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Positive Energy: This Command Center Turns Hazardous Waste into Clean Power

Chemical products are a key part of everyday life with more than 100,000 substances available and in use around the world. According to data from the UN Environment Program (UNEP), the global chemical industry produces more than 400 million tons of hazardous waste annually. These residues can present a severe threat to health and the environment if not discarded safely and quickly.

Chemical company BASF is tackling this challenge in an innovative way: converting chemical waste into reusable energy. The company recently upgraded its central waste incineration plant, which processes all the chemical waste from its site in Ludwigshafen, Germany, the largest chemical production site in the world with more than 250 plants, as well as from outside of the complex. The upgrade completely modernized the 60-year-old incineration control room with our Experion technology.

Nearly 30 controllers were installed to handle thousands of input and output signals from the incineration process each day. These signals help plant operators monitor the temperature, flow, level and pressure of the combustion process used on hazardous chemical waste. Once the waste is burned, the generated heat is converted into steam, which is then placed under high pressure in turbines to generate electricity—turning hazardous waste into clean energy.

Fully integrated into the consoles are live video feeds from several points of the incineration plant such as the boiler, combustion chamber and turbine. Barco OpSpace provides integration of video and interactive (third-party) computer sources into the Experion Orion console workspace, with control from one keyboard and mouse. A complete visualization of operations at any given moment offering insight into the incineration process from the beginning to the end.

Operators and production staff use two Collaboration Stations to access a large variety of plant information and documentation in real time — for example electricity and steam reports that provide important updates about how effectively the plant is converting hazardous waste into clean energy.

The incineration plant is responsible for burning hazardous chemical waste that cannot be recycled or reused in other production processes. These residues are introduced into the plant via pipelines, tanks and containers – mostly from the site itself but also from other nearby facilities. With these systems, plant operators monitor and control devices and equipment, while continuously receiving information on variables such as temperature, pressure and flow.


Yokogawa Control System Improves Production Efficiency at Lubricant Plant in SFC Excellence

SFC Excellence Co., Ltd, a subsidiary of The Siam Chemicals Public Company (SCC), was found in 1975 and has registered capital of 70 million baht. SFC Excellence is exceptionally well-known for its manufacturing products and considered to be one of the largest importers of base oil and lube oil manufacturing (toll blenders) in Thailand. SFC Excellence is able to produce the best quality of lubricants for automotive and machineries in industrial usage with a total capacity of 10 million liters per month.

SFC Excellence has been certified ISO9001 since 2003 and ISO/TS16949 since 2008 for its own manufacture of lubrication oil. SFC Excellence is responsible to produce many types of OEM oil brands from the UK, Germany, Japan, including Thailand etc. SFC Excellence provides itself with a research laboratory performing a variety of scientific research and quality control.

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MAC and Rich Engineering Expertise are key to Success of Modernization Project at Thai Refinery

Thai Refinery migration Yokogawa.jpgThis project was conducted for PTT Aromatics and Refining Public Company Limited (PTTAR), which was established in September 2007 through the amalgamation of Aromatics (Thailand) Public Company Limited (ATC) and Rayong Refinery Public Company Limited (RRC) and was Thailand’s no.1 integrated oil refiner and aromatics producer. In October 2011, PTTAR was amalgamated with PTT Chemical Public Company Limited to form the current PTT Global Chemical Public Company Limited.

PTTAR’s AR1 crude oil refinery at the Map Ta Phut industrial estate in Rayong started operation in 1996 and was capable of converting 280,000 barrels per day. By 2006, after 10 years in use, the refinery’s original Foxboro IA Series (v4.3) distributed control system (DCS) was beginning to show its age. To decrease downtime and maintenance costs, the decision was made to replace it with a more modern control system.

In this modernization project, PTTAR chose to go with a Yokogawa control system solution and work with Yokogawa Engineering Asia as its main automation contractor (MAC). The main reasons for this decision were:

  • Star Petroleum Refining’s refinery at the same industrial estate has had good results with a Yokogawa DCS that has been in operation there for 15 years.
  • Yokogawa’s proven MAC project execution capability
  • Yokogawa’s excellent local support
  • Yokogawa’s experience in plant revamps involving migrations from industrial automation systems such as the Foxboro IA Series DCS
  • Yokogawa’s knowledge of the process technologies that PTTAR had licensed from Shell
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Yokogawa achieves Hot Cutover at Chevron Bangladesh Gas Plant with new Upstream Solutions

suc-chevron-bangladesh-004.pngChevron Bangladesh is the largest natural gas producer in Bangladesh, who is supplying approximately 50 percent of Bangladesh’s natural gas consumption. Through subsidiaries, Chevron Bangladesh produces natural gas and condensate from three fields at Bibiyana, Jalalabad and Moulavi Bazar, in northeast of Bangladesh. Bibiyana Gas Plant is located at the Bibiyana field in Block 12 of the Habiganj District, Sylhet Division. The plant is approximately 150 kilometers in the northeast of Dhaka.

The existing gas plant had four gas processing trains. In order to process increased natural gas volumes from the Bibiyana field, the Bibiyana Expansion Project (BYX) was launched to add two new gas processing trains with additional development wells and an enhanced gas liquids recovery unit.

Project Background:

Chevron Bangladesh was looking for a process automation system for which operations can control the plant safely at its optimum performance with minimum downtime and keep the process within the limit of safety operation. Yokogawa offered CENTUM VP as the Distributed Control Systems (DCS), and ProSafe-RS as the Safety Instrumented Systems (SIS) and the fire and gas system(FGS), through the integrated Human Interface Station (HIS) between CENTUM VP and ProSafe-RS. Yokogawa (Thailand) Limited received a purchase order to replace Allen Bradley PLCs at the existing four gas processing trains with CENTUM VP and ProSafe-RS, and install CENTUM VP and ProSafe-RS at the two new gas processing trains. Yokogawa Engineering Asia Pte. Ltd. provided the engineering work and Yokogawa India Limited commenced the site activities for erection/commissioning and startup support to complete the project.

Yokogawa’s scope of work includes engineering, supply of CENTUM VP, ProSafe-RS, the DPharp (EJA-E) pressure/differential pressure transmitters, the YTA temperature transmitters, the ROTAMASS Coriolis Flowmeters, the Rotameter Variable Area Flowmeters, the Plant Resource Manager (PRM) asset management package, the Unified Gateway Station (UGS) subsystems integration package, the Advanced Operating Graphics (AOG) consultation and implementation for HMI graphics, Network Security Solution service, Alarm Management System, CCTV package, Data Historian, Vibration Monitoring System, and Erection and Commissioning/Startup support.

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Operator Training Simulator Application reduces Start-up Time at Iowa Fertilizer Complex

Construction of IFCo’s $1.8 billion plant began in March 2013. By late 2015, the new plant will begin producing between 1.5 and 2 million tons of nitrogen fertilizer each year. IFCo will be the first world-scale fertilizer plant built in the United States in nearly 25 years. Nitrogen fertilizer accounts for about 60 percent of global fertilizer use. The output of the IFCo plant will drastically reduce US dependence on imported fertilizer. In addition, a domestic fertilizer source will save farmers across the country millions of dollars annually.

IFCo chose Yokogawa as the Operator Training Simulator (OTS) vendor for its IFCo complex due to Yokogawa’s proven capability with OTS in the fertilizer industry and track record in integrating Yokogawa’s OTS seamlessly with CENTUM VP Distributed Control System (DCS) and ProSafe-RS Safety Instrumented System (SIS). CENTUM VP, ProSafe-RS and OmegaLand were used for the development of the OTS for IFCo. Yokogawa’s simulator offers a highly accurate operator training system with a realistic feel, an environment for examining and verifying control methods, functions for plant optimization, energy saving designs, and online operation support through the use of modeling and simulation technologies. The IFCo OTS implementation is being carried out in the ammonia, urea, and nitric acid units. Yokogawa provided support by designing, developing, implementing, and testing the OTS in the processing units.

About Iowa Fertilizer Company:  Iowa Fertilizer Company (IFCo) is a wholly owned subsidiary of the Netherlands-based company, OCI NV, a global leader in nitrogen fertilizer production and an engineering and construction contractor. OCI NV has an international fertilizer distribution platform spanning from the Americas to Asia. IFCo is located in Southeast Iowa and near the western boundary of Illinois.

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