Last updateWed, 15 Aug 2018 2am

Case Study: PT. Tanjung Enim Lestari Pulp and Paper, Indonesia

Case Study by Yokogawa: PT. Tanjung Enim Lestari Pulp and Paper (PT. TEL) operates a pulp mill in Muara Enim, which is 130 km west of Palembang, the capital of Indonesia’s South Sumatra province. This is the only pulp mill in the world to produce high-quality, bleached-hardwood kraft pulp solely from plantation grown Acacia mangium trees. Using a single vessel hydraulic type continuous digester that is designed for lo-solids cooking, the pulp mill produces 500,000 tons of pulp per year, making it one of the largest mills in southeast Asia.

With ISO 14001, ISO 9001, and Forest Stewardship Council - Chain of Custody (FSC-CoC) certification, PT. TEL is recognized for its diligent adherence to both quality and environmental management. The company’s operation in Indonesia is world class, and it has paid special attention to minimizing the environmental impact of the pulp mill’s digesting and recovery processes. The use of elemental chlorine has been completely eliminated in the bleaching process, and the mill has won the elemental chlorine free (ECF) designations. This pulp mill is very energy efficient, using only natural gas as the fuel source in the lime kiln process and black liquor and bark as fuel sources in the other processes.

In 2000, Yokogawa Indonesia installed CENTUM CS, a UNIX-based production control system (PCS), to control all operations at this mill. Although this system was running smoothly, technology change had made it obsolete. To improve operational efficiency, PT. TEL decided to upgrade this system to Yokogawa’s latest PCS offering, CENTUM VP. Installation by Yokogawa Indonesia was completed within a short period and the entire mill has been operating smoothly ever since.

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SCADA Systems: Comparison & Evaluation

White Paper by Motorola: With the wide range of RTU (Remote Terminal units) and PLC (Programmable Logic Controllers) currently on the market, SCADA system engineers and decision makers face several challenges. Which classes of units provide the optimal functionality, expandability, and cost effectiveness for a given SCADA application?

What type of unit will serve the mission not just today, but years into the future? As implemented, RTUs and PLCs serve overlapping application niches and share some design details. To combat industry confusion, the discussion that follows provides a background of RTU and PLC units, and compares the various technical aspects for specifying the units including environmental ruggedness, modularity and scalability, and CPU performance. With remote applications for PLCs and RTUs continuing to expand, the discussion also helps the reader understand crucial remote system communication requirements including store and forward, report by exception, support for multiple protocols, and two-way communication with acknowledgements.

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Ensuring Safe and Reliable Operations at PT PLN Lahendong III and IV Geothermal Power Plants

Yokogawa Success Story: PT PLN is a government-owned company that manages the electric power industry in Indonesia. To ensure a stable power supply for North Sulawesi province, PT PLN has built and currently operates four geothermal power plants in Lahendong, which is located 30 km south of Manado, the provincial capital. The two newest plants, Lahendong III and Lahendong IV, each produce 20 MW of electricity, and the financing for their construction was provided by the Japanese government’s Official Development Assistance (ODA) program and the Asia Development Bank (ADB), respectively.

Indonesia’s economy is growing at a remarkable rate, and the country’s demand for electricity far outstrips supply. Despite holding 40 percent of the world’s geothermal reserves, enough to produce about 30,000 MW, the country has done relatively little till now to make use of this resource. However, the Indonesian government has signaled a strong intention to begin developing the country’s geothermal resources.

Geothermal energy is a clean and renewable power source, and plants of this type produce extremely little CO2, which is a major contributor to the greenhouse effect. For this reason, efforts to make use of this resource are gaining momentum, and its development is expected to bring great environmental and economic benefits.

At the Lahendong III geothermal power plant, Yokogawa installed the CENTUM CS 3000 distributed control system (DCS) with redundant controllers, a backup system, and a test system. Based on the success of these installed systems, Yokogawa subsequently received an order to install its CENTUM VP DCS at the Lahendong IV geothermal power plant.

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Fine Chemical Plant Automates Operations and reduces Production Losses with Yokogawa’s Exapilot

Success Story by Yokogawa:  SAMSUNG Fine Chemicals (SFC) produces many kinds of fine chemicals that have been well received both in Korea and the global market. SFC’s products include mecellose (methylcellulose), epichlorohydrin (ECH), dimethylformamide (DMF), methylamines, tetramethylammonium chloride (TMAC), barium titanate powder (BTP), and AnyCoat. SFC also produces a range of general chemical products such as ammonia, urea, melamine, methylene chloride, methyl chloride, formic acid, and caustic soda. One of SFC’s primary next-generation strategic businesses is the production of electronic chemical materials (ECM) such as BTP.

SFC has four BTP plants in Ulsan that, altogether, produces 4,000 tons per year of this material. One of these plants, plant C, was built in 2010 and uses Yokogawa’s CENTUM CS 3000 distributed control system to control all of its operations. In 2012, SFC introduced Yokogawa’s Exapilot package solution to automate processes throughout this plant. As a result, SFC has been able to reduce operator workload, improve product quality, and reduce production losses.

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S-SBR Production automated Using CENTUM VP, ProSafe-RS, PRM, and FOUNDATION fieldbus Solutions

Asahi Kasei Synthetic Rubber Singapore Pte. Ltd. (AKSS), a subsidiary of Asahi Kasei Chemicals Corporation, has built a plant on Singapore’s Jurong Island that produces 50,000 tons per year of solution-polymerized styrene-butadiene rubber (S-SBR), a type of synthetic rubber that is used in green tires to improve fuel efficiency and performance. As the demand for S-SBR is rapidly growing due to increasingly strict environmental regulations and rising awareness of environmental issues, Asahi Kasei Chemicals has made it a priority to accelerate production of this key material.

To automate production at this greenfield plant, AKSS selected Yokogawa’s systems solution that was installed by Yokogawa Singapore. The provided solutions included the CENTUM VP production control system (PCS), the ProSafe-RS safety instrumented system (SIS), the Exaquantum plant information management system (PIMS), the Plant Resource Manager (PRM) asset management package, and a variety of FOUNDATION™ fieldbus-enabled field devices.

The successful installation of these systems for this new plant demonstrates how the Yokogawa Group can work as a best solution partner with its customers around the world to automate their plants.

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