World's First Large-scale Green Ethylene Plant Uses CENTUM VP, ProSafe-RS, and FOUNDATION™ fieldbus Technology

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Executive Summary

Braskem, Rio Grande do Sul, BrazilIn August 2010, Braskem, a Brazilian petrochemical company, completed the commissioning of a new ethylene plant at the Triunfo Petrochemical Complex in Triunfo municipality, Rio Grande do Sul state, and the plant began production operations the following month. Based on a process that was developed by Braskem, this plant uses ethanol produced from sugarcane as its feedstock to produce 200,000 tons per year of bioethylene, also known as green ethylene. As such, it is the world's first commercial-scale plant of its type to use 100% renewable raw materials.

At an adjacent polymerization plant in the Truinfo complex, the green ethylene is converted into polyethylene (PE) resin and plastic, and is sold to companies like Acinplas, Toyota Tsusho, Procter & Gamble, Shiseido, Tetra Pak, Petropack, Johnson & Johnson, and Natura.

As the main automation contractor (MAC) for this plant construction project, Yokogawa Brazil engineered, installed, and commissioned an integrated control and instrumentation solution that included the CENTUM VP process control system, the ProSafe-RS safety instrumented system, FOUNDATION™ fieldbus devices, and the Plant Resource Manager (PRM) package. Under the terms of the MAC contract, Yokogawa Brazil also provided training on the new systems to Braskem's operators and engineers. Yokogawa Brazil completed the commissioning of these systems ahead of schedule and the production of green polymer was started just one week later.

Since this fully automated green ethylene plant came online in September 2010, operations have been running smoothly and no major problems have been reported.

The Challenges and the Solutions

1. Asset maximization
To get the most out of its assets, Braskem decided that all the field devices at this new plant should be interconnected using FOUNDATION fieldbus, the most reliable field digital technology in use in the industry today. For a solution, Braskem turned to Yokogawa, a recognized leader in this field with deep global experience in implementing FOUNDATION fieldbus solutions.

Yokogawa Brazil configured Yokogawa EJX pressure transmitters, d/p transmitters, AXF magnetic flowmeters, ROTAMASS Coriolis flowmeters, YTA temperature transmitters, and YVP valve positioners as well as other vendors' devices in about 200 segments throughout the plant. Prior to plant startup, all device configuration was done using FieldMate and FDT/DTM technology. By using PRM's function view window, engineers working in the control room were able to speed up the process of checking loops and confirming valves.

With the plant now fully operational, Braskem efficiently receives a steady flow of data from field devices, from which status of both process conditions and field devices can be confirmed on the PRM display by an operator in the control room. An added benefit of the PRM package is its ability to manage and perform partial stroke tests for a specific SIL level, as calculated through HAZOP studies. This can thus confirm whether a safety valve will perform as specified in a plant emergency. This not only makes the plant safer, it saves operators considerable time and effort in the testing process.

2. Total system integration
Braskem's challenge in this project was to integrate all systems in order to facilitate the vizualization of operations throughout the plant. Braskem understood that if operators could remain constantly apprised of what was happening around the plant, they would be able to quickly take the correct action when required. The same engineering environment can be used to configure and integrate Yokogawa's CENTUM VP and ProSafe-RS systems. During normal operations, operators can view and operate the SIS faceplates, providing they have the required permission. This ensures smooth and safe operations. Other vendors' sub-systems such as an MCC PLC system are completely integrated through modbus interfaces. A continuous environment monitoring system (CEMS) monitors oxygen levels in the furnace as well as NOx and SOx levels in exhaust gases to minimize harmful emissions, and also monitors pH and conductivity. All of this data is readily available to operators thanks to the integration of these systems.

Central control room
Central control room

Customer Satisfaction

Regarding the startup of the Braskem Triunfo plant, a Braskem production manager commented as follows:

"This green ethylene plant is the first industrial unit in the world to use sugarcane ethanol to produce ethylene from a 100% renewable source on a commercial scale. The implementation of this project confirms Braskem's commitment to contributing towards development of the Brazilian petrochemical sector, Rio Grande do Sul, and sustainable processes."

"The unit has the capacity to produce 200,000 tons/year of ethylene, which is transformed into an equivalent volume of polyethylene at existing industrial units within the Triunfo Complex. The green polymer project is part of the strategy to access competitive renewable raw material sources in line with the company's vision of sustainability. It also contributes towards society's sustainable development since the green plastic removes more carbon from the atmosphere than it emits over its entire lifecycle, from growing the sugarcane crop to post-consumption recycling. We are very happy to use Yokogawa's systems and products, because their reliability is so high. This minimizes our maintenance costs. We will continue to work with Yokogawa Brazil as our partner in the future."



      

업종

Related Products & Solutions

ADMAG AXF

The AXF magnetic flow meter is a sophisticated product with outstanding reliability and ease of operation, developed on the basis of decades of field experience. Based on FOUNDATION™ fieldbus specifications, AXF Fieldbus Magnetic Flow meter models offer more flexible instrumentation.

CENTUM VP

CENTUM VP는 다양한 산업의 안전하고 믿을 수 있는 최적의 플랜트 운용을 위한 통합 생산 제어 시스템입니다. HMI(Human Machine Interfaces), FCS(Field Control Stations), 제어 네트워크(Control Network)로 구성됩니다.

Plant Resource Manager (PRM)

Plant Resource Manager (PRM)는 플랜트 운영 및 유지 보수의 환경을 개선하고  높은 예측 기능을 통해 플랜트 자산의 신뢰성 및 가용성을 극대화하는 것을 목표로하는 Yokogawa의 독창적인 자산 관리 핵심 플랫폼입니다.

YTA110/310/320 Temperature Transmitter

The YTA110/310/320 series is Yokogawa's base traditional temperature transmitter in the field-mount transmitter line.

YTA50

YTA50은 측정된 온도에 상응하는 단순한 4 ~ 20 mA 출력을 출력하는 2 선식 아날로그 온도 전송기입니다.

YTA510 무선온도전송기

고성능 온도 전송기 YTA510은 써모커플(열전대), RTD, 옴 또는 DC mV 입력을 받아 들입니다. 이 전송기는 무선 신호를 사용하여 프로세스 변수 뿐만 아니라 설정 Parmaeter도 전송합니다. 전송기는 내부 배터리로 작동하며 하드 와이어 링이 필요하지 않으므로 설치 비용이 감소 될 수 있습니다. 통신은 ISA100.11a 프로토콜 스펙을 기반으로 합니다.

YTA70

YTA50과 마찬가지로 YTA70은 측정 된 온도에 상응하는 단순한 4 ~ 20 mA 출력을 출력하는 2 선식 아날로그 온도 전송기입니다. 그러나 HART 5 (코드 -E) 또는 선택 가능한 HART 5 또는 HART 7 (코드 -J) 디지털 통신을 추가 할 수 있습니다.

안전 계장 시스템 ProSafe-RS (SIL3)

ProSafe-RS는 IEC 61508에 명시된 SIL3 (Safety Integrity Level)를 충족하기 위해 독일 인증 기관 (TÜV)에서 인증받은 안전 계장 시스템입니다. 대규모 통합 공정 자동화 프로젝트뿐만 아니라 독립 구성 솔루션에 이르기까지 2,400개 이상의 프로젝트를 수행하였습니다.

분산 제어 시스템 (DCS)

Yokogawa는 프로세스 자동화를 위해서 중요한 운영 인프라를 제공합니다. 분산제어시스템(DCS)은 플랜트 또는 산업 공정의 자동화 된 제어 및 운영을 위한 플랫폼입니다. 10,000개 이상의 플랜트에서 고객의 생산 목표 달성하기 위해서 Yokogawa DCS가 적용되었습니다.

온도 전송기

Yokogawa는 head-mount형, panel-mount형 또는 field-mount형 온도 전송기 제품 군을 제공합니다.

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