Adding value through digitalization

Bilfinger uses digital technologies to increases the competitiveness of companies. Digitalization holds tremendous potential for the process industry: Digital solutions can deliver increases in Overall Equipment Effectiveness (OEE), further improve occupational safety, reduce operating and maintenance costs as well as downtime and preserve and transfer valuable expertise. With intelligent solutions, Bilfinger supports process industry customers every step of the way as they move toward a successful digital transformation. In order to ensure that digitalization progress achieve long-term success, Bilfinger takes into account more than "just” the appropriate technology: In cooperation with strong partners, Bilfinger also brings the necessary mindset change to your company and makes it possible for your employees to experience the value added by digital solutions.

Intelligent solutions

Bilfinger relies on customized solutions to generate added value through digitalization for customers in the process industry. Using Big Data as a basis and combining it with the application of artificial intelligence, Bilfinger's experts leverage their extensive process knowledge from industry in addition to their IT knowledge. As an experienced industrial services provider, Bilfinger can optimally integrate digital solutions into customers' production processes. The solutions at a glance:

BCAP: The AI and IoT solution for the process industry

BCAP (Bilfinger Connected Asset Performance) is the modular platform for digitalization in the process industry. BCAP combines data from various sources including engineering, operations, maintenance and from sensors for status monitoring. By combining this data, analyzing it and supporting it with Data Science, BCAP makes it possible to gain new insights to optimize production processes, predictive analytics and plant digitalization. With BCAP, Bilfinger can increase the efficiency of a plant by up to 15 percent, reduce maintenance costs by up to 30 percent and cut downtimes by up to 20 percent.

PIDGraph: The AI-based digitalization of plant documentation

PIDGraph is the next generation of plant documentation: Through the application of AI methods, the intelligent software is able to digitalize piping and instrument flow diagrams (P&IDs) that would otherwise only be available in paper or PDF formats. The digital formats created by PIDGraph can be processed by any modern engineering and asset management system, thereby forming the basis for creating "digital twins" of industrial plants, for example. P&IDs is not only significantly cheaper, but also much faster than conventional methods.

The new digital intelligence saves time and money.

Franz Braun, Managing Director of Bilfinger Digital Next GmbH

Project examples from digitalization:

Plant Intelligence optimizes production (ALMATIS)

Challenge

Almatis wanted a way to increase productivity and overall plant effectiveness. In addition, production scrap for premium aluminum oxide is to be reduced by improving the presentation of production data.

Solution

Implementation of BCAP's Plant Intelligence module using four quality improvement apps that include two operator dashboards (TiO2 Alerting and pH Alerting) and three production engineering dashboards (First Time Yield, Quality Optimization, and OEE).

Advantages

  • Improved quality of product results
  • Improved overall plant effectiveness + 7%
  • More efficient work steps for the plant operator with automated data acquisition and visualization

To case study


Increasing batch quality and productivity of a mixing process (Münzing)

Challenge

Production time is limited by personnel resources to 8 hours per day. This time will be extended and productivity increased - while at the same time product quality will be maintained.

Solution

A data-driven dynamic model that considers all process parameters in order to reach the optimal operating point.
BCAP provides recommendations on mixing time. This saves time in the mixing process and allows for the production of an additional batch in the same time and quality.

Advantages

  • Productivity increase + 10%
  • Quality assurance

Energy transparency and optimization (Münzing)

Challenge

For the most part, the energy management system is not connected to other relevant data sources.

Solution

Combining data from energy meters with other sources of data including production schedules, operating hours and process parameters.
Bad actor analysis highlights an unusually high energy consumption.

Advantage

  • Increased plant integrity through standardized information for audits, for example (ISO50001)

Read more


Model-based optimization for manual operation of a multi-stage process (BASF Colors & Effects)

Challenge

A drain pipe is added to the process at irregular intervals. This leads to an unstable process and thus also to lost time and quality problems in subsequent processes.

Solution

In each batch, quality parameters are calculated depending on temperature profile, service life, volume and quality of previous batches. Recommendations for action can be derived for the processing of future batches.

Advantages

  • Increase in Overall Equipment Effectiveness (OEE)
  • Increase in quality

Production capacity and quality increased and reduced complexity for operator (Lhoist)

Customer Challenge

The production of mixed products requires a manual measurement once per hour for process control. The objectives are increased productivity, quality and reduced manual activities.

Our solution

Bilfinger continuously models the viscosity as a product quality parameter to reduce manual measurements. To provide throughput-optimized set-points for mill and pump, a recommender model is created.

Advantages

  • Productivity increase + 8 %
  • Improved Quality + 11 %
  • Decreasing complexity for workforce

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Frank Hertling

Get to know BCAP

THE AI-BASED DIGITALIZATION OF PLANT DOCUMENTATION

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