EPOC: Increased efficiency for your systems

EPOC® Suite

Key Takeaways

The EPOC® Suite is a higher-level optimization and control solution for the efficient control of energy-intensive industrial and energy systems.
The EPOC® Suite combines advanced process control, simulation, energy balancing, monitoring and diagnostics to continuously improve efficiency, process stability and emission behavior.
The CONENGA Group integrates the EPOC® Suite into existing plant structures and develops individual process and control technology optimization concepts.
Thanks to forecast-based control strategies, load management and simulation-based optimization, the EPOC® Suite reduces fuel consumption, CO₂ emissions and manual intervention in system operation.
The CONENGA Group uses the EPOC® Suite for the holistic optimization of energy supply, energy distribution and energy consumption in industrial and energy parks.

With the EPOC^® Suite takes your site to a new level of efficiency.
The interaction between energy supply, energy distribution and energy use is optimally controlled and clearly displayed with the help of definable criteria. This means you have existing and future challenges well under control.

We are looking forward to answering your questions

Our experts will be happy to help you optimize your systems! Would you like to find out more? Should we call you or would you like to receive further information by e-mail?

Let’s talk about it!

I am looking forward to answering your questions

Sebastian Sturm is your expert concerning the EPOC® Suite

With the EPOC® Suite, the CONENGA Group develops data-based control and optimization solutions for the efficient, low-emission and stable operation of energy-intensive industrial plants.

EPOC^® – Energy & Production Optimization Control

For energy-intensive industries and utilities, the challenges are changing dynamically. Scarce availability causes prices for energy sources to rise massively. The requirements of the “European Green Deal” impose additional costs (CO₂ pricing) and restrictions on fossil fuels in order to reduce greenhouse gas emissions. In addition to compliance with statutory emission limits and the reduction of greenhouse gas emissions, there is also the parallel challenge of the Cost reduction by reducing the use of primary energy. More and more often, a shortage of skilled workers is also a task to be overcome when staffing the operating team.

EPOC® stands for “Energy & Production Optimization Control” and offers a higher-level optimization solution that can be used site-wide. With the core modules from the areas of advanced process control, simulation, energy balancing, diagnostics and monitoring, built with deep process engineering know-how, you get a comprehensive tool to achieve and maintain a maximum efficiency level and adapt to new conditions. The modules can be deployed quickly and are integrated precisely into existing systems.

The EPOC^® Suite consists of six standardized process and control engineering modules and the integrated web platform for monitoring, data availability, visualization and reporting. Demand-driven implementation combines fast realization with optimal impact. You benefit from the improvement of the overall efficiency by increasing the degree of automation and the constantly efficient operation of your plants in compliance with legal requirements.

Fluctuations in energy demand are optimally managed using forecasting tools in the control of energy supply and distribution. Using less fuel, reducing the CO₂ footprint and optimizing the balance between energy supply and energy use have a direct positive effect in terms of climate protection and costs.

Smoother driving and less work due to a significant reduction in the number of manual interventions required are significant from an organizational and economic point of view. Thanks to the simplification and stabilization of (production) processes, productivity and quality are increased. The life and travel time of your equipment will be extended thanks to uniform operation.

You can download the EPOC^® implementation project as an investment or without CAPEX via a user agreement.

In this case, a usage fee is served via the optimization revenues. EPOC overview drawing

In both cases, the implementation is compliant with the EU Taxonomy Regulation on the achievement of climate targets (EU 2020/852). The EPOC^® Cloud enables a clear presentation of your investments and the explicit identification of your contributions to climate protection.

learn more:

EPOC® Boiler

EPOC® Dryer

EPOC® Industry Specific Solutions

EPOC® Load Hierarchy Management

EPOC® Steam Manager

EPOC® Local & District Heating

Bioenergie Kufstein

to the CONENGA-YouTube channel

“As part of the upgrade of our fluidized bed boiler by the experts from CONENGA, an SNCR system was also integrated. This not only enables us to stay below the emission limits, it is also stable and reliable in operation after more than a year of use. The SNCR control system was implemented as part of the integrated EPOC® Suite.”

DI (FH) Bernhard Pichler, Project Manager Norske Skog

“Communication with CONENGA is always swift and solution-oriented. CONENGA works on its own initiative in close coordination with the plant personnel, which leads to a high level of acceptance of the optimized control of the EPOC® Boiler. Commissioning was very efficient and the new control system was able to remain active in continuous operation faster than planned. After a well coordinated tuning phase with the operating personnel, all the targeted goals were achieved. We look forward to further projects with the CONENGA engineers.”

Maik Hawrylak, Power Plant Manager EGGER Wood-Based Panels

“CONENGA are good communicators and experts on combustion control with deep process know-how integrated in their control product EPOC® Suite. As a very reliable and self responsible partner our project could proceed according to schedule and problems were detected and solved shortly after.”

Mr. Dae-Yeon Kim Director, G&Tech Global Environment Tech Waste Incineration Plant

Reference project: UPM Schongau

Energy park management

Potential studies

Training courses

Your benefit at a glance

Holistic

Based on a detailed analysis as part of the potential study, we work with you to select the combination of EPOC^® modules and toolboxes to suit your specific system configuration. Necessary adaptations – especially concerning sensors and actuators – are also clarified. Accordingly, in the superordinate EPOC^® Suite, we design the control of the systems included.

Optimizing

The EPOC^® Suite increases the overall performance of the systems included through innovative control concepts that are optimally designed for the processes of energy-intensive industry. The EPOC^® Suite acts as a higher-level control system with different system controls in the existing building and ensures an optimum balance of energy supply and energy use using intelligent forecast models, storage and buffers. Integration into the existing environment is seamless during operation – without downtime and with full cloud connectivity.

Safe

The safety of your system is our top priority, which is why EPOC^® Suite follows a higher-level control strategy that specifies setpoints for existing control loops. This ensures that the existing data stored in EPOC^® will continue to be operated within the process engineering limits and corresponding safety concepts specified by the plant manufacturer. The existing safety concept remains fully in place and is not affected or restricted in any way by the overriding regulation. As a result, your plant runs better and is just as safe as before.

Sustainable

Thanks to improved overall efficiency and a significant reduction in fuel consumption and energy losses in distribution and balancing, the use of EPOC^® Suite optimizes the sustainability of your system in step with the increase in efficiency. This also leads to a reduction in emissions. The EPOC^® Cloud also enables precise reporting on the reduction of your carbon footprint and thus makes a valuable contribution to sustainability reporting.

FAQ about the EPOC® Suite

What is the EPOC® Suite?

The EPOC® Suite is a modular platform for higher-level control, energy optimization and process management in energy-intensive industrial plants. It combines process data analysis, simulation, advanced process control and monitoring to improve efficiency, operational stability and emission behavior. The solution can be integrated into existing plant and automation structures and works on the basis of existing control loops. The CONENGA Group develops individual control and optimization concepts, analyses operating data and implements the EPOC® Suite tailored to the respective plant configuration.

What tasks does the EPOC® Suite perform in industrial and energy systems?

The EPOC® Suite optimizes the interaction of energy generation, energy distribution and energy consumption within complex system structures. To this end, process data, load states, storage, consumers and energy sources are combined in a higher-level control strategy. The aim is stable and efficient operation, taking into account technical, economic and emission-related boundary conditions.

How does the EPOC® Suite improve energy efficiency and emission behavior?

The EPOC® Suite uses model- and forecast-based control algorithms to optimize furnaces, steam systems, load distribution and heating networks. This reduces load changes, stabilizes energy flows and uses fuels more efficiently. This lowers CO₂ emissions, reduces internal energy consumption and improves compliance with emission limits.

How does the CONENGA Group integrate the EPOC® Suite into existing systems?

The CONENGA Group first carries out a potential study with operating data analysis, plant inspection and evaluation of the existing control structure. The sensors, actuators, PLC, server and network technology are then adapted and the higher-level control system is implemented. The integration takes place during ongoing operation and without affecting existing safety concepts.

What modules does the EPOC® Suite include?

The EPOC® Suite consists of standardized modules such as EPOC® Boiler, Steam Manager, Load Hierarchy Management, Dryer, Local & District Heating and solutions for industrial systems. These are supplemented by monitoring, reporting, simulation and forecasting functions. The modular structure enables system-specific adaptation to different industrial requirements.

What services does the CONENGA Group provide after implementation?

As part of our service offering, the CONENGA Group supports the EPOC® Suite throughout its entire life cycle with remote maintenance, monitoring, data analysis and continuous optimization. This includes parameterization adjustments, software updates, hardware checks as well as process and control engineering support for new operating states. This enables the system performance to be stabilized and further developed in the long term.

Integration into the inventory, topology, hardware

The integration of EPOC^® into your IT inventory involves several levels:

EPOC^® PLC (Customer OT): Level with connection to existing control technology
EPOC^® Server (Customer IT): Engineering station, data hub for other data sources
EPOC^® Cloud (External Services): Reporting, service, monitoring, remote maintenance connection

The hardware used for the controllers (PLC) is highly available and can optionally also be designed redundantly. The connection to the existing infrastructure is carried out with the highest IT and OT security criteria. Between the inventory and EPOC^® there is a signal tracking system that enables skip-free switching. The signal switching is implemented together with the I&C programmer responsible for the site.