Specialty Chemicals

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With unpredictable raw material costs, increasingly stringent health and environmental regulations, and stiff global competition, specialty chemical manufacturing requires agile and reliable process control.

The Solution

NovaTech is easing that pressure and increasing revenues for its specialty chemical customers like Arizona Chemical, Hubei Shanshui Chemical CO. Ltd., Nalco, and Kemira with solutions that improve yields, decrease waste, achieve higher equipment utilization, speed up product introductions, and bring their plants and process improvements on-line faster.

The NovaTech D/3 DCS provides the digital infrastructure and decision making components of successful chemical and specialty chemical plants worldwide.  With its ability to handle complex processing algorithms, safety interlock logic, high performance visualization, and advanced optimization tools, D/3 is the control system of choice for many chemical manufacturers. NovaTech solutions have a proven track record and continue to control the most critical operations of chemical plants for 3 decades and counting.

In a recent application for Nalco–a specialty chemical and water, hygiene, and energy technologies manufacturer–an Energy Management solution was implemented to reduce operating costs related to energy expenditure. By integrating real-time energy and utility costs, equipment efficiencies, and asset and emissions data into a common and verifiable data set, plant managers and operators are able to manage their processes using accurate energy costs per unit of production, minimizing energy costs and environmental impact.

Working closely with Nalco, NovaTech engineers built a sophisticated set of programs and algorithms to track the efficiency and energy usage of critical plant equipment and drive behavioral change, conducting a series of Factory Acceptance Tests (FATs) using sophisticated simulation techniques and historical plant data. Using this information, a comprehensive set of role-based dashboards and trends were created to facilitate efficient visualization of KPIs associated with plant operations. These detailed screens are utilized by utilities supervisors and plant operators, arming them with information regarding the historical and real-time efficiency of each utility area of the facility. All displays, including summary screens for plant managers, are web-based and available to all plant personnel via a web server on the plant’s intranet.

The NovaTech Energy Management solution helps NALCO monitor the performance of all major utility equipment at the facility, including water and glycol chillers, cooling towers, de-ionized water trains, and air compressors and boilers. The system automatically quantifies potential savings or losses caused by consuming energy at peak demand rates and inefficient utilities operations. In particular, NALCO sees a primary reduction in utility costs resulting from an adjustment in operations to avoid peak demand penalties, and reduced natural gas costs by replacing that energy source through steam generated from its most efficient boilers. KPI dashboards offer a simple and effective solution for reducing costs and keeping operators and plant managers informed, leading to better decision making about purchasing utilities, reducing utility demands, and generating utilities more efficiently.

Related Processes and Experience

Catalytic Reactors/Crackers, Batch Reactors, Distillation Columns, Wiped Film Evaporators, Centrifuges, Crystallizers, Fluid Bed Dryers, Pelletizers, Extruders, Powder Storage/Transfer/Handling, Blending/Finishing, Pellet Storage/Transfer/Handling, Product Load-Out, Boilers/Steam, Refrigeration, Water/Wastewater, Air/Vacuum, Tank Farm Management

Related Product Categories

Additives, Adhesives, Amino Acids, Bio-Degradable Plastics, Cellulose-Based Fibers, Coatings, Fertilizers, Lactic-Acid, Oil & Refining Chemicals, PET, PVC, Pigments, Plastics & Specialty Plastics, Polycarbonate, Polymers,Pulp-and-Paper Chemicals, Resins, Specialty Chemicals, Water Treatment Chemicals

Related Solutions

Distributed process control, Operator training simulators, Recipe driven state based control, S88 Batch Management and control, S106 Procedural automation and control, Electronic batch reporting, ISA 18.2 Alarm Management, Data historian, Trend visualization, Process analytics, Process simulation, Asset management, Control Loop performance monitoring and optimization, Energy and asset management, Overall Equipment Effectiveness (OEE) Analytics, Regulatory compliance and validation, System hardware and custom I/O cabinet design, Product Lifecycle Services

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