UNIFYTWIN: SUSTAINABLE OPERATIONS THROUGH PLANT EMISSION PREDICTION
The challenge
Regulation in the USA calls for cement producers to report and monitor greenhouse gas emissions to comply with standards set by the National Emissions Standards for Hazardous Air Pollutants (NESHAP). To accurately monitor emissions and plan plant schedules around these guidelines, plant data must be accurately analyzed to make a prediction on plant emissions. Each plant employs varying methods for tracking and ensuring compliance so a ‘one size fits all’ needed to be carefully designed.
The solution
UnifyTwin enables real-time emission data ingestion from multiple sources and the calculation of plant specific NESHAP compliance forecast data. To help accurately measure greenhouse gas emissions, they analyze massive amounts of both structured and unstructured environmental data. During the pilot phase various AI based forecasting models were deployed across two plants in the US footprint. As these models were tested for accuracy and efficiency, standardization was developed to consider multiple ‘what if’ scenarios all while ensuring NESHAP compliance. This allowed the team to develop a standard model that can be utilized at all plants regardless of measurement methodology.
The result
The goal of this pilot was to ensure 100% compliance with NESHAP guidelines with real-time visibility across the two plants initially involved. Within 6 months and across several dozen scenarios, 100% automated compliance was achieved without additional manual intervention, resulting in a highly accurate model. Today, the UnifyTwin solution is scaling to all 12 plants in the US with full API integration for automated modeling.
Derrick Dease
Director, ESG Implementation
“Employing a solution from the open innovation ecosystem allowed us to move faster to not only demonstrate results, but also to grow this solution to scale across the manufacturing footprint”
In a game-changing partnership, UnifyTwin has revolutionized Holcim’s approach to emissions compliance! Through cutting-edge AI and real-time data analysis, UnifyTwin played a pivotal role in achieving a flawless 100% NESHAP compliance record across Holcim’s US plants. This innovative solution not only ensured environmental responsibility but also demonstrated the power of open innovation in accelerating results and driving growth.
