1. 1500 jobs
2 share holders : OCP - SRIW
ARC

2. Des réductions d’énergie et d’émissions grâce à la « digitalisation » et … à la participation collective

3. Prayon – production facilities
Engis
Head office
Belgium
Puurs
Belgium
Les Roches de Condrieu
France
Augusta
Prayon Inc.
USA 3

4. Prayon - Products
Prayon - Products 4

5. Energy Target : 12 % reduction

6. Emissions CO2

7. Assets
Organ- ization
People

8. SAVINGS THROUGH OPERATIONAL MANAGEMENT
Procurement
Investments
Operations

9. Approach Roadmap FLASH ENERGYmaestro APPROACH 2-3 weeks 1-2 weeks
Gap Analysis
Workshops
Diagnostic analysis
Deployment
Training
Follow-up
2-3 weeks
1-2 weeks
6 weeks
4 weeks
1-2 weeks
Monthly

10. APPROACH:Gap analysis
Workshops
Advanced analytics
Implementation
Training & follow-up
Define initial KPIs
Analyse and quantify historical variability against baseline target of initial KPIs.
Nb of hours
Specific energy
Performance gap analysis
Period where much higher that target
Potential Savings
Period where on/lower that target
Time

11. APPROACH:Workshops:Profits tree indentification
Gap analysis
Workshops
Advanced analytics
Implementation
Training & follow-up
Workshops with operators and plant staff
Brainstomring root causes of variability and process improvement ideas
Objective to engage operators in the project
Ideas presented on a cause tree
Cause tree communicated to operators

12. Reporting structure at PRAYON
Gap analysis
Workshops
Advanced analytics
Implementation
Training & follow-up
CORPORATE LEVEL
SITE LEVEL
PLANT LEVEL
LINE LEVEL

13. ENERGY DASHBOARD AT CORPORATE LEVEL
Gap analysis
Workshops
Advanced analytics
Implementation
Training & follow-up

14. APPROACH:Advanced Analytics:Root Causes Analysis model
Gap analysis
Workshops
Advanced analytics
Implementation
Training & follow-up
Decision trees machine learning to map impact of top parameters on efficiency

15. Develop useful indicators in control screen
Gap analysis
Workshops
Advanced analytics
Implementation
Training & follow-up
Develop useful indicators in control screen
Developor update daily/weekly/monthly reporting
Tracking of root causes for loss of performance

16. APPROACH:Training plant staff
Gap analysis
Workshops
Advanced analytics
Implementation
Training & follow-up
Training of plant staff and operators on control screens, reports and regular monitoring

17. Evaluate and update dynamic target models for continuous improvement
APPROACH:Follow-up and KPI/KPE updates
Gap analysis
Workshops
Advanced analytics
Implementation
Training & follow-up
A. DCS – real time
B. Production report daily
C. Monthly reviews
Evaluate and update dynamic target models for continuous improvement

18. Sodium - phosphate salts– Roches (FR)
METHODOLOGY
Methodology and advanced analytics supported by PEPITe sa
20 kEur/year within 6 months without capex
SAVINGS : 20 kEur/Year
ADVANCED ANALYTICS

19. Steam network optimization – Engis (BE)
METHODOLOGY
Methodology and advanced analytics supported by PEPITe sa
400 kEur/year without capex since 2012
SAVINGS : 400 kEur/Year
ADVANCED ANALYTICS

20. Purified phosphoric acid – Puurs (BE)
METHODOLOGY
Methodology and advanced analytics supported by PEPITe sa
300 kEur/year within 6 months without capex
SAVINGS : 300 kEur/Year
ADVANCED ANALYTICS

21. Facteurs clés de succès
Management and operator involvement
Data availability and quality
KPI for all decision levels
Advanced analytics capabilities
Integrated project team

22. Conclusions Participation des personnes clés Support de la hiérarchie
Distribuer les bonnes informations, aux bons destinataires, au bon moment.
Communication
Utiliser les technologies de l’information

23. Vos questions ?

24. Merci pour votre attention