Innovation is writ large in its annals: it has been associated with the creation of thermostats, aircraft autopilot systems, lead-free gasoline, barcodes, biodegradable detergents and even support systems underlying the Apollo 11 moon landing. Today, it continues its long history of creativity as a global leader in asset and process control software across the world's buildings, airlines, industrial operations and critical infrastructure.

One area of particular interest to the contemporary iteration of this icon of American business is its work in Digital Twins. What are Digital Twins? Effectively, they are virtual digital replicas of physical operations, processes and control systems. And they are generating excitement in the mining vertical and for many other sectors in various ways…

Digital Twins in action

For example, they can be used in experiential training for staff before mineral processing goes into operation and then provide analysis and decision-making support throughout the plant's lifecycle. When implemented, Digital Twins can assist operators by providing key performance indicators, identifying process obstacles, optimising operations and acting as early-warning systems, for example by detecting when the performance of a given process begins to stray from optimal.

Digital Twins also have important implications for Health & Safety.

"Dynamic simulation-based Digital Twins form the foundation of training programmes that provide a safe, repeatable and interactive environment for operators to ‘learn by doing'," said Dr. Yanling Wu, global product marketing manager at Honeywell. "In addition to the application of operator training, the entire plant can be dynamically simulated for transient engineering studies, HAZOP studies, safety procedure development, control and safety system testing, validation, and delivering safe start-up and commissioning."

Dr. Wu added that Digital Twins go well beyond the familiar visualisation software types such as geographic information systems (GIS), virtual reality (VR) and augmented reality (AR).

"Digital Twin is a high-fidelity process simulation and can be connected to the actual plant PLC/DCS via device simulation. In addition to use in operator training, it is an analysis tool for various engineering studies, performance monitoring, de-bottlenecking and root-cause analysis. Through soft sensing or inferential capability, it provides valuable insights that cannot be measured directly by instrument or on an online basis. It allows users to try out powerful what-if analysis to evaluate potential solutions and provides important updates enabling APC and plantwide optimisation of non-linear processes."  

Best practices

As with any emerging technology it's important that pioneers establish best practice frameworks and apply lessons as they learn what works best in the real world and what actions can improve effectiveness and optimisation.

Honeywell's Dr. Wu outlines four positive approaches.

First, it's essential for process rigour to define the scope of the Digital Twins being created.

Second, users should work closely with experienced partners to decide the most suitable emulation and deployment choices. They should also consider retaining partners for monitoring and maintenance when projects go live as few will have the in-house resources with specialised skills

Third, think about integration. It will be necessary to leverage a field-proven, fast and robust simulation platform that has out-of-the-box data connectors, data pre-processing capabilities and inherent extensibility to match current and future needs. 

Finally, for optimal impact it's important to democratise the use of Digital Twin (and for that matter other technologies) across functions and people with different skills levels.

Hurdling obstacles

And again, as is the case with any emerging technology, there are obstacles to the success of Digital Twins that need serious consideration.

A leading example here is sustaining execution through the life cycle of Digital Twins. Often, initial deployment phases will be successful with everybody focused on the new job at hand but retaining that success over long periods can be tougher and requires persistence in performance monitoring and maintenance. Other challenges include software compatibility and integration with other software applications.  

Honeywell's unique selling point

Of course, burgeoning interest in Digital Twins is making it a popular sector for vendors, so where does Honeywell differentiate from its many rivals?

Wu says that completeness of offer and usability are two key aspects.

"We provide a simulation platform that has both steady state and dynamic modelling under the same environment. This modelling can allow easy transition between modes, equations-oriented modelling for robustness and speed, and extensible capability. The extensibility enables end-users to develop and deploy specific and proprietary models from simple to complex, without the need for specialised programming skills. End-users can enable the smooth integration of models and data and interoperability with third-party technologies including standard and reusable asset models."

Support for cloud platforms and artificial intelligence (and machine learning) also mean that customers can move fast.

"Cloud-hosted deployment for workforce competency training and online Digital Twins can enhance data streaming and accessibility for remote cross-functional collaboration," says Dr. Wu.

"AI/ML hybrid models and reduced-order models are options to develop a fit-for-purpose model for faster model execution and manageable model maintenance."

Honeywell's depth of experience in large-scale, complex industrial operations and maintenance is also highly relevant.

Powered by a robust UniSim dynamic engine for high stability, Honeywell has delivered over 1,500 simulation-based training solutions worldwide, including crushing and grinding, flotation, hydrometallurgy, water management, alumina processes, and oil sands extraction.

Says Dr. Wu:

"Our extensible simulation offering affords smooth integration of customised model and data and interoperability with third-party tools. Our online Digital Twin is a virtual replica of all important characteristics of the process environment, providing a safe interactive platform for what-if scenario analysis, training, and optimisation. Our technology, domain knowledge, methodology and people will help users mitigate risks and improve efficiency in every stage of the project lifecycle."

Digital Twins act as second worlds where experts such as designers, engineers and operators can analyse and take action, all without incurring the risks of the physical world. Honeywell provides the experience across some of the most mission-critical environments to support Digital Twins deployment and maintenance, and help companies bridge to this exciting new sphere of activity to drive profitability and sustainability.