98 INTERVIEW Full lifecycle digital twins are changing the game for chemicals Modern advanced process simulation enables manufacturers to optimise operations, cut costs and expedite development times, says Stephen Reynolds of AVEVA BY REBECCA GIBSON Advanced process simulation (APS) is transforming how chemical companies operate by decreasing the time it takes to test and scale new chemical formulations and empowering them to optimise operations, cut costs, drive innovation and remain compliant with industry regulations. Stephen Reynolds, industry principal for chemicals at AVEVA, explains why the technology offers such potential, particularly when combined with cloud and AI solutions. What is the state of the global chemicals industry and what are the biggest challenges it faces? The global chemicals market is fast-moving and shaped by dynamic pressures. The industry must constantly innovate within tight time frames while managing volatile demand, supply chain disruptions and ever-increasing regulations. Amid rising global costs and a high compliance environment, manufacturers are looking to boost operational efficiency while meeting sustainability key performance indicators. In practice, this means introducing solutions for agile and reliable operations, while reducing emissions and energy consumption. Firms are also looking to optimise yields, reduce waste and enable green chemistry to sharpen their competitive edge. Chemical companies must keep up with evolving red tape and legislation, which requires ongoing investment in technology and process adaptation. Additionally, the industry is under pressure to undertake digitalisation to help attract, train and retain a new generation of engineers. The need for faster time-to-market and expedited R&D processes is also paramount. How is APS revolutionising the digital twin? APS, specifically AVEVA APS, enhances digital twins by integrating engineering models, realtime data and operational visualisation tools to provide a continuous digital representation of physical assets, ensuring a smooth transition from basic design to detailed engineering and then to operations. Engineers have historically grappled with using multiple specialised simulators, between commercial and in-house tools and often a lack of customisation capabilities. However, modern APS brings all the relevant tools together in one place. It unifies multiple processes into a single, integrated platform to design a chemical plant, predict its future dynamic behaviour and improve operations after the plant startup. All of this adds up to transformative accuracy, efficiency and speed “ APS helps chemical companies innovate faster, reduce costs and stay competitive”
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