Bentley Incorporated: BIM technology delivers a green and smart cement plant

17.03.2022A guest article by Anne-Marie Walters*

Citic Heavy Industries has won a contract from Fujian Jianfu Cement to develop a smart green cement plant in Yongan, Fujian, China. For this, the company used Bentley’s collaborative BIM technology to integrate 3D parametric design of the main equipment, perform construction simulation and generate a full-process green cement production plant with smart controls. Itwin Services was also used to establish a digital twin that helped monitor assets, saving $2 million in equipment maintenance costs.

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To promote the transformation of China’s building materials manufacturing industry, Fujian Jianfu Cement has launched the construction of a first-class green and intelligent cement plant with a daily production capacity of 4,500 tons. The $135.96 million project required the design and layout of the entire equipment system, as well as the integration of various process parameters and data related to equipment operations to achieve a smart factory management.

As one of the world’s leading companies in the cement industry, Citic Heavy Industries was contracted to provide overall engineering design, procurement, construction and delivery of the plant. The large-scale, full-process cement manufacturing project involved working with multiple engineering disciplines, which presented technical and coordination challenges. They soon realized that conventional design and construction methods would not deliver the smart, energy-efficient factory.

Pushing the boundaries of conventional design

To achieve a breakthrough in delivering a green and energy-efficient cement plant, Citic had to consider multiple factors at once, including equipment design, construction management, plant operations and monitoring processes. They sought to push the boundaries of traditional design methodologies to achieve process automation by design, leveraging visualization and digitization technologies to bring intelligence to large-scale equipment. They wanted to build a digital factory, synchronizing design, construction, delivery and operations with the physical factory through 3D parametric equipment design and digital twin technology.

“We needed to provide parametric equipment design system, green cement plant system and smart cement plant system,” explained Ruan Jian, BIM director of Citic’s innovation institute. To achieve their deliverables, they needed a cloud-based collaborative platform and integrated BIM applications to coordinate multidisciplinary design, generate equipment models, and integrate artificial intelligence and the Internet of Things. thereby maximizing data potential for lifecycle operations.

Leverage 3D BIM and Digital Twin technology

Citic used Bentley’s collaborative BIM technology to integrate 3D parametric design of the main equipment, perform construction simulation and generate a full-process green cement production plant with intelligent controls. “We used Bentley software for all collaborative design and construction processes for intelligent project delivery,” commented Jian. They selected Open Buildings and Open Plant for process design, civil engineering and equipment modeling.

Citic has also developed a 3D parametric equipment design system to meet rapid design needs and accommodate different design specifications. Using Project Wise as a collaborative engineering platform, they created a 3D digital design and construction management system. The system allowed them to visualize and synchronize design modeling and construction, streamlining workflows to avoid design collisions. They were able to almost completely eliminate on-site construction errors and associated costs, as well as reduce material waste to protect the environment.

By leveraging Bentley BIM applications in a connected data environment with Itwin Services, Citic has created a digital twin to visually manage assets and integrate process data related to asset operations. This process facilitated online and intelligent equipment monitoring and diagnostic services, establishing a preventive maintenance system that improved the operational safety and reliability of equipment. Using Bentley’s integrated cloud-based applications, Citic has produced accurate 3D models of all major equipment and can now digitally monitor plant equipment and processes, achieving BIM cycle management. life cycle, from design to delivery and operations.

Digitization drives smart delivery

With Bentley’s open BIM applications, Citic has made a breakthrough from traditional 2D design methods to 3D parametric design and 4D construction monitoring, industrializing the delivery of Fujian Ansha’s latest energy-efficient cement plant. Implementing digital collaborative engineering workflows has streamlined multidisciplinary design, improving modeling accuracy and enabling early collision detection, which has reduced design changes by 80% and design time by a month. Specifically, collision conflicts between civil engineering and electrical installation during construction have been reduced to zero.

By creating a digital construction and management platform in a connected data environment, they automated previous manual processes that improved work efficiency, saving three months of construction time and $3 million in project costs. Additionally, accurate 3D equipment design models reduced equipment costs by 1.5% and enabled equipment to be pre-installed before shipping to the factory, reducing the time assembly on site.

By integrating Itwin Services to generate a digital twin, Citic linked the 3D equipment model with smart digital data processes, enabling visual monitoring of the cement production process to save more than 30% on operating costs and of maintenance. By digitizing asset management processes, they were able to predict equipment failures and quickly provide operation and maintenance solutions. Using an online spare parts management system, Citic was able to quickly supply needed equipment components to customers for the first time, avoiding losses caused by maintenance or plant shutdowns. Using the digital twin, they implemented a preventive asset maintenance system that reduced equipment maintenance costs by $2 million, compared to a planned and reactive asset management process.

Citic expects the smart and green digital factory manufacturing processes to reduce annual electricity consumption by 3.5 million kilowatts, saving significant energy consumption costs. Overall, these processes are expected to save Fujian Ansha $1.24 million per year. “3D parametric equipment design has made a breakthrough in equipment design automation, while digitization has added an intelligent brain to large-scale mining equipment,” said Jiang Huimin, Associate Dean at Citic.

* Anne-Marie Walters, Director of Industrial Marketing, Oil, Gas and Manufacturing, Bentley Systems

(ID: 48103439)

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