Leiden - The Institute for Sustainable Process Technology together with Nouryon, Vopak, Semiotic Labs, TPA Adviseurs and the Universiteit Utrecht's Copernicus Institute have received a grant to develop technology that reduces energy waste from industrial AC motors. AC motors consume roughly 40% of the world’s electric energy resources. The consortium will develop algorithms that analyze electrical waveforms in order to provide asset owners with the insights needed to reduce energy consumption by 15% to 30%, without compromising on output.
“The goal of ISPT is to promote sustainable practices in the process industry," says Frans van den Akker, director of sustainability at ISPT. "To that end, we will work with asset owners and technology providers on developing both tools and practices that enable the reduction of energy waste. The reality of the global economy also mandates that these technologies improve sustainability without compromising output performance. We believe this project will create such a tool: it provides the insights that are required for energy reduction as well as increases in system performance. A win for the environment, for the production manager and for the CFO.”
Semiotic Labs has developed the first condition monitoring solution to offer efficiency improvement insights, paving the way for sustainability improvements across a number of clients.
SAM4 by Semiotic Labs measures current and voltage signals to detect developing faults in AC motors and rotating equipment such as pumps, conveyors and compressors up to 5 months in advance of the fault causing a failure. The motor data has now been reapplied to detect inefficiencies in industrial processes. SAM4 can now offer the insights needed to increase electrical asset efficiency by 15-30%.
“Sustainability is a crucial part of modern industry, and our tool will enable organizations to drastically reduce electrical energy consumption," says Simon Jagers, Semiotic Labs' founder. "Around 40% of global electrical energy consumption comes from the use of industrial AC motors, and the insights offered by SAM4 can help our clients make a big dent in that number. Together, we can develop technology that helps to reduce the world’s energy consumption in a meaningful way.”
Working alongside partners Vopak and Nouryon, Semiotic Labs is continuously testing new ways to provide even greater efficiency improvement insights.
“Sustainability is high on our list of priorities, and the reduction of electricity consumption is a crucial part of that," says Leo Brand, CIO at Vopak. "Integrating SAM4 into our critical processes is an important step in realizing our energy efficiency targets.”
“SAM4 gives our maintenance staff the insights they need to identify which processes in our factory are not running as efficiently as possible," says Marco Waas, director of RD&I and technology at Nouryon. "This means we can focus our efficiency improvements on processes where we can make the greatest impact on energy reduction. The technology, which is part of the company’s Industry 4.0 program, is initially being tested at several of the company’s sites in the Netherlands and Germany.”
The scalability of the solution has also meant that a large deployment can take place in a cost-efficient way. Traditional condition monitoring requires sensor installation directly on the asset, which is an issue when the assets are located in ATEX zones, hard-to-reach places or hazardous locations. SAM4 sensors are installed inside the motor control cabinet, meaning that SAM4 can be installed and scaled quickly and cheaply.
Together with Vopak and Nouryon and a number of other partners, Semiotic Labs is rolling out a solution that will make a significant difference to world energy consumption.
We believe that radical change can be achieved through technological innovation and cooperation. As an active and open innovation platform for sustainable process technology we connect stakeholders from different sectors and disciplines. At ISPT, industry, SMEs, scientists and governmental bodies find the inspirational and trusted environment where they can optimally work together to stimulate breakthrough innovations. Together we aim to realize a circular and carbon neutral industry in 2050.
About Semiotic Labs
Semiotic Labs was established in 2015 with the aim of making maintenance 100% predictable. A team of data scientists, software developers and technical specialists have developed SAM4, an AI-driven predictive maintenance solution for AC motors and rotating equipment. Semiotic Labs is active in various industries and works with customers such as Vopak, Nouryon, ArcelorMittal, Tata Steel, Schiphol Airport and Engie.
Royal Vopak is the world's largest independent tank storage company. Vopak operates a worldwide network of terminals at strategic locations along important trade routes. With more than 400 years of history and a strong focus on safety and sustainability, Vopak provides safe, clean and efficient storage and handling of liquid bulk products and gases for their customers. In this way Vopak enables the delivery of products that are vital for our economy and daily life, ranging from chemicals, oils, gases and LNG to biofuels and vegetable oils.
We are a global specialty chemicals leader. Markets worldwide rely on our essential chemistry in the manufacture of everyday products such as paper, plastics, building materials, food, pharmaceuticals and personal care items. Building on our nearly 400-year history, the dedication of our 10,000 employees, and our shared commitment to business growth, strong financial performance, safety, sustainability and innovation, we have established a world-class business and built strong partnerships with our customers. We operate in over 80 countries around the world and our portfolio of industry-leading brands includes Eka, Dissolvine, Trigonox and Berol.