Periodic Reporting for period 1 - SmartMelt (SmartMelt: A Data-Driven Melting Process Optimizer)
Berichtszeitraum: 2019-08-01 bis 2020-01-31
Recycling of aluminium scrapes include melting process. This melting process is very inefficient because the operation of larges furnaces is still mainly based on human decisions. Typically, a non-adequate door opening decreases the efficiency by ~5%. There is no tool to indicate the optimal times for door openings. Optimizing the melting efficiency by only 10% can save nearly 0.5 M€ / year operational costs of a medium-size furnace with a huge beneficial impact on energy saving and environment.
This process optimization enabler has a very positive impact of 5-10% CO2 emissions reduction, serving the society by reducing the energy consumption and the environmental impact of aluminium industry. The solution proposed for this problem is a disruptive technology in line with the global digitalization, thus contributing the worldwide efforts for industrial sustainable development.
Novamet develops SmartMelt, a unique and patented data-driven controlling system. SmartMelt solution includes a digital-twin furnace in which data coming from the furnace controller are analysed during the process and compared on-line to results coming from a very efficient numerical simulation software. Any operation such as door opening or melt skimming or stirring can be optimized on-line during the operations, while guiding the operator for future actions, in particular the end of the melting cycle, with the optimal timing.
The aim of feasibility study was: a) to identify the actual market opportunities for secondary Aluminium melting, b) evaluate and quantify the technical and financial benefit of introducing SmartMelt technology on medium range volume furnaces (=>30 tonnes), and c) validate the pertinence of an add-on software licensing business model.
Objectives:
O.1 Market viability: i) Evaluate the secondary Al melting furnaces capacity to confirm addressable target market share; ii) strengthen relationships with customers acting as partners.
O.2 Technological viability: Quantify the impact of the product utilization on productivity and energy saving.
O.3 Business model viability: i) Quantify the value added for the customer; ii) validate the licensing sales model through quotations and orders placed by customers; iii) generate specific value propositions for indirect sales.
O.4 Economic Viability: i) Consolidate the business growth timeline; ii) identify and apply to potential funding sources (Eurostars, SME Instrument II, World Materials Forum) and identify potential investors.
O.5 Organizational viability: i) Define a company structure; ii) integrate a project management engineer.
This process optimization enabler has a very positive impact of 5-10% CO2 emissions reduction, serving the society by reducing the energy consumption and the environmental impact of aluminium industry. The solution proposed for this problem is a disruptive technology in line with the global digitalization, thus contributing the worldwide efforts for industrial sustainable development.
Novamet develops SmartMelt, a unique and patented data-driven controlling system. SmartMelt solution includes a digital-twin furnace in which data coming from the furnace controller are analysed during the process and compared on-line to results coming from a very efficient numerical simulation software. Any operation such as door opening or melt skimming or stirring can be optimized on-line during the operations, while guiding the operator for future actions, in particular the end of the melting cycle, with the optimal timing.
The aim of feasibility study was: a) to identify the actual market opportunities for secondary Aluminium melting, b) evaluate and quantify the technical and financial benefit of introducing SmartMelt technology on medium range volume furnaces (=>30 tonnes), and c) validate the pertinence of an add-on software licensing business model.
Objectives:
O.1 Market viability: i) Evaluate the secondary Al melting furnaces capacity to confirm addressable target market share; ii) strengthen relationships with customers acting as partners.
O.2 Technological viability: Quantify the impact of the product utilization on productivity and energy saving.
O.3 Business model viability: i) Quantify the value added for the customer; ii) validate the licensing sales model through quotations and orders placed by customers; iii) generate specific value propositions for indirect sales.
O.4 Economic Viability: i) Consolidate the business growth timeline; ii) identify and apply to potential funding sources (Eurostars, SME Instrument II, World Materials Forum) and identify potential investors.
O.5 Organizational viability: i) Define a company structure; ii) integrate a project management engineer.
Conclusions:
SmartMelt first addressable market target are secondary Al producers in Europe, with the aim of having in 5 years 15% of the medium-size furnace market.
The SmartMelt pilot installation has demonstrated: a) a reduction of gas consumption of ~11%; b) consistent lower energy consumption; c) major reduction in process variability; and d) increase of productivity of ~10%.
SmartMelt is the reliable solution for a robust and sustainable melting process of Aluminium.
SmartMelt first addressable market target are secondary Al producers in Europe, with the aim of having in 5 years 15% of the medium-size furnace market.
The SmartMelt pilot installation has demonstrated: a) a reduction of gas consumption of ~11%; b) consistent lower energy consumption; c) major reduction in process variability; and d) increase of productivity of ~10%.
SmartMelt is the reliable solution for a robust and sustainable melting process of Aluminium.
To continue its development and commercialisation, we have identified the following needs:
Funding: We applied for a 3-year Eurostars project for the development of an operational customer friendly web-oriented SmartMelt version and improved thermophysical modules to increase its accuracy. We will apply for EIC Accelerator Pilot with a focus on marketing, commercialisation, reduction of implementation timeline and strategy to achieve growth plan. In case this is not successful, we will work on making our company and product investment ready to pursue venture capital investment.
Human Resources: We have enlarged our team with a project management engineer taking an operational role for the end-to-end implementation of SmartMelt. The founders will concentrate on the development of the product and the growth strategy. We aim to enlarge our team with personal having proven marketing and sales force expertise.
Partners: We are in discussions with different furnace and gas burners manufacturers as a customers with added-value potential as SmartMelt could be integrated into their sales offer.
Funding: We applied for a 3-year Eurostars project for the development of an operational customer friendly web-oriented SmartMelt version and improved thermophysical modules to increase its accuracy. We will apply for EIC Accelerator Pilot with a focus on marketing, commercialisation, reduction of implementation timeline and strategy to achieve growth plan. In case this is not successful, we will work on making our company and product investment ready to pursue venture capital investment.
Human Resources: We have enlarged our team with a project management engineer taking an operational role for the end-to-end implementation of SmartMelt. The founders will concentrate on the development of the product and the growth strategy. We aim to enlarge our team with personal having proven marketing and sales force expertise.
Partners: We are in discussions with different furnace and gas burners manufacturers as a customers with added-value potential as SmartMelt could be integrated into their sales offer.