02/01/2024
Redefining success: Conversations with AIMEN
Why did you join the ACHIEF project and what’s your role?
AIMEN has joined the ACHIEF project trying to reply to the challenges of the several energy intensive industries (EIIs) as one of the cornerstones of the EU economy but also responsible of generating large levels of CO2 emission together with a high energy demand.
The ACHIEF project has been an opportunity for AIMEN to move towards a more energy and resource efficient solutions, which will be enabled by the implementation of the novel high-performance materials solutions and protective coatings together with the sensor’s implementation. The use of digital tools will also accelerate this process compared with the more empirical and traditional materials development scenario.
For this, AIMEN count on a multidisciplinary group or researchers with a strong experience and different competences covering all the activities needed to address the ACHIEF requirements, mainly in Artificial Intelligence and Data Analytics based on Generative Adversarial Networks, Advanced Materials and Manufacturing Processes as HEAs and Laser Metal Deposition and Cladding and Electrochemistry and Optics focused on using these capabilities for designing sensors (Fiber Optic Sensors and Electrochemical Impedance Spectroscopy) to monitor industrial parts on line and in real time conditions.
What are the main solutions you are exploring to face challenges in the framework of the ACHIEF project?
On the digital side of the project, ACHIEF has developed a tool relying on Artificial Intelligence (AI) techniques for the discovery of new formulations for high entropy alloys (HEAs) and Polymer Derived Ceramics (PDCs). The tool relies on an specific AI technology called Generative Adversarial Networks which belongs to the Generative AI domain which has been already delivered. This tool has been developed with the aim of facing the massive problem of HEA design considering the countless amount of element combinations or their proportion within a potential candidate alloy. The capabilities along the ACHIEF consortium provided an ideal scenario to on the one hand put AIMEN work on the development of this digital tool and on the other hand to combine it with the simulation capabilities provided by VTT. These two branches triggered the possibility of generating candidate alloys based on the generative approach and evaluate the performance of such candidates through computer simulations in order to evaluate the alignment with user requirements, that are related to processes with fluctuating and extreme conditions. Together with the chemical composition HEAs design, ACHIEF aims to cover such requirements using innovative manufacturing techniques as the ones based on Additive manufacturing as Directed Energy Deposition and Laser Cladding to maximize the potential of these alloys though also a suitable microstructure given the expected properties. And Mechanical Alloying to improve the alloy characteristics through the addition of nanoparticles.
Considering these extreme conditions (high temperature, wear, corrosion), AIMEN also envisaged the use of sensors to monitor the behavior in real conditions of industrial components belong to steel, aluminium and oil & gas sectors. In one side, fiber optic sensors directly embedded during the additive manufacturing process of parts, can give powerful information about temperature and strain at the same time. On the other hand, AIMEN also proposed another solution for the on-line and continuous monitoring of the corrosion rate of different materials/coatings combinations used within the pipes in a refinery plant. The main advantage of this monitoring system is that it provides not only real-time quantitative data of PDC coatings’ performance but also information on the mechanisms controlling the materials´ degradation behavior.
What have been the main challenges to develop a new High Entropy Alloys?
One big challenge was the lack of large digital datasets of high entropy alloys, or also validation methods for the outcome of the generative models before sending the candidate materials for simulations which requires a significant computational cost and time. AIMEN addressed the own definition of a large dataset and has combined with tools such as AFLOW and OQMD for DFT calculations. This has provided an extensive dataset for training including also hints about the synthesizability of the candidate. Also, the second step that include computer simulations to validate the performance of candidate solutions has been a remarkable obstacle since not large amounts of simulations could be launched due to their computational cost and the timeline of the project. Meaning that the relationship between generated candidates and evaluations remained significantly asymmetric and eventual automatic feedback loops to improve the generative procedure could not be implemented.
Another aspect referred to HEAs is to match the chemical composition with the processability and properties. Most of known HEAs have been developed by traditional methods as casting and mechanical alloying. The processing conditions of these technologies are not as aggressive as the additive manufacturing ones that means strong thermal cycles together with high-speed rates giving as a consequence poor quality due to high porosity or cracks.
What are the main results you have achieved as partner in the ACHIEF project to drive energy efficiency in heavy industries?
The economic feasibility of many industries, as metal based, or refineries relies on continuous operation of the installations loop. To be competitive operators must pay attention to proper maintenance of critical equipment, while reducing shutdown times.
In this regard, the implementation of sensors as the novel corrosion monitoring technology developed by AIMEN will contribute to an overall extension of the plant operative life and a reduction of the O&M costs linked to failures due to corrosion processes, and so contributing to a reduction of CO2 emissions. This can be extrapolated to the FOS, that will be used in the aluminium and steel sectors in order to monitor the lifetime of industrial parts in high temperature and wear conditions.
Together with this, the development of new HEA materials and coatings able to substitute current used materials will also a potential benefit to the durability of industrial parts that normally fail as a consequence of extreme conditions as high temperature using during long time and high temperature wear. Increasing heat conduction or improving the performance and quality of a process are some of the advantages provided by these materials in order to enhance energy efficiency of the different process covered by ACHIEF (rolling, casting or heat treatment).
Little changes in maintenance and operations can significantly impact the efficiency of a facility. A large portion of savings can be maximized through ensuring components perform at optimum level and appropriate planning of maintenance activities.
Sensors developed by AIMEN provides real-time quantitative data of the material or the coating degradation in industrial parts. Users can assess and diagnose issues even long before they become operational, taking action and preventing dangerous future failures. This information then can be used to alter operating conditions and optimize the maintenance strategy maximizing the plant efficiency and the energy output.
How would you explain to a wider public what will be the impact of the ACHIEF project?
ACHIEF project aims to looks for replies for common problems of energy intensive industries like Metal base or Petro-Chemical. The conditions of these industries are extremely demanding of the equipment and materials involved in process. Together with these, the high energy consumption and a consequence, the CO2 emissions are one of the most relevant among all sectors. To increase the equipment lifetime, new solutions based on coatings and materials coming from the use of powerful digital tools together with new manufacturing processes facing the material challenges will be deployed after ACHIEF project end. Also introducing sensors for real time and online monitoring of parts and equipment will means saving of energy and cost avoiding premature failure or stop of the plants.
How do you see the future of the ACHIEF project?
ACHIEF will implement proved technologies based on novel materials, protective coatings and monitoring tools to reduce the overall consumption of the industries, the CO2 emissions and increase the lifetime of the equipment. Therefore, the successful of ACHIEF is considered as an important opportunity for other industrial partners to increase their process performance and competitiveness at long term, while reducing the environmental impact due to the energy consumed for compensating heat losses at components and equipment.
ACHIEF can offer promising opportunities if the consortium partners are committed to continuing to work together to ensure that the technologies and knowledge developed during the project are effectively exploited and contribute to a sustainable future. Some points to consider to guarantee the implantation of ACHIEF technologies could be:
- Collaboration and Partnerships: Build on existing collaborations and partnerships with industry stakeholders, including power plant operators and government agencies. Strengthen these relationships and explore new partnerships to promote the adoption of ACHIEF technology.
- Scaling Up: Based on the successful implementation of pilot projects, scale up deployment efforts where ACHIEF has demonstrated its effectiveness. Increase the number of installations and expand the geographical reach to capture a larger market share.
- Customization and Adaptation: Customize ACHIEF systems further to suit the specific industry characteristics.
- Knowledge Transfer and Capacity Building: Continue organizing workshops, training programs, and technical exchanges to facilitate knowledge transfer and capacity building.
- Monitoring and Evaluation: Implement a robust monitoring and evaluation framework to assess the performance and impact of ACHIEF systems in terms of emissions reduction and energy efficiency. Continuously gather data and feedback to improve the technology and enhance its value proposition.
AIMEN MAIN RESPONSIBLES TEAM
Pilar Rey, responsible in ACHIEF of the Materials and Additive Manufacturing process of HEAs
Santiago Muiños, responsible in ACHIEF of the Artificial Intelligence Materials development
Lorena Freire, responsible in ACHIEF of the development of the EIS sensor
Tania Grandal, responsible in ACHIEF of the development of FOS sensors.
