Digital Twin-Enabled Thermal Energy Management System for Sustainable Manufacturing Process Optimization
Otabek Mukhitdinov et al.
What the paper says
Manufacturing processes consume substantial thermal energy, yet siloed management approaches cannot exploit facility-wide synergies. This study develops and validates an integrated Digital Twin (DT) that fuses physics-based thermal models with machine-learning forecasts and multi-objective optimization to coordinate process heat, waste-heat recovery, thermal storage, and on-site renewables in real-time. Deployed across four heterogeneous manufacturing facilities, the DT generated operator-ready knee-point recommendations that balanced energy use, operating cost, and emissions under changing production and weather conditions. Across sites, deployment produced substantial, sustained gains in thermal-energy efficiency and marked reductions in carbon intensity (approximately 27% higher efficiency and about one-third lower emissions in aggregate), demonstrating that system-level orchestration outperforms isolated component upgrades. Novelty lies in plant-scale, real-time co-optimization of process heat, waste-heat recovery, thermal storage, and on-site renewables using a hybrid physics–ML digital twin with uncertainty-aware multi-objective control, field-validated across four heterogeneous manufacturing sites.
Evidence weight
Balanced mode · F 0.40 / M 0.15 / V 0.05 / R 0.40
| F · citation impact | 0.50 × 0.4 = 0.20 |
| M · momentum | 0.50 × 0.15 = 0.07 |
| V · venue signal | 0.50 × 0.05 = 0.03 |
| R · text relevance † | 0.50 × 0.4 = 0.20 |
† Text relevance is estimated at 0.50 on the detail page — for your query’s actual relevance score, open this paper from a search result.