Digital twin framework for the ex-ante evaluation of process-level decarbonisation measures
Year: 2026
Type: dissertation
Abstract: The paper industry plays a central role in the European bioeconomy but remains highly energy- and emissions-intensive. Although decarbonisation pathways exist, their implementation at mill level is constrained by the lack of robust ex-ante evaluation under site-specific production conditions. Digital twins provide a promising approach to enable scenario-based ex-ante evaluation of process-level decarbonisation measures. The objective of this thesis is to develop and validate a digital twin framework for the scenario-based evaluation of the techno-economic and CO₂eq effects of process-level technology and operating strategy changes under heterogeneous brownfield conditions. To this end, a design-oriented research approach based on the Design Science Research Methodology (DSRM) is applied. The analysis identifies central deficits in process-level energy and CO₂eq transparency, data integration, interoperability, and role-specific decision support. To address these deficits, the digital twin framework FOREST (Framework for Operations, Resources, Energy and Sustainability Transformation) is developed. The framework comprises six modules. It combines interoperable communication interfaces, Asset Administration Shell (AAS)-based semantic modelling, and Functional Mock-up Unit (FMU)-based simulation to enable the structured integration of heterogeneous data and models. FOREST is demonstrated and validated in an industrial environment on a tissue production line. It enables process-level transparency and scenario-based evaluation of decarbonisation measures, such as heat pumps, raw material changes, and flexible electrification strategies, under site-specific conditions. Its transferability is further validated through transfer pilots covering three within-industry applications as well as one cross-industry application in nonwovens. FOREST supports industrial decision-making. The demonstration corresponds to a technology readiness level of 7. The economic evaluation indicates that amortisation within less than three years is achievable, depending on the specific measure and site conditions.
Source: RWTH Publications (RWTH Aachen)
Author: Othen, Rosario
Institution: RWTH Aachen University
Language: English
Subfield: Industrial and Manufacturing Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: green
OpenAlex ID: W7202384106
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