Energy Execution Intelligence
Process mining, dispatch conformance, prescriptive optimization
Energy execution intelligence — not just monitoring, but reconstructing what actually happened in your production processes and closing the loop to what should happen next. Ingest timestamped event logs from SCADA, ERP, and MES systems to rebuild the actual energy flow through your operations. Compare against optimal dispatch plans and energy-efficient process references to discover exactly where, when, and why your plant consumes more than it should — with timestamps, euro costs, and kgCO₂ attribution. Process mining applied to industrial energy, not IT workflows.
Key capabilities
Energy process discovery
Reconstruct the actual energy flow through your production process — not the design-basis heat and mass balance from commissioning documents, but what the plant actually did shift by shift. For a cement plant, that means mapping the real thermal energy path from raw mill through preheater tower through kiln through clinker cooler, timestamped and correlated with production output. Most plant managers have never seen their actual energy Sankey reconstructed from operational data — they work from design documents that are 5–15 years stale.
Process variant energy profiling
The same production output can be achieved through different operational sequences. Process mining discovers all variants and ranks them by energy intensity — revealing that variant A consumes 12% more than variant B despite identical output. In cement, steel, and chemicals, this alone can represent seven-figure annual savings.
Dispatch conformance scoring
If the Optimizer says run the waste heat recovery unit at 85% load and curtail grid draw between 14:00–16:00, and the actual SCADA data shows an operator override at 14:23 pulling 2 MW from the grid — that is a conformance gap. Produce a daily conformance score with monetary and kgCO₂ cost-of-deviation breakdown. The dispatch plan is the reference model, the SCADA stream is the event log, and the delta is where value leaks. No competitor in MENA offers this.
Deviation-to-consumption correlation
Delayed maintenance, degraded equipment states, and unplanned process interruptions all leave energy signatures. Connect the timestamps of operational deviations to consumption spikes — quantifying the energy cost of each non-conformance event. Build the financial case for predictive maintenance with hard consumption data, not estimates.
Shift & handover analysis
Startup and shutdown cycles triggered by poor shift handovers create disproportionate energy spikes. Process mining surfaces which handover patterns, operators, and shift transitions correlate with excess consumption — turning an invisible operational cost into a documented training and protocol improvement opportunity.
Tariff-process misalignment
Discover that certain production batches are systematically scheduled in peak tariff windows — not by design, but because upstream process delays cascade through the schedule. Quantify the cost in local currency terms and identify which upstream bottlenecks to fix. Immediately actionable without capital investment.
Conformance & compliance trails
For clients exporting to Europe under EU CBAM, apply process mining to the data collection and reporting process itself. Reveal where manual workarounds, missing records, and non-conforming measurement practices create compliance risk. Quantify gaps in the embedded carbon data trail per production batch before auditors find them.
Closed-loop process optimization
Move from analytics to operations. Instead of a dashboard showing you wasted $4,200 last week, push a real-time alert to the operator: switching to self-consumption mode now would save $380 over the next 4 hours based on current grid pricing and your PV output forecast. Feed process variant energy profiles into dispatch and scheduling decisions so production biases toward energy-optimal process paths. Auto-trigger dispatch adjustments when clients authorize it — the Celonis execution management concept applied to energy operations.
How it connects
Energy Execution Intelligence reconstructs event traces from the same SCADA and metering data that Facilities & Metering already ingests. Conformance findings feed into Energy Audits as quantified improvement opportunities. Tariff-process misalignments inform Procurement cost models and Demand Response scheduling. CBAM compliance trail analysis integrates directly with Carbon & ESG reporting.