Role of Industry 4.0 in Transforming the Chemical Industry

The digitalisation of the chemical industry has been one of the most remarkable transformations of the century. The transformation has been so compelling that it is being called 'industry 4.0' to represent the fourth revolution in the manufacturing industry. The fourth revolution aims to optimise computers and automation — started in the third revolution — by introducing autonomous systems fueled by data and machine learning. Even though the fourth revolution is still in its early stages, the shifts in the manufacturing industry are significant enough to seize our attention.

When computers were introduced in Industry 3.0, they were disruptive because back in the 70s, the technology wasn't as enhanced as it is now, and it was a challenging endeavour to try to incorporate its use when every task was done manually. Now, as Industry 4.0 unfolds, computers are connected and communicate with one another to ultimately make decisions without human involvement. This has been possible because of the combination of cyber-physical systems, also known as the Internet of Things (IoT) or the Internet of Systems, which has made the smart factory a reality.

Significant strides in the tech industry have allowed intelligent machines to keep getting smarter. Furthermore, people's endeavours towards assimilating automation and mechanisation into their daily lives have empowered these machines to access more data, making factories more efficient and productive and less wasteful. But ultimately, the network of these machines—digitally connecting with one another and creating and sharing information—resulted in the true power of Industry 4.0.

The Era of Chemistry 4.0

Industry 4.0 has the potential to transform the chemical industry by streamlining operations and promoting strategic growth. Technologies such as the Internet of Things (IoT), additive manufacturing, advanced analytics, artificial intelligence, and robotics can be efficiently integrated with core conversion and marketing processes to digitally transform operations in the chemical industry.

Chemical production, in reciprocity, plays an important role in Industry 4.0 as a crucial provider of innovative substances for digitised and intelligent technology. The modernisation of chemical production calls for the continuous adoption of three strategies, mainly the transformation of existing systems, a data-driven operating framework, and a digitised corporate structure. These mechanisms are being utilised in the chemical industry by implementation of the following branches:

A) Digitisation

The last decade witnessed incremental innovation and digital transformation, but now digitalisation is speeding up. The pandemic rocked customer demand, supply chain operations, workforce interactions, and maintenance routines, while demands for sustainability, personalisation, and greater efficiency rose in the background. This rise enabled chemical companies to create new business models by integrating digital technologies with customers’ operations & customised products, extended product life, and refined information & services.

B) Internet of Things

Technologies such as the Internet of Things (IoT), robotics, artificial intelligence, advanced analytics, and additive manufacturing have revolutionised the chemical industry. Data analysis aided the identification, measurement and tracking of parameters to prevent machine failure as well as ensure the safety of workers. Big data analytics, virtual environments, broad connectivity, machine-to-machine communication, and new manufacturing techniques created new opportunities for the chemical industry. The IoT applications allowed chemical manufacturing companies to streamline operations and promote strategic growth. Businesses could also monitor and analyse energy and other utilities consumed by critical processes to save operational costs.

C) Customer-Driven Innovation

Industry 4.0 enabled companies to provide end-customer solutions and new services by adapting business models according to the customers’ demands. Demand modelling analytics incorporated internal and external elements such as market trends, seasonal demand profiles, and order history byproducts and accounts and brought together demand and forecast data from multiple sources in a web-based platform, helping to support better promotion planning and forecasting and monitoring of customer demand. Improved knowledge and forecasting about the customer improved connectivity, increased customer proximity and strengthened customer loyalty by allowing chemical companies to successfully integrate themselves into their customers’ businesses over the long term.

D) Enhanced Production and Material Management

Advanced analytics capabilities of Industry 4.0 assisted chemical firms in tracking trends, encouraging innovative approaches to quality control, and decreasing outages as well as nonconformances. Furthermore, Industry 4.0 technologies are evolving for better process administration, giving operators greater freedom to monitor instrument data and facility activities. Thus, making it easier for the chemical industry, an asset-intensive sector, to continually monitor proper equipment such as rotors, compressors, and extruders in order to determine and forecast any breakdowns. In a nutshell, Industry 4.0 forced chemical makers to swiftly transition from reactive to predictive maintenance.

E) Circular Economy

Circular economy is a concept that encompasses all contributions toward saving resources (such as raw material base and ecological systems), including increasing resource efficiency at all levels of the value chain (suppliers, chemical industry, customers), extending the lifespan of products and components, and reducing resource consumption in the application phase. As far as possible, proponents of circular economy aim at closing cycles by reusing and recycling, promoting biological degradation, as well as maximising efficient utilisation of residual materials.

Chemistry 4.0 and circular economy work hand-in-hand to support sustainable management by avoiding wastage via multiple usages and efficiently utilising byproducts, surplus materials, and CO2 as raw materials (Waste-to-Chemicals and Carbon Capture Utilisation). In addition, significance is also given to chemical recycling (also called feedstock recycling), biodegradability as CO2 cycle, and climate protection through “biologization of chemistry” (use of industrial biotechnology, genome editing for precision breeding, biorefineries, and the utilisation of renewables as raw materials).

F) Reducing Waste

Plants deal with high energy costs, making it crucial to reduce waste as much as possible. Therefore, cutting costs has so far been one of the key benefits for plants that have undergone a digital transformation.

Early alerts about potential plant failures and inefficiencies enabled maintenance teams to carry out an economical repair job instead of replacing the parts, thereby extending the lifespan of the equipment. More efficient processes meant pursuing a more rigorous effort towards establishing a circular economy, lowering energy consumption and wasting fewer raw materials along the way.

Analytics solutions tracking fluctuating prices of raw materials also helped plants prepare in advance for the dramatic changes in prices and get the best deal from suppliers. More accurate demand forecasting also enabled plants to estimate the right amounts of different products, lowering the risk of oversupply.

G) Cleaning-In-Place

One of the key ways Industry 4.0 has helped automate Cleaning-In-Place (CIP) is through the use of sensors and data analytics. Sensors can monitor various parameters during the CIP process, such as temperature, pressure, flow rate, and chemical concentration. This data can be collected and analysed in real time, allowing for automated adjustments to the CIP process based on the data.

In addition, the connectivity brought on by the Internet of Things (IoT) allows for better control and monitoring of CIP systems. For example, a CIP system can be connected to a plant's central control system, allowing for remote monitoring and control of the CIP process. In essence, Industry 4.0 has eliminated the requirement for human labour. By inputting the correct process parameters and having the necessary chemicals prepared, the system can operate without any human intervention, which simplifies the achievement of the Hazard Analysis Critical Control Points (HACCP) standards for companies.

ORAPI’s Effort to Integrate Chemical 4.0 (Chemtech)

ORAPI has a three-pronged approach to digitalisation. In the short term, the company focuses on improving reliability and supply chain performance by optimising its day-to-day operations. In the mid-term, ORAPI aims to enhance customer experience by utilising information and channels to augment the way they do business with the company. Finally, in the long term, ORAPI plans to develop new, digitally-enabled business models, exemplified by the launch of the ORAPI E-Shop. This initiative reduces paper consumption, streamlines order processing, and allows customers to purchase products 24/7, track orders, and download SDS.

Another step ORAPI has taken towards integrating technology in our daily workings on a larger scale is by digitising maintenance service checks. This implies easier and faster and easier communication for our customers — communication between two parties will no longer require the involvement of a middle-man, significantly reducing the chances of miscommunication. Plus, the spontaneity of the process will give the customers the option to provide signatures, access reports, share remarks, and monitor activity remotely from any location.

Conclusion

To summarise, Industry 4.0 has had a significant impact on the way chemical companies operate and grow their businesses, as they embrace digital solutions for remote working and supply chain visibility, pursue their sustainable development goals, and optimise production. Furthermore, the trajectory set by Industry 4.0 has enabled chemical companies to identify ways to connect their cyber and physical assets through various levels of the value chain and integrate these novel advancements in their manufacturing and planning. Beyond technology, however, it is the agility of the chemical organisations in adapting to changes set forth by Industry 4.0 — including digitalisation, sustainability, waste reduction, customer-driven innovation, and implementation of IoT and the Circular Economy — that will determine how effectively they revolutionise Chemistry 4.0. As these changes have already been set in motion, time is of the essence. Industry 4.0 is no longer a discussion for the future.