Chemical plant operations consist of two types of processes, Batch Production Process and Continuous Production Process. Each of these processes require uniquely designed control system utility. The Continuous Production Process requires a sturdy and uniformly acting control system, which can deliver minimum downtime. However, the Batch Production Process requires a control system which is flexible enough to incorporate changes and shifts in procedure. TAS has a vast industry-specific solution offerings, experienced talent pool and a long-lasting experience in handling plant processes.
The Industrial Control or Automation system within the petrochemical industry is broadly utilized for three purposes
Real Time Control and Monitoring
Control system solutions like SCADA are implemented to gain primary control, monitoring and safety maintenance. These are very basic control system solutions capable of only upstreaming data regularly, with minimum reporting and analytics features.
Plant Control and Management
Control system/automation solutions for this purpose are mainly aimed at pulling out precise plant operation data trends and delivering it to the management enabling them to utilize the plant and its assets optimally, increase revenue, minimize losses and gather useful decision making assistance. These systems are a level above the real-time control systems, the output of the real-time control systems becomes the input for plant control management systems, out of which they can deliver data history, production accounts, mass balance, resource optimization, performance management, laboratory information management etc.
Enterprise Resource Management.
Enterprise Resource Management is aimed at generating insights regarding the facility as an enterprise, which would assist in efficient financial management, human resource management, stock monitoring and management, supply chain management etc. Being a cloud based solution, it is highly useful to big enterprises which operate across the world since the solution is scalable to any size and streamlines the enterprise’s engagement with its various stakeholders.
The base chemicals produced as a by-product in the petrochemical and derivatives industry are valuable input resources in other chemical processing factories. However, immense volume management, complex operations, strict environmental compliance and safety management become some of the limiting factors in handling and processing operations. Some of these base chemicals are toluene, toluene diisocyanate (TDI), 1,4-Butanediol BDO, ethylene etc.
TAS has been a long-time service provider of some of the major chemical processing companies and understands the needs and requirements of a chemical processing life cycle. TAS is fully equipped to address any kind of control system and automation requirement of a chemical processing enterprise at any stage of its processing cycle.
Specialty and Fine Chemical
Specialty chemicals are chemicals with a high added value that can be added to a number of products (such as plastics, coatings, adhesives and inks, cosmetics and cleaning products) in relatively small amounts to enhance the performance of these products.
Fine Chemicals are a special category of specialty chemicals, falling within the domain of bio-based chemicals. When specialty chemicals are used for the food or pharmaceutical industry they are usually called fine chemicals. Fine chemicals such as polypeptides and polysaccharides are produced in smaller volumes and at a higher cost than bulk chemicals. These specific chemicals are developed for high value application as aroma substances and flavorings or pharmaceuticals.
TAS has a long-standing experience in delivering automation and control system solutions to the fine and specialty chemical enterprises. With the cutting edge, industrial grade solutions comprising of Industry 4.0, Quality 4.0, IIoT, IoT, site instrumentation, control system solutions addressing safety, security and reliability, risk mitigation, asset management, regulatory compliance management etc. TAS can promise to be a long-lasting solution provider for any fine or specialty chemical enterprise.
Unlike fossil fuels, biofuels are made from renewable organic materials and has the potential to limit the ill outcomes of fossil fuel consumption such as greenhouse gas emission, export dependence, depletion of non-renewable resources. Though biofuel consumption has the potential to boost farm income, yet research showcases that biofuel production may cause some unpleasant consequences such as changes in the land use pattern, increased pressure on the local water resource, increment in food prices, greenhouse gas emission and shift in land use pattern.
With an aim to counter global warming and limit consumption of fossil fuels, production and consumption of biofuel is accelerating across the world. In the production of biofuel some of the significant limitations are the requirement of different temperature treatment to different raw materials, lack of consistency in operations procedure due to a mix of batch and continuous processes, efficient loading operations and strict quality check before dispatch.
The control system/automation solution provided by TAS for the biofuel production operations, is equipped with differentiated temperature control facility from a wide range of presets, the production control system is integrated enough to offer seamless procedural continuity to both batch and continuous processes; the loading operations are made error proof by interlinking tank gauge with loading system and the quality standards are maintained by conducting online gas chromatography.
Production Management Solution
Manufacturing Execution System (MES)
For effective production management, every system in the production chain needs to be closely connected. A variety of such system connectivity, sufficient to engage the entire production chain is provided in the MES.
To put into action a production cycle that can be monitored and utilized technologically, with the viability to predict outcomes, identify limits to production, take corrective action and further observe for improvements, a standardized production workflow is immensely important for any industrial grade chemical processing/manufacturing enterprise.
Production Control Solution
Loop tuning is aimed at adjusting the control parameters of the production cycle to an optimum value combination to receive expected control response.
An efficiently automated production/processing operation require advanced process control technology application and intelligent navigation systems.
Optimization in Real-Time
In order to draw maximum out of the invested resources, both as men and as material, in a production enterprise a holistic effort is required to find out the optimum performance parameters of each production system, in order to derive a configuration for the optimum performance of the entire production/processing cycle.
Production Monitoring Solution
Rationalization of Alarms
Alarm rationalization methodologies as put down by the Engineering Equipment and Material Users’ Association (EEMUA) No.191, is a recommended exercise to safeguard the entire production/processing cycle.
Key Performance Indicators (KPIs)
An extensive list of KPIs needs to be put in place covering the entire production/processing cycle. Dedicated monitoring across the indicators and prompt corrective action will go a long way in ensuring efficiency, reliability and optimum utilization of the systems in place.
Navigation management plays a vital role in ensuring reliability of each and every system within the production cycle, it also acts as a connecting link between the planning and implementation stage of a production/processing plant.
Production Environment Improvement Solution
Manpower upskilling solution allows the operational manpower to upskill themselves in adopting counter measures in a variety of scenarios like design failures, catastrophic failures, compounding failures, human error failures etc.
Operational Set up
Operational Set up scheme is required to take into account a holistic view of the operational conduct and pay precise attention to each and every operational necessity.
Seamless Equipment Utilization
A central operational hub is a necessity to ensure streamlined production. Each production sub unit needs to be placed in the closest vicinity of each other to ensure seamless communication.