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Reduced operating costs |
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Improved operational performance at current plant rates |
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Improved production management to account for frequently changing prices |
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Better process management reducing overhead costs |
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Case study analysis for process investigation including detailed tailor-made models |
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Project payback < 1 year |
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Challenge
This BASF site manufactures intermediate chemicals for the acrylics
and nylon polymer supply chain. The production processes are largely
continuous and highly integrated, and include Adiponitrile (ADN) and
Acrylonitrile (AN). This process consumes a large amount of valuable
raw materials and energy including electrical power, which is
subject to fluctuating prices from the supplier.The objectives of
this project were to install a system to achieve the following:
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Minimize cost/te of final product |
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Minimize electricity costs |
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Provide key performance indicators on equipment
performance |
Solution
The system was built using AMS Optimizer which is one of the key
components which form part of AMS Suite, an integrated family of
applications for predictive maintenance, performance monitoring and
economic optimization.Simply put, the AMS Optimizer interfaces
with the plant instrument / information systems to obtain real-time
plant data and provide operators and managers with accurate
information and results from which they can make informed decisions.
Emerson has developed, in conjunction with BASF, a rigorous
reaction model to account for the operation of the reactor package.
This model includes a kinetic reaction system for the calculation of
reactor selectivity components. As a result, the model represents
the reaction system closely enough to be used for ‘pilot plant’
calculations.
The remainder of the plant has been modeled using the standard
model libraries available with the AMS Optimizer. This application
comprises the following components:
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Model for process simulation and provision of key
performance indicators |
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Optimizer to calculate supervisory optimal operating
conditions |
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Data reconciliation to tune plant model to changing
plant conditions |
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‘Look-ahead’ optimizer to plant operational strategy
based on changing plant conditions and process costs |
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‘What-if’ interactive system for engineer case studies |
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