Zeltener – Consulting and Innovation in Energy

energy innovation

Development of an energy Digital Twin in a new warehouse (and new production, administrative and auxiliary processes)

The main objective of this project is the realization of an energy Digital Twin (electrical, thermal and other industrial consumption) of the new SETGA warehouse that allows the company to define the most efficient layout and provides information on consumption and supplies that helps it in making decisions.

ZELTENER’s purpose is to create a Digital Twin of the customer’s new warehouse, with which to evaluate the development in a completely computerized way, from the design to the implementation and even the dismantling of that warehouse, allowing to anticipate downtime, react to changing circumstances, test design improvements, study supply alternatives (solar panels, geothermal, natural gas, …).

Once the machines and processes that will be carried out in the new warehouse are known, the Digital Twin is developed to predict the effects and behavior of the entire production plant, it also allows time and money to be saved, whenever it is necessary to test a process industrial carried out in the plant, the design, location of the production line, monitoring or improvement. Likewise, it allows reducing maintenance and associated costs, anticipating possible failures and anticipating them.

Therefore, the functions of ZELTENER within the project are defined in the following points:

• Analysis of energy consumption based on the list of consuming equipment and its characteristics provided by the client.

• Analysis of energy production capacity based on the detailed plans of the new warehouse.

• Calculations of consumption by time slot.

• Advanced numerical analysis of the production-consumption gap to calculate the necessary electrical and/or thermal storage capacity.

• Study of the best thermal and/or electrical storage solution and its location.

• Basic architecture of the energy Digital Twin.

Proposal of applicable lines of research.

• Proposal for sensors to be implemented in the representative equipment of the machinery fleet to optimize the contribution of valuable data to the twin.

• Proposal for the future development of an algorithm that correlates electricity consumption with the carbon footprint, incorporating other inputs to the twin (climatology databases, electricity pool information, the contracted rate…).

• Pilot of the twin with various KPIs (which are already generating information based on the situation) for data collection in the new plant (using third-party tools such as Power BI).

With the development of these functions, a Digital Twin of the new facilities will be obtained, which provides the customer with valuable information on the best location of machinery, precise simulation of energy consumption, distribution of photovoltaic panels on the roof of the warehouse, energy generated by the photovoltaic installation and other industrial consumption data with which to make decisions prior to the physical construction of the warehouse on, facilities, supplies and processes.

The general objectives that the client wants to achieve with the development of the Digital Twin are, among others:

• Reduction of implementation costs.

• Reduction of energy costs.

• Greater process efficiency.

• Reducing process interruptions, improving operations and managing market dynamics.

• Understand, quantify and classify the ship’s energy demand.

• Efficient management of the generation and storage of the energy produced in the photovoltaic installation.

• Adequate determination of the size and position of the photovoltaic panels.

• Choice of supply in paint chamber.

• Optimization of air conditioning.