Chemistry 4.0 Growth through innovation in a transforming world Chemistry 4.0 | Table of contents
Table of contents
A new development in the chemical industry: the era of Chemistry 4.0 06
Incremental innovations and disruptive changes in the chemical sector 08
The digital transformation of the chemical industry 11
The chemical industry’s key role in the circular economy 15
Mutual enhancement between digitalization and circular economy 19
Recommendations 23
Contact 28
03 Chemistry 4.0 | Foreword by the VCI President
Dr. Kurt Bock, President, German Chemical Industry Association (VCI)
04 Chemistry 4.0 | Foreword by the VCI President
Foreword by the VCI President
Chemical and pharmaceutical com- Digitalizing the chemical industry today in order to take advantage of panies in Germany have shown time offers new opportunities as well as opportunities through transforma- and again that they can successfully risks. Research and development, tion tomorrow. From this foundation, master the tectonic shifts in our com- manufacturing, and business models we have derived recommendations petitive environment; examples in will be transformed. It is not easy aimed at the association and its the 150 year old history of industrial to separate myths from real risks member companies, as well as poli- chemistry are changes in raw mate- and opportunities, take appropriate cy-makers. If we all work together, we rials, relocation of growth centers measures, and gain a competitive will be able to expand the role of the to emerging economies, and the call advantage. This transformation offers chemical industry as an innovation to make business more sustainable, great opportunities for the highly center for Germany. which has been receiving broad pub- developed chemical industry in Ger- lic support recently. many in terms of enhancing its global I would like to express my special competitiveness. The chemical and thanks to the many experts, The key to our competitiveness is pharmaceutical industry’s innovative particularly from the member com- the innovative power held in our processes, products, and services panies, who took part in numerous companies: new and improved make a significant contribution to sus- workshops and contributed to this molecules, production and business tainable development of our society. study, as well as the medium-sized processes. In Europe, our sector has Our sector will continue to be a tradi- enterprises that responded to the been characterized by globalization, tional supplier of materials, while our online survey. specialization, and focusing on the role as a service provider will grow in core business since the 1980s. We importance at the same time. Their knowledge and their assess- have now reached the next level: ment of the industry’s future have Chemistry 4.0. Digitalization and Against this background, the VCI, its made this study possible at all. circular economy are the key cha- member companies, and Deloitte racteristics, and these two elements Consulting have examined which will fundamentally alter the way we developments will influence the work, as well as support sustainable chemical and pharma business up management. to 2030, and what we need to do
05 Chemistry 4.0 | A new development in the chemical industry: the era of Chemistry 4.0
A new development in the chemical industry: the era of Chemistry 4.0
The chemical and pharmaceutical icals that until now had often been Circular economies will gain in impor- industry (in the following: chemical covered by German exports. These tance, and digitalization will lead to industry) is an important driver for changes mean a further increase in extensive changes in all sectors. These innovation and growth in the German competitive intensity for the chemical two core topics are of central impor- economy. However, fulfilling this role sector in Germany, both in its Euro- tance to the trends in the chemical in the long term will require significant pean home market and in the export sector up to 2030 and beyond. efforts; like all industries in Germany, markets: in Europe, import pressure the chemical and pharma sector is on base chemicals and intermediate As part of these changes, a new phase faced with elementary strategic and products from resource-rich regions of development is beginning in the structural challenges. will go up, while in export markets, German chemical industry. Following competition with local providers and industrialization and coal chemistry On the one hand, demand for chemical other importers will intensify. (Chemistry 1.0), the emergence of products in Western Europe will grow petrochemistry (Chemistry 2.0), and only modestly in the decades ahead, On the other hand, a paradigm change increasing globalization and speciali- moving the focus toward markets in in demand structures and public zation (Chemistry 3.0), the industry is Asia, South America, and, eventually, preferences has been taking place for a entering a new phase with Chemistry Africa. Since international and local while. The desire to use resources in an 4.0, in which digitalization, circular competitors are expanding their pro- efficient and environmentally friendly economy, and sustainability play key duction capacities there, and additional way has noticeable effects on energy roles (see diagram). capacities in resource-rich regions are supply and consumption habits. The to be expected, the whole competitive trend toward the Sharing Economy environment in the chemical industry is illustrates this transformation. By about to face a transformation. In addi- developing strategies to serve changing tion, manufacturers in developing and customer requirements, companies resource-rich countries are expanding make an important contribution toward their scope to include specialty chem- reaching UN sustainability goals.
06 Chemistry 4.0 | A new development in the chemical industry: the era of Chemistry 4.0
Development from Chemistry 3.0 to Chemistry 4.0
Chemistry 3.0 Chemistry 4.0 lobalization Specialization Digitalization Circular Economy
Globalization, the European internal market, Drivers for growing competition from gas-based chemistry, Digital revolution, sustainability, climate protection, transformation the influence of financial markets on corporate closing material cycles strategies, commodification
Intensive use of data, recycling of carbon-containing Increasing use of renewable raw materials and Raw materials waste, H from renewable energies in combination natural gas 2 with CO2 used to produce base chemicals
New synthesis and production processes through Technology biotechnology and gene technology, enlargement Digitalization of manufacturing processes of individual processes
Close cooperation between basic research in Decentralization of R&D in customer markets, Research universities and application-oriented research in utilization of Big Data, oint development with companies customers
Internationalization of trade and on-site Corporate production abroad, specialization and growth in More flexible cooperation as part of economic net- structure SMEs, consolidation through M&A, creation of works, digital business models, and consolidation chemical parks
Expanding product range, specialty chemicals Expanding the spectrum of value creation: chemical oriented to specific customer requirements, new sector becomes a supplier of extensive and Products drugs, replacement of traditional materials with sustainable solutions for customers and the chemical products environment
Environmental protection integrated into produc- With Chemie3 (ecology, economy, and social affairs), Environment, tion, increasing product safety through expanded sustainability becomes a comprehensive model and Health and Safety review of material properties, Responsible Care future concept for the industry
07 Chemistry 4.0 | Incremental innovations and disruptive changes in the chemical sector
Incremental innovations and disruptive changes in the chemical sector
As part of this study, a systematic continue to offer growth opportunities analysis identified 30 trends that will in future. be of key importance to the chemical industry in Germany until 2030. These The chemical sector in Germany is trends were analyzed with regard to well-positioned to master the chal- the underlying drivers, and assessed lenges of incremental change. A strong according to their probable impact industry network in Germany, the inno- (see diagram). vative power of the chemical industry, and especially well-developed, focused, The results show that many innova- and customer-oriented medium-sized tions in important customer industries enterprises are key success factors. of the chemical industry, e.g. in the au- As such, these incremental changes tomotive, construction, and packaging continue to offer the chemical sector industries, will likely happen gradually. opportunities for growth, although any Specific examples of such fields of competitive advantages gained erode innovation are lightweight construction faster and faster due to intensifying using plastics and composite materials competitive pressure. in the automotive industry, and more energy-efficient construction mate- rials. These incremental innovation processes are part of the business and success models that already exist in the chemical industry in Germany, and will
08 Chemistry 4.0 | Incremental innovations and disruptive changes in the chemical sector
Trends in the chemical industry up to 2030
Societal politically driven Genome editing in Renewable energy – medical applications Bio-plastics as production technologies packaging material Carbon Capture Storage / Genome editing for Carbon Capture Utilization precision breeding
Lightweight vehicles Waste-to-Chemicals Bio-refinery Renewable Agricultural turnaround resources Self-medication New medical technology Genetically modified plants Electro mobility Energy-efficient Power-to- buildings Material mix for Perception of chemicals packaging (discussion on ingredients)
Personalized Disruptive
Incremental Urban Farming Personalization medicine
New mobility Changing relationship Raw material mix concepts chemical supplier – and supply for end customer ermany Industrial Biotechnology Digitalization of Modular building Material efficiency E-Health agriculture in construction Additive Manufacturing Small impact
Medium impact
Big impact Entrepreneurial economically driven
09 Chemistry 4.0 | Incremental innovations and disruptive changes in the chemical sector
An exceptionally large proportion of electricity, hydrogen, and CO2 will gain the changes expected over the coming in importance. The chemical sector years has a disruptive character for the can play a key role here in linking the chemical industry, however. Several energy and industrial sectors by mak- of these expected developments are ing use of supply peaks in renewable closely linked to the ongoing digitaliza- energies to manufacture synthetic raw tion of business models. In addition, materials, thus reducing the share of many developments have an evident fossil resources. relationship with sustainability topics and circular economy concepts (e.g., renewable raw materials, renewable Product portfolios energy, carbon capture & utilization, biorefineries, bioplastics). On the one An example of fundamental change in hand, these disruptive changes offer demand structures is the increase in opportunities in new growth areas electro mobility, which causes demand for chemical companies. On the other to decline for many chemical products hand they also pose challenges. from catalysts to heat, oil, and gaso- line-resistant plastics, as well as oil They have a massive influence on tech- and fuel additives. At the same time, nologies, product portfolios, structures new business segments are opening of value creation, and business models around electric engines such as batte- in the chemical industry, as well as on ry technology and battery recycling. its clients and suppliers. Additionally, the demand for lightweight materials increases. Process technologies
Examples of disruptive changes in Business models process technologies can be found in biotechnology and the utilization of The digital transformation can also renewable sources of energy. The ad- change whole value creation struc- vances in industrial biotechnology will tures. Depending on the scope of the lead to an increased and more efficient disruptive change, chemical companies application of biological raw materials will then need to redefine their custom- in production processes (biologization er relationships or business models of chemistry). In the medium term, (examples in the following chapter). the production of chemicals from
10 Chemistry 4.0 | The digital transformation of the chemical industry
The digital transformation of the chemical industry
Digitalization offers an opportunity for Transparency and areas like predictive maintenance, net- chemical companies to collect extensi- digital processes worked logistics, and the application ve data in their own businesses, then of concepts from virtual reality and evaluate and utilize it to improve ope- ...as the first category, include the advanced simulation (‘in-silico’) for rational processes within the company. collection and initial utilization of research. The chemical industry is comparatively comprehensive process data within the well-developed in this area, especially company. These lift efficiency potenti- its continuous and discontinuous als in the context of largely unchanged production processes, as well as its bu- manufacturing and business models. siness processes. However, due to new Even in an industry that is already technologies and a systematic collec- comparatively advanced in this respect, tion of large data volumes (digital bulk digitalization offers new technologies data, e.g., on customer behavior and for progress, for example, by further preferences, utilization of products, automating manufacturing processes. environmental properties of products), digitalization opens new opportunities to make further improvements in the Data-based operating efficiency of processes and operating models models, and to develop new business models. In future, data utilization will ...intensively utilize operational big therefore become more and more data, external data (e.g., about the important for value creation in the che- behavior of markets, customers, and mical sector. It can be split into three competitors), and advanced methods categories: of analysis for making decisions and increasing efficiency. The industry is currently driving developments in
11 Chemistry 4.0 | The digital transformation of the chemical industry
Digital business models undergoing dynamic expansion: 30% of chemical SMEs in Germany already ...describe value creation structures achieve 5% of their revenue through that fundamentally alter existing digital business models, and a further processes, products, or business 40% intend to introduce digital busi- models. What differentiates them is ness models in future years. Over the that products and services are digitally next three to five years, chemical com- augmented to increase customer utility. panies are planning to invest a total of Often, this is not created by an individu- more than a billion euros in digitaliza- al company, but within digital networks tion projects and new digital business in which different providers join to models to achieve this. Digitalization generate solutions for their customers. will therefore become an integral part Customers are often actively involved of the business and success model of in this process, enabling them to the chemical industry. specify their individual requirements. The combination of digital services with products from the chemical industry in the digitalization of agriculture, in addi- tive manufacturing (3D printing), and in e-health concepts in the health sector are examples of current developments in this area.
The industry currently finds itself in a phase of change and development. Digital processes and data-based operating models are applied more frequently. Half of small and medi- um-sized chemical companies (SME) intend to invest extensively into the digitalization of their processes and business activities. Likewise, the importance of digital business models to the future viability of the German chemical industry has been recog- nized, and digital business models are
12 Chemistry 4.0 | The digital transformation of the chemical industry
Digital case examples in the chemical sector
Data-based operating models Digital business models
1. The further development of ‘in-silico’ experiments aims 1. In digital agriculture, established companies from the at simulating larger chemical systems with regard to chemical, agricultural and food processing industries quantity, foresight and scalability. Advances in quantum form an economic network with new providers, which computing technologies, in analysis methods such as enable a realtime analysis of weather, soil, plant, and the atomic force microscope, as well as in machine machine data, as well as realtime optimization of agricul- learning are intended to make these possible. Based on tural processes. Field View by Climate Corp. is an exam- these insights, companies can digitally conceptualize ple of a digital business model in the chemical industry materials with the required chemical, electronic, and in this network. The platform collects and analyzes physical characteristics, and determine an economically images and data about weather and soil conditions to and ecologically efficient manufacturing route. calculate the optimum use of fertilizer, seeds, and crop protection for the farmer.
2. In predictive maintenance, sensors collect realtime big 2. A number of established companies and start-ups are data about the current operating status, with which spe- crowding into all areas of additive value creation, e.g. cifically developed algorithms predict machine failures into hardware manufacturing, software development, as well as their cause. In this way, production losses can service provision, and material manufacturing. Such be avoided through appropriate maintenance measures, as BASF: the company is working with HP to offer significantly reducing the costs and time required for customers novel materials for 3D printing through the maintenance. Multi Jet Fusion Open Platform. Customers can directly contact BASF via the platform to commission the de- velopment of materials for specific 3D applications.
13 Chemistry 4.0 | The digital transformation of the chemical industry
The potential for increasing efficiency through remote-controlled, preventati- through digital processes and data-ba- ve, and proactive maintenance and the sed operating models differs depending corresponding operation of plants. In on the specific segment of chemical downstream segments, closer to the industry. In upstream segments of the customer, efficiency gains lie more in value chain, close to raw materials and the improvement of sales, marketing, energy, efficiency gains in manufac- and administration. turing come into effect, for example
Overview of implications of digitalization