Covestro
At a Glance
Industry
Industrial Goods and Manufacturing
Project Types
Commercial Energy Efficiency, Data Analysis
Year
2024
Location
Shanghai
Summary
Zilong developed models that optimized Covestro’s SCDN system, leading to cost savings, energy efficiency, and better forecasting.
Goals
Covestro’s SCDN (Steam, Condensate, Demi-water, Natural gas) system integrates four critical utility resources essential for the operation of its production facility. Given the complex interrelationships and transformations in SCDN system, Covestro hoped Zilong can assist in developing a comprehensive optimization model for the SCDN system aimed at minimizing costs and enhancing energy efficiency.
Solutions
Zilong approached the challenge through the following process:
1. Initially, Zilong defined the scope and created flowcharts to analyze the complex SCDN system, then collected and preprocessed data required for modeling.
2. Zilong analyzed the steam boiler’s performance and modeled the boiler’s Specific Energy Consumption (SPE) and Load based on historical data.
3. By applying differential evolution algorithm, Zilong develop an integrated Real-Time Optimization Model of SCDN system based on mutiple constraints.
4. To enable forecasting functions for SCDN systems, Zilong built predictive models for multiple subplants and integrated them into the Forecasting Model.
Potential Impact
By implementing the recommended operations from the Real-Time Model, Covestro is able to achieve significant cost savings of over 2 million RMB annually while also conserving nearly 6 million kWh of energy each year. This not only enhances the facility’s operational efficiency but also contributes to its sustainability goals. Furthermore, the deployment of the Forecasting Model equips Covestro with more precise energy predictions and management strategies, allowing for better resource planning and more informed decision-making, ultimately leading to improved long-term energy efficiency and cost-effectiveness.