Specialty Chemicals

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

    September 17, 2017 – September 20, 2017 Baltimore, MD

    2017 NovaTech Automation Summit – Register Now!

    Please join us at the 2017 NovaTech Automation Summit. With the theme of "Delivering Competitive Advantage," this year's event will focus on topics related to improving safety, quality, and plant performance.

  • Introducing FlexBatch 5.0

    FlexBatch integrates recipe management and the automation layer so operators can quickly and easily develop, scale up, modify and schedule batch manufacturing recipes for products ranging from beer to chocolate to specialty chemicals and more. FlexBatch delivers shorter time to first batch, reduced changeover times, increased throughput and production yield. New and existing products are brought to market faster and at lower cost, providing a strategic and financial advantage. Production staff can execute library procedures to overcome process upsets. All of which means a more nimble, responsive, and profitable process.

    July 5, 2017

  • Planning an Effective I/O Upgrade

    Reviewing the benefits, considerations, and steps required to migrate legacy I/O subsystems to NovaTech 8000.

    This webinar focused on NovaTech 16000 and Modicon Quantum, and touch on Siemens 505, Rockwell 1771, and Modicon 200.

    Topics Covered:
    * Hardware installation alternatives
    * Wiring options
    * Software considerations
    * Proven implementation strategie

    April 20, 2017

  • D3v15 Webinar

    The latest release of the D/3 Distributed Control System includes new configuration tools that make the system easier for new and existing users. The webinar covers building tags with MDL Builder, writing automation code with D3Edit, web-accessible History and Reports, features to facilitate migration to High-Performance HMI, and OSIsoft PI integration.

    March 24, 2016

  • D/3 Distributed Control System Overview

    This video introduces the D/3, the Distributed Control System trusted by many Fortune 100 companies to keep their global operations’ continuous and batch processes running smoothly and efficiently. Part one reviews the system architecture and configuration tools.

    November 21, 2014

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