Researchers at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have developed a digital twin system designed to improve water purification efficiency while reducing energy consumption and costs.
The project pairs a physical pilot water treatment plant with a real-time digital twin that monitors operations and electricity prices remotely. The digital twin updates the physical system’s settings at least every hour, aiming to enhance performance, reduce energy use, and prevent maintenance downtime. This approach provides cost savings for utilities and local governments.
“Digital twins are increasingly used as platforms for safely testing how new approaches affect complex systems,” said Subrata Mukherjee, the project lead at ORNL. “This project pairs a digital twin with a physical system, so they provide constant feedback to each other while operating. This unique approach supports data-driven decision making for water utility owners and operators.”
The project pairs a physical pilot water treatment plant with a real-time digital twin that monitors operations and electricity prices remotely
The physical pilot plant is managed by the University of California, Irvine, in partnership with the Orange County Water District (OCWD). The pilot replicates a full-scale drinking water reuse facility and operates dynamically, adjusting flows in response to fluctuating electricity prices. Conventional water treatment plants typically operate at fixed rates and require manual adjustments. ORNL’s digital twin enables a more adaptive approach that could inform future utility operations.
Unlike traditional digital twins that rely on large-scale physics-based simulations, ORNL developed a data-driven model using a limited set of flow observations and operational data to predict power demand and minimize costs. This method allows faster deployment and can be applied to various water systems, including drinking water reuse plants and seawater desalination facilities.
Funding for the project was provided by the National Alliance for Water Innovation, DOE’s Office of Critical Minerals and Energy Innovation, the California Department of Water Resources, and the California State Water Resources Control Board. ORNL researchers contributing to the project include Kris Villez, Alex Melin, and Sally Ghanem, with OCWD staff providing operational support.
ORNL is managed by UT-Battelle for DOE’s Office of Science, the largest supporter of basic research in the physical sciences in the United States, which focuses on addressing pressing scientific and technological challenges.
