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Operational excellence matters in the petrochemical and bulk chemical industries

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Design continuous processes that are efficient and reliable

Large plants, high upfront investments, complex and closely intertwined processes, as well as high energy and resource consumption: Low lifecycle costs of plants and processes are key for improving competitiveness in the petrochemical and bulk chemical industries. Only highly available, reliable, and comprehensively optimized plants are capable of achieving maximum yields, thereby contributing to the success of a business.

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The perfect solution for every process

Biofuel production

Biofuel production


Biofuels are an important factor when considering a substitute for fossil fuels. Biofuel production is increasing around the world. Find out how you can achieve sustainable success in this market.
 

Fertilizer production

Fertilizer production

Fertilizers play an essential role in supplying the world’s continuously growing population with sufficient food. Global competitive pressure within the industry is correspondingly high. Read how we can support you with our solutions.

Gain a competitive edge

Supporting you throughout the entire lifecycle

The competitive pressures in the petrochemical and bulk chemical industries are enormous. Investments are high and plant lifecycles often span decades. With our solutions for plant optimization and process safety, also availability and performance, you can secure a competitive advantage over the long term.

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Lifecycle solutions for increased availability and higher performance

The systematic improvement of efficiency extends to all areas and all phases of a plant’s lifecycle. Innovative solutions such as integrated engineering, integrated operations, and comprehensive plant management permit the intelligent use of data in real-time. The advantages are tremendous: Already in terms of engineering, you benefit from significantly faster project planning and high-quality results. Software tools offer seamless – including virtual – commissioning and guarantee efficiency in continuous operation. They also permit the implementation of intelligent maintenance strategies. The following applications demonstrate how the advantages pay off in concrete use.

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Separation column

Seperation is used in lots of processes in chemical industries. With the separation column, you have a flexible, easy-to-use solution for separation operations. The columns must be precisely monitored during operation to ensure plant availability and process assurance. At the same time, power consumption must be optimized. The process can be sustainably optimized throughout all phases of the plant lifecycle – for more efficiency and security.

Maintenance concepts for condition-based maintenance: Asset Performance Management

The intelligent use of data offers even more advantages. The available engineering and operating data allows for simple maintenance concepts such as condition monitoring – for condition-based maintenance and optimized servicing strategies. Solutions such as SIMATIC PCS 7 and COMOS MRO support you with efficient planning, implementation, and analysis of your maintenance activities – including the connection of portable terminal equipment for remote services, even when it‘s explosion-proof. The powerful COMOS Walkinside 3D visualization software presents realistically highly complex plant models based on 3D engineering data.

An intelligent decision: XHQ

The XHQ Operations Intelligence platform creates the foundation for continuous optimization. It visualizes operating processes at chemical plants in real-time. The large amounts of data that we generate by monitoring plants are intelligently combined to create, for example, reports and evaluation lists based on key performance indicators (KPIs). With XHQ, all of the results can be very simply and graphically displayed on an information dashboard. This provides an overview that illustrates the current performance of the entire organization and reveals possibilities for optimization. All decision-making data are available in black and white in real-time.

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Process control system

With SIMATIC PCS 7, you have a powerful process control system that can be flexibly scaled to meet your specific needs – from utilization in the individual laboratory to entire plant networks. In addition, we support operators in upholding safe and smooth chemical plant operations with innovative operating concepts.

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Advanced Process Control

The advanced control functions of the SIMATIC APC library are a standard part of the SIMATIC PCS 7 process control system, including model predictive control (MPC), which is used in quality control in distillation columns. Tremendous energy savings can be achieved through the dedicated modification of control setpoints: For optimal operation of the column with minimal energy consumption, the head temperature setpoint is selected as high as possible and the bottom setpoint as low as possible, i.e. the temperature span inside the column is minimized. In other words, it isn’t the best quality achievable that is produced, but exactly the acceptable quality that can be produced with minimal costs. Other advantages of MPC are a more even process control with precisely adjustable product control and fewer manual interventions.

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Engineering-Software

COMOS, our software solution for plant lifecycle management, consistently implements the complete integration of all processes – during both the engineering stage and the operation/maintenance stage. This close interconnection between the individual stages and the uniform data platform contribute significantly to increased plant availability and security. With COMOS, you benefit as a plant designer and operator from increased productivity and quality.

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Safety Integrated

With our "Safety Integrated" concept, standard components of automation and drive unit concepts can be enhanced with safety functions. The innovative SIMATIC Safety Matrix safety lifecycle engineering tool is also a part of Safety Integrated. All of the measures are not only safety-related. They also significantly enhance plant performance.

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Process instrumentation and analytics

Our portfolio of  instruments and analytic devices fully meets the high demands of the chemical industry (SIL 2/3). Thanks to comprehensive diagnostic functions, you always know when processes are running according to plan, or when corrective action needs to be taken.

It also lets you lay the foundation for condition monitoring and asset performance management. For example, you can check the functioning of the emergency shutdown valves during operation using the partial stroke test.

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Industrial communication

Digitalization and transparent information management require stable and secure communication. Standards, established interfaces such as PROFIBUS, PROFINET, and Industrial Ethernet, as well as wireless, remote, and RFID technologies permit seamless vertical and horizontal integration – at all levels and over the entire value chain.

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Drive technology

Safety is also integrated into our control and drive technology – for example, in our Chemstar motors, frequency converters, and integrated drive system (IDS). Our drive technology is also equipped for extreme conditions and furnished with explosion protection and numerous certifications. When integrated into the control system, data from the field becomes valuable information that contributes to the safe control of the entire plant.

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Reactor

Whereas separation involves separating materials, reactors create new materials. Typical reactor types include stirred tank reactors and polymerization reactors for producing plastics. They are components of the overall plant and must be seamlessly integrated into the process for maximum safety, efficiency, and availability. In continuous operation, reactants are constantly added products continuously withdrawn. Process interventions such as filling, heating, cooling, mixing, and monitoring of all process conditions are constantly conducted. Parameters such as pump capacity, temperature, pressure, energy consumption or emissions are also measured, analyzed and monitored. Actuators such as pumps are necessary to change the flow rates.

Maintenance concepts for condition-based maintenance: Asset Performance Management

By systematically monitoring non-intelligent plant components such as pumps, the service life of these components can be purposefully extended, process reliability improved, and plant availability thereby significantly increased. Thus, Asset Performance Management makes an important contribution to the smooth operation of your plants. Solutions such as SIMATIC PCS 7 and COMOS MRO support you with the efficient planning, implementation, and analysis of your maintenance activities. The powerful COMOS Walkinside 3D visualization software presents realistically highly complex plant models based on 3D engineering data.

An intelligent decision: XHQ

The XHQ Operations Intelligence platform creates the foundation for continuous optimization. It visualizes operating processes at chemical plants in real-time. The large amounts of data that we generate by monitoring plants are intelligently combined to create, for example, reports and evaluation lists based on key performance indicators (KPIs). With XHQ, all the results can be very simply and graphically displayed on an information dashboard. This provides an overview that illustrates the current performance of the entire organization and reveals possibilities for optimization. All decision-making data is available in black and white in real-time.

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Process control system

Innovative operating concepts of the process control system support the operator in operating the plant safely and without a hitch – for example, by means of tools like the Advanced Process Library for automation and Advanced Process Control (APC) for advanced control functions – even for smaller plants.

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Engineering software

COMOS, our software solution for plant lifecycle management, consistently implements the complete integration of all processes – during both the engineering stage and the operation/maintenance stage. This close interconnection between the individual stages and the uniform data platform contribute significantly to increased plant availability and security.

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Simulation software

Our SIMIT simulation software provides valuable support not only for the engineering, commissioning, and startup of a system but throughout the plant lifecycle. The simulation also allows users to gain plant expertise. Virtual commissioning supports the definition and clarification of plant specifications in an efficient manner and at an early point in time, thus shortening and simplifying the actual implementation later on.

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Energy management

We can support you in optimizing your energy utilization and consumption, and can advise you on how to maximize the efficiency of your operations. At the plant level, SIMATIC powerrate for the SIMATIC PCS 7 process control system offers a convincing performance. The software records all of the plant’s energy-related consumption data, assigns the data to the consumer, visualizes it clearly, and saves it in the archive. In this way, it helps you to reliably detect hidden savings potential for targeted energy consumption optimization.

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Process instrumentation and analytics

The portfolio fully meets the high demands of the chemical industry (SIL 2/3). Thanks to comprehensive diagnostic functions, you always know when processes are running according to plan, or when corrective action needs to be taken.

It also lets you lay the foundation for condition monitoring and asset performance management. For example, you can check the functioning of the emergency shutdown valves during operation using the partial stroke test.

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Energy-efficient switchgear technology

Electric drives are the biggest industry-related energy consumers, accounting for approximately 70% of the overall electric power demand. Our SIRIUS modular system for industrial switchgear technology offers a wide range of products enabling you to leverage the full savings potential of your electric drive systems – and increase your energy efficiency over the long term.

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Drive technology

Safety is also integrated into our control and drive technology – for example, in our Chemstar motors, frequency converters, and integrated drive system (IDS). Our drive technology is also equipped for extreme conditions and furnished with explosion protection and numerous certifications. When integrated into the control system, data from the field becomes valuable information that contributes to the safe control of the entire plant.

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Extruder geared motors

MOTOX extruder geared motors are equipped with high-performance axial self-aligning roller bearings and can be adapted to your requirements using the standard flange (mounted at the front) or application-specific flange. A high degree of operational safety and reliability is guaranteed by a separate oil chamber in the flange.

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Totally Integrated Power (TIP)

Totally Integrated Power (TIP) comprises the complete portfolio for reliable, safe, and efficient power supply. In response to all of the challenges of the chemical industry, we offer intelligent solutions covering all voltage levels and every stage of facility lifecycles. From planning to management and service, our TIP offering encompasses a broad range of possibilities for optimizing your power flows.

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Dryer

Drying operations require a high amount of energy, which is why optimal and economical drying – meaning as dry as necessary – is the objective. Over-drying wastes energy, while insufficient drying can cause difficulties in downstream process phases, such as decay, mold, lumps, etc. Therefore, precise controlling of the particle moisture content has great economic significance. The sample application presents a fluidized bed dryer whose energy consumption can be optimized by using an MPC (Model Predictive Control) controller. With the integrated controller, control concepts can be effectively implemented that, among other things, increase plant yield.

Maintenance concepts for condition-based maintenance: Asset Performance Management

By systematically monitoring non-intelligent plant components such as pumps, the service life of these components can be purposefully extended, process reliability improved, and plant availability thereby significantly increased. Solutions such as SIMATIC PCS 7 and COMOS MRO support you with the efficient planning, implementation, and analysis of your maintenance activities. The powerful COMOS Walkinside 3D visualization software presents realistically highly complex plant models based on 3D engineering data.

An intelligent decision: XHQ

The XHQ Operations Intelligence platform creates the foundation for continuous optimization. It visualizes operating processes at chemical plants in real-time. The large amounts of data that we generate by monitoring plants are intelligently combined to create, for example, reports and evaluation lists based on key performance indicators (KPIs). With XHQ, all the results can be very simply and graphically displayed on an information dashboard. This provides an overview that illustrates the current performance of the entire organization and reveals possibilities for optimization. All decision-making data are available in black and white in real-time.

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Process control system

Innovative operating concepts of the process control system support operators in operating plants safely and without a hitch – for example, with tools like the Advanced Process Library for automation and Advanced Process Control (APC) for advanced control functions – even for smaller plants.

image

Engineering-Software

COMOS, our software solution for plant lifecycle management, consistently implements the complete integration of all processes – during both the engineering stage and the operation/maintenance stage. This close interconnection between the individual stages and the uniform data platform contribute significantly to increased plant availability and security.

image

Energy management

We can support you in optimizing your energy utilization and consumption, and can advise you on how to maximize the efficiency of your operations. At the plant level, SIMATIC powerrate for the SIMATIC PCS 7 process control system offers a convincing performance. The software records all of the plant’s energy-related consumption data, assigns the data to the consumer, visualizes it clearly, and saves it in the archive. In this way, it helps you to reliably detect hidden savings potential for targeted energy consumption optimization.

image

Process instrumentation and analytics

The portfolio fully meets the high demands of the chemical industry (SIL 2/3). Thanks to comprehensive diagnostic functions, you always know when processes are running according to plan, or when corrective action needs to be taken.

It also lets you lay the foundation for condition monitoring and asset performance management. For example, you can check the functioning of the emergency shutdown valves during operation using the partial stroke test.

image

Industrial communication

Digitalization and transparent information management require stable and secure communication. Standards, established interfaces such as PROFIBUS, PROFINET, and Industrial Ethernet, as well as wireless, remote, and RFID technologies permit seamless vertical and horizontal integration – at all levels and over the entire value chain.

image

Energy-efficient switchgear technology

Electric drives are the biggest industry-related energy consumers, accounting for approximately 70% of the overall electric power demand. Leverage the full savings potential of your electric drive systems and increase your energy efficiency over the long term. Our industrial switchgear technology is here to support you.

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Drive technology

Safety is also integrated into our control and drive technology – for example, in our Chemstar motors, frequency converters, and integrated drive system (IDS). Our drive technology is also equipped for extreme conditions and furnished with explosion protection, numerous certifications, and fulfills the highest energy efficiency classes. When integrated into the control system, data from the field becomes valuable information that contributes to the safe control of the entire plant.

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Totally Integrated Power (TIP)

Totally Integrated Power (TIP) comprises the complete portfolio for reliable, safe, and efficient power supply. In response to all of the challenges of the chemical industry, we offer intelligent solutions covering all voltage levels and every stage of facility lifecycles. From planning to management and service, our TIP offering encompasses a broad range of possibilities for optimizing your power flows.

Services

Available around the world: services for the chemical industry

From plant designs and concepts to retrofits, from the development of new processes to the optimization of existing ones – with a global network of experts and committed employees in more than 190 countries, we can support you anytime and anywhere around the world with process engineers, automation technicians, project managers, or together with industrial partners over the entire lifecycle of your chemical plant.

References

At home in the petrochemical and bulk chemical industries

Find out more about the implementation of our solutions worldwide

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Contact

We’re happy to answer all your questions

To stay competitive, you must be efficient. That’s why the efficiency of chemical plants must be continually maximized. Our industry solutions reduce total cost of ownership (TCO), improve performance, and increase availability. As a result, your continuous processes are more competitive. We’ll be happy to advise you on how to achieve systematic improvement over your plant’s entire lifecycle.

Let our experts answer your questions
Your personal contact