains by automating transport and shipping routes. They have decreased supply chain transport transit time, thereby avoiding significant greenhouse gas emissions. The model builds on historical supply chain data and machine learning. It self-adjusts shipping routes based on changing requirements and customer purchase orders. This enables transport routes to be predicted more flexibly and accurately. The company has added carbon footprint as a metric to the model in order to track emission reductions, and a digital twin to run multiple model comparisons. The company is now working toward scaling and deploying the model.
- Contracting type: For collaboration
- Technology level: High
- Country of origin: United States
- Availability: N/A
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4. Industry / Industry 4.0 / HorizonAutomated factories for mass production of buildings
ADMARES + KUKA
Getty Images /© JARAMAADMARES has been working with Siemens and KUKA on digitally transforming the construction industry via smart factories (including automation) and homes. KUKA – a supplier of intelligent automation systems – will be supporting the development of the world’s first automated factory for off-site buildings production. Elements will include digital twins, robotized manufacturing and life-cycle digitalization. The technology aims to allow entire buildings to be mass produced at a factory by assembly-line workers.
- Contracting type: For collaboration
- Technology level: High
- Country of origin: Finland
- Availability: N/A
Innovation examples
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4. Industry / Industry 4.0 / Innovation examplesIndia’s industrial lighthouse
Getty Images /© xavierarnauSteel plants operators use a process known as superheating to bring molten steel to the correct temperature for casting. The ideal temperature range is narrow. And if the steel is either too hot or not hot enough, quality can be affected. To improve the process, plant managers at Tata Steel’s Kalinganagar plant (one of the largest in India) have created an advanced analytics model that uses historical data to recommend process set points for higher strike rates (i.e., correct temperature predictions). The model is able to assess plant conditions and calculate how much heat to supply during superheating, in order for the molten steel to remain within target temperature range. This has resulted in a more effective process plus cost savings of USD 4 million a year. The plant has also invested in building the digital capacity of staff. It now employs over 30 analytics specialists who integrate the model into the company’s plan to improve performance indicators such as energy consumption, throughput, quality and yield.[181]
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4. Industry / Industry 4.0 / Innovation examplesDigital twin and predictive maintenance within the cement sector
Getty Images /© metamorworksHolcim – a large multinational cement producer – has launched the world’s first digital twin cement plant. The digital twin in question is a real-time 3D virtual model of a company site in Switzerland. Holcim’s software and performance prediction algorithms are integrated into this 3D model, which uses sensors, data analytics and machine learning to prevent costly downtime and enable predictive maintenance. The project is part of Holcim’s Plants of Tomorrow program, using Industry 4.0 technologies across its sites to boost efficiency. The company plans to scale this digital twin technology across its operations, beginning in Europe. It expects this will save over 400,000 tonnes of CO2 emissions, albeit over an undefined period of time.
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See Notes here