Digital Twins in the Shipping Industry - Benefits, Use Cases and Possibilities

What are digital twins? 

In 2002, scientist Dr. Michael Grieves first coined the term and concept of "digital twin" at a conference for manufacturing engineers in Michigan. Today, a digital twin is more than just a classic model but evolves dynamically. This means that whatever happens to the physical object or system also happens to its replica aka the digital twin. 

The concept of a digital twin first made history in 1960 as part of the Apollo 13 mission. NASA created a digital model of the spacecraft to allow scientists and engineers back on Earth to test possible solutions in the event of problems. 

This first-of-its-kind digital twin system was critical in the 1970 astronaut rescue mission, although it was not called digital twin at the time. NASA used 15 simulators to train and test the mission parameters that engineers used to figure out what went wrong during the mission. After weighing up possible solutions, the best one was passed on to the crew. 

The widespread usage of digital twins, however, only began after the introduction of IoT connectivity and sensor technology combined with more advanced data analytics techniques. 

At Hapag-Lloyd we are also trying to integrate IoT into our daily business. For example with our visibility solution Live Position.

What are the advantages of digital twins? 

Digital twins already help entire industries to modernize entire processes. By analyzing and interpreting data, they ensure more effective decision-making: 

• Visualization: The design of a digital twin allows port authorities, for example, to simulate the construction and operation process and then visualize various infrastructure elements of vessels, premises or other objects in real-time. Thanks to that entire port operations, such as vessel berthing, cargo handling, and storage space allocation can be optimized by playing out the scenarios with the digital twin first. 
• Forecasting and troubleshooting: By combining virtual and physical reality, problems can be identified and solved at an early stage. For example, warehouse and delivery processes can be optimized by using digital twins of the respective premises to virtually experiment with various scenarios for storage and process optimization. 
• Understandability:  Digital twins transform maritime data that is difficult to understand into understandable options for action. For example, input sectors of the digital twin measure the behavior of the ship in response to various environmental influences such as waves, currents, wind, and temperature. This not only increases the efficiency of logistics processes, but also minimizes potential risks. 
• Product development: 3D models and simulations on a digital twin provide a glimpse into the future and enable faster production. For example, they can analyze how rising sea levels will affect supply chain processes and container shipping in general. Digital twins can also be used to test out new shapes or propellers until the ideal format for maximum efficiency has been found. The can also be used to forecast maintenance occurances before they actually happen. 
• Improved safety and longevity: Digital twins facilitate proactive maintenance and risk management, minimizing the likelihood of equipment failures, accidents, and environmental incidents, thereby enhancing safety standards and regulatory compliance. 
• Sustainability management: Through optimization of fuel consumption, route planning, and resource allocation, digital twins contribute to reduced carbon emissions, energy consumption, and environmental impact, aligning with the industry's goals for sustainability and eco-efficiency. 
  

How are digital twins used in ports and container shipping? 

Container shipping also requires constant diagnosis and forecasting in order to optimize processes. After all, shipbuilding is a highly complex field of development. Digital twins are also used in ports to address challenges such as efficiency, emission control and ergonomics of operating systems. 

Some use cases of digital twins in shipping include: 

• Predictive maintenance: Digital replicas of ship components, such as engines and propulsion systems, enable predictive maintenance by analyzing real-time sensor data to anticipate failures and schedule proactive repairs, minimizing downtime and optimizing performance. 
• Supply chain visibility: Comprehensive digital twins of the supply chain provide real-time visibility into inventory levels, transportation routes, and delivery timelines, enabling companies to identify bottlenecks, mitigate risks, and improve overall supply chain resilience and responsiveness. 
• Port operations optimization: Virtual representations of port facilities, including berths, cranes, and storage areas, facilitate optimization of port operations by simulating vessel berthing, cargo handling, and storage space allocation, leading to improved efficiency and reduced congestion. 

A real-life example is the italian port of Livorno. It has been working on its technological infrastructure since 2016 - and digital twins are already being used. The entire port has been virtually modelled to replicate physical elements such as cargo containers, cameras, and general cargo storage. 

WDR (Wide Dynamic Range) cameras capture every aspect of daily work and model the digital twin port. Combined with VR (virtual reality) applications, operators can virtually navigate the twin model and get a complete overview of the digital port area. After all, the accurate and efficient storage and location of goods is crucial for logistics processes. 

The future of container shipping will also be determined by digital twins of ships. By switching to a virtual control system, entire fleets and port operations can be optimized. Digital twins of vessels can carry out software integration and thus act as simulators for the physical object and analyze real situations like maintenances or even engine failures and prevent them.   

But not only the Port of Livorno is using digital twin technology to improve their operations. Even one of the largest and busiest ports in the world, the Port of Rotterdam, is taking advantage of digital twins. One the port’s innovations is the use of the so-called “digital dolphins”, which are sensor-equipped quai walls and buoys to track tides, weather wind speed and other weather-related measures.  

The port also uses an innovative concept with a 42 container – a container that is equipped with all kinds of sensors and functions as a research tool that travels the world. Thanks to the sensors, not only data from the container within such as temperature and humidity can be tracked, but also data throught the entire transportation journey. With the collected data, journeys can be improved and re-shaped. 

The innovative power of digital twins   

In conclusion, digital twins represent a transformative technology with immense potential to reshape the landscape of the shipping and logistics industry. By using the power of virtual replication, real-time data analytics, and predictive modeling,the entire industry can unlock new levels of efficiency, safety, and sustainability across all operations. Embracing new technologies like digital twins will be instrumental in charting a course towards a more connected, resilient, and agile future.