特種和精細化工

特種和精細化工的生產企業面臨很多挑戰。 研究驅動型創新、把切合客戶需求的產品快速引入市場是實現盈利的關鍵。同時我們展望未來,提供能滿足客戶需求的產品和解決方案。

橫河電機長期以來一直為特種和精細化工的客戶提供服務。通製先進的批量解決方案、為客戶提供良好的可靠性和靈活性,同時我們還擁有在複雜要求下設計批量解決方案的行業專家。您可以放心,在與橫河電機合作期間我們將提供給您一個系統,使您能夠在保證安全和遵從法規的前提下,生產滿足客戶需求的產品。

客戶面臨的挑戰

化工公司不僅對產品質量有嚴格的要求,而且對產品工業也有嚴格的規定。這也適用於化工行業規範分支的流程工廠的設計、安裝和自動控制。

我們的解決方案

特種和精細化工產品通常用批量製程生產。為了適應範圍更廣的產品,這類工廠的生產系統必須非常靈活。憑借基於ISA-88的批處理功能,橫河電機的綜合控制解決方案CENTUM VP集散生產控制系統可以很好地滿足要求。在製程分析和產品質量方面,批次性能數據必須以易於訪問的格式存儲。批量生產、設備和配方的現狀和曆史性能數據被基於ISA-88Exaquantum / Batch訊息管理系統收集、保存、顯示和報告。同時Exapilot在線導航工具可幫助操作員可靠執行諸如停車和啟動等非常規程序。

使能技術

生產控制系統:CENTUM VP批量控制系統
化工產品批處理需要批量操作,其中一些具有功能性,可以制造多種不同產品,而實現這些需要使用縝密的批量控制系統。集散生產控制系統CENTUM VP,提供基於ISA-88 Batch標準的批處理功能。


製程訊息管理系統:Exaquantum/Batch
批量生產和控制記錄需要整體維護,可隨時備查。這些訊息還將用於決策支持、生產計劃、製程分析、製程改進質量保證目的。Exaquantum / Batch是基於ISA-88的智能訊息系統。它提供經製驗證的分析和設備報告,用於批量生產、設備和配方操作中收集存儲和顯示當前和曆史數據。


提高操作效率:Exapilot 
Exapilot是一種在線導航工具,可指導操作員逐步完成工廠操作程序。
使用Exapilot按照規範格式創建標準操作程序(SOP)。通製減少或消除人為錯誤來提高效率並降低業主總成本。

 

客戶面臨的挑戰

如電力、蒸汽、壓縮空氣能源的採購成本和可用性是不斷變化的,特别是在大型工廠,它們是能源效率管理(EEM)的關鍵參數。

使能技術

明確的行動建議

工廠能效管理系統(PEEMS)是橫河電機深入研究、全方位考慮後的EEM解決方案,可根據工廠的能耗提供合適的解決方案。

上述圖表清楚地表明橫河電機解決方案的基本原理和架構,通製這些操作可以幫助客戶提高EEM

從現場層面(能源儀表)到製程層面(控制系統或緊湊型定制訊息系統)MES層面(能耗分析和評估),橫河電機提供一套整體能源解決方案,就好像是一個自動化金字塔

然而,在製程工業中,確定和實現工廠的潛在成本削減有四個基本條件:
1.一個數據量龐大且合格的數據庫
2.智能數據分析和說明
3.清晰可視化結果
4.明確且有意義的行動方案

點擊看大圖


所有相關能源流的概述

目的是通製評估原始數據儘可能自動推導出最合適的能源使用方案然後以結構化形式將這些方案傳達給相關操作人員。這是一個優勢,用熟悉的流程圖像解決工廠操作員的問題,並為他們提供容易理解的能量流概覽。為了這個目的需要一個其他的指標,類似於Sankey中的箭頭。

在多級菜單中提供了詳細的補充訊息。直觀的配色方案清晰的屏幕布局和簡單的圖標使關鍵分析結果能夠快速準確地被理解吸收。對於負責橫河新的工廠能效管理系統PEEMS)的研發團隊來說,易理解是首要被考慮的。

專用訊息製濾器

企業決定運行EEM系統時,必須同時考慮當工廠擴和複雜增加時,EEM系統的擴展性。在極端情況下,一個基於記錄儀的小系統可以逐步發展為使用獨立PLC進行控制,並最終引入製程控制系統。EEM製程的結構 - 通常是能量優化操作的最重要手段 - 保持完整無缺,因此需要有意識的保留和擴展這種技術。

EMM系統不是取代工廠操作員的自動操作儀。相反,一系列其他參數,例如安全性原材料質量、特殊產品質量、生產效率和生產能力要求的可用組合都有著至關重要的影響。該系統就像是操作員輔助工具,集成以下重要功能:
1.比較趨勢和能量優化操作
2.向工廠操作員顯示,切換到不同的操作模式能節省多少能量
3.必要的時候,幫助操作員完成從現有操作模式到優化操作模式的轉換

為了圓滿完成這些任務,需要滿足幾個條件:可靠、有意義的數據庫對數據的結構和優先級的說明,清晰且易於理解的可視化結果以及推薦一個或多個行動方案。

除了滿足這些要求,橫河電機的EEM系統可以最大限度地提高效率和降低成本,同時最大限度地減少工廠操作員的額外負荷

點擊看大圖

 

 

客戶面臨的挑戰

流程工廠常常會使用幾十年以上隨著技術的發展革新,建設初期使用的自動化技術都會漸漸落後,這使工廠的業主浪費很多潛在的生產力。

我們的解決方案

我們在化學和制藥行業的自動化經驗超製40年,可以幫助您充分調動這些潛在的生產

成為現代化的工廠有很多益處

  • 不斷增長的生產力和競爭力
  • 保護環境和自然資源的高效節能的生產流程
  • 切實以安全為導向,面向實際需要的
  •  用戶友好操作
  • 通製橫向和縱向整合提高訊息透明度
  • 工廠資產的創新管理,提高工廠的效益
  • 更靈活的生產

在一定程度上,我們可以完成所有這些工作 - 保存已經實驗和測定的內容,精確定位消除障礙優化結構通製模擬器進行虛擬工廠的培訓,儘可能減少停機時間。

我們通製實施比較有效性分析來對舊的系統概念進行全面審查。使用我們自己的基準測試程序,從設計階段開始,確定為工廠增加價值的最恰當的措施。

在風險分析的框架內,我們會儘快確定出現代化方面的關鍵指標,並根據狀況有序實施計劃措施。

點擊看大圖

使能技術

DIN EN 62402NAMUR NE 121的專業製時管理可以確保您獲得可靠和可持續解決方案,在您工廠的整個生命周期內持續提供卓越的性價比。

使設備現代化不僅僅是升級。我們提供全方位的服務,無論是單獨的設備還是整體工程的一部分,從最初的設想到工廠的運營,我們始終為您提供現代,高效的製程自動化。

 

摘要:

Honshu Chemical has successfully improved product quality by process data analysis.
On-site capabilities were further strengthened by sharing each other's knowledge in the project.

摘要:

MGC Mizushima Plant selected Yokogawa's PDA to achieve one of its improvement activities.
MGC has successfully stabilized the process and reduced the operator work load.

摘要:
  • Nan Ya had been using Yokogawa Micro-XL DCS since the plant opened in the 1990s.
  • Step-by-step approach for migration from Micro-XL to CENTUM VP keeps downtime to a minimum.
摘要:
  • PRM allows a preventive maintenance approach where maintenance can be scheduled and performed before a field device fails.
  • Exaquantum gathers plant data from the CENTUM VP to generate a variety of reports on the polymerization process.
摘要:
  • Exapilot is Effectively Applied to Polypropylene Plant and Optimizes Operation, Cost Savings.
  • By using Yokogawa's Exapilot, Safripol were able to eliminate product variations and kept the operations consistent.
摘要:
  • Migration from Micro-XL and CENTUM CS 1000 to CENTUM CS 3000 Improves Reliability.
  • Operations at this plant, which runs more than 330 days per year, are carefully managed by the CENTUM CS 3000 DCS and the CS Batch package.
摘要:
  • Highly reliable CENTUM CS 3000 replaces legacy system and automates batch plant operation.
  • Working together, Hanwha Chemical and Yokogawa Korea project personnel completed this work on time and on schedule.
摘要:
  • Integration of CENTUM CS 3000 with ProSafe-RS improves plant safety and reliability.
  • Yokogawa's PRM package manages more than 500 HART field devices including control valves.
摘要:
  • Fieldbus technology introduced to realize predictive and preventive maintenance.
  • ISAE to improve the reliability of diagnosis and parameter setting, utilizing data collected by PRM.
摘要:
  • CENTUM CS 3000 and Exaquantum PIMS improve production efficiency at Chinese synthetic rubber plant.
  • Exaquantum provides data on long-term trends needed to make improvements to plant processes.
摘要:
  • Based on a careful review of all operational procedures and operator roles and configured new SOPs in Exapilot.
  • As a result, SFC has been able to reduce operator workload, improve product quality, and reduce production losses.
摘要:
  • The work was based on a preceisely formulated roadmap with detailed checklists for every control cabinet, process station, and network component.
  • The seamless use of the same HMI for both PCS and SIS, and improved safety and integrity.
摘要:
  • CS Batch is used to automate a wide range of Reichhold's batch processes and multi-product/multi-path processes.
  • Using PRM, process engineers can immediately find out the status of every field device without having to do an onsite inspection.
摘要:

Taiyo Nippon Sanso Corp. was looking for a system that could be easily adopted to its plant architecture. For the following reasons, Yokogawa's STARDOM system with the FCN autonomous controller and the VDS Web-based SCADA software was selected as their control system for a Water-18O plant and other facilities.

摘要:
  • Exapilot was built up as e-SOP system based on the standard operating procedures and the know-how of experienced operators.
  • e-SOP system improved the quality and productivity in the performance chemical plant in China.
摘要:
  • Installation of Exaquantum PIMS package improves efficiency of process data management.
  • Improve quality and yield through proactive maintenance of plant assets.
摘要:
  • Easy-to-understand sequence programs' creation
  • An entire programming system built by operators
  • Operator workloads reduction
摘要:

As the demand for food is increasing worldwide, fertilizers are playing an essential role in improving agricultural productivity. OCI Nitrogen (hereinafter OCI) is a leading producer of mineral fertilizers and the world's largest producer of melamine, which is used to make adhesives and resins for a wide range of applications, such as furniture panels, laminate flooring, coatings, paints, and plastics.

摘要:
  • IFCo chose Omegaland operator training system to make ready for a flawless and safe plant start-up.
  • Omegaland is contributing to operator training prior to completion of the greenfield fertilizer plant.
摘要:
  • Up to 90% of all manual tasks can now be carried out automatically.
  • Increasing productivity by means of partially automated start-up and load change procedures.
摘要:
  • Yokogawa's CENTUM VP and PRM improve efficiency at new nylon plant in Thailand.
  • At the plant startup stage, PRM was used together with FieldMate to thoroughly check all loops.
摘要:
  • At the company's Ulsan resin plant, six Exaquantum servers were connected to CENTUM CS 3000 and other vendor's systems.
  • KKPC needed to expand its SBC capabilities and improve production efficiency at its plants.
摘要:
  • TOK decided to start local production of high-quality photoresist for semiconductor manufacturing near its customers in Taiwan.
  • The MES with traceability comparable with pharmaceutical manufacturing is one of the factors to win the trust of its customers.
摘要:
  • FDT compliant FieldMate manages a wide variety of digital process instruments of multi-vendors.
  • The SNF engineers can manage the complete lifecycle of assets and configure devices by using FieldMate.
摘要:
  • Kuraray EVAL and Yokogawa prepared carefully for the expansion and modernization of the CENTUM system.
  • Management of 400+ fieldbus instruments by Yokogawa's PRM plant resource manage also helped the project to proceed smoothly.
摘要:

The UT series of temperature controllers is perfect for controlling the heating temperature of sealing parts and the temperature of sealing rolls (pre-heating) in a variety of different wrapping machinery.

摘要:

This introduces a system that uses Ethernet communications to acquire measured values, target values, and control output values from a controller installed on site into a PLC at high speed (ten units' worth within one second).

摘要:

In the plants of food and beverage manufacturers, there are times when monitoring and recording of production equipment is necessary inside clean rooms. This is an introduction to monitoring and recording in clean rooms using paperless recorders.

摘要:

The ADMAG AXR is the world's first 2-wire magnetic flow meter which employs the unique "Dual Frequency Excitation Method," achieving 0.5% of rate of best-in-class accuracy and excellent stability for process measurement. In addition, the newly developed AXR key technologies," achieves the same level of noise immunity as 4-wire type under the fluid condition change and delivers enough performance to meet the requirement to apply in the control loop.

摘要:

Control of sodium chloride (NaCl) concentration at a salt dissolver where solid salt is dissolved in water, is highly important because of the electrolysis efficiency. A conventional way of measuring the concentration of supersaturated NaCl solution had been performed by using non-contact type sensors (e.g., γ-ray density meter) since NaCl, impurities, and precipitates are in the solution.

摘要:

In the manufacturing process of Pharmaceutical, Chemical and Food & Beverage industries, the cleaning and sterilization of tanks and piping are done with various cleaning solutions, fresh or hot water and steam after manufacturing products. Clean-In-Place (CIP) is the system designed for automatic cleaning and disinfecting.

摘要:

There are various methods for continuous fabric dyeing as well as dye fixing. When dye is directly applied, steaming (heat treatment) is required. At present the pad-steam method is widely used for continuous dyeing. To ensure stable product quality, the humidity in the steamer is kept at a constant level. 

摘要:

In flue gas desulfurization systems that use magnesium hydroxide (Mg(OH)2) slurry, the consumption of the desulfurization agent (Mg(OH)2) is controlled by using online pH analyzers. A great concern in the pH measurement is heavy staining of the pH electrodes by the Mg(OH)2 slurry. To ensure accurate measurement, frequent cleaning of the electrodes with an acid is required, adding to both maintenance workload and cost.

Industry:Chemical, Power

摘要:

Recently, air pollution legislations such as the Clean Air Act to reduce the amount of air pollution are increasing worldwide. The Clean Air Act address numerous air quality problems. One of these problems is acid rain caused by sulfur dioxide and nitrogen oxide emissions from fossil-fueled power plants and other industrial and transportation sources.

摘要:

Caustic soda is an important basic material in the chemical industry and is mainly produced by the electrolysis of soda. In the electrolysis process to make concentrated caustic soda, the DM8 Liquid Density Meter ensures high product quality through accurate measurement of liquid density.

摘要:

One of the most common applications for differential pressure transmitters is flow measurement. DPharp differential pressure transmitters have some unique signal conditioning features to eliminate instability at low flow rates.

摘要:

Process liquid analyzers such as pH meters, conductivity meters, ORP meters, and density meters play an important role at electrolysis plants in the control of concentrations of various process solutions. This requires both precision and stability under harsh conditions that include highly corrosive substances, high temperatures, and many impurities.

應用
摘要:

Level transmitter configuration can be very time consuming. DPharp transmitters with advanced software functionality eliminate this time consuming task. With maintenance shops getting smaller, finding equipment that allows us to do more with less becomes a priority.

摘要:

Many different types of gases are consumed in industries as varied as chemicals, food & beverages, and medical. These gases are normally delivered in liquid form by trucks and dispensed at the customer site. Although the flow volume of cryogenic liquefied gas is used for billing purposes, it is not easy to accurately measure this because the gas is always at saturation temperatures.

摘要:

The CX1000/CX2000 offers an average value computation function making it ideal for controlling temperature and other fluctuating phenomena. The operating status can be controlled in real time, providing operating cost reductions.

摘要:

Reverse osmosis (RO) is a separation process that uses pressure to force a solution through a membrane that retains the solute on one side and allows the pure solvent to pass to the other side. More formally, it is the process of forcing a solvent from a region of high solute concentration through a membrane to a region of low solute concentration by applying a pressure in excess of the osmotic pressure.

摘要:

The discharge of improperly treated industrial chemicals and fuel gas can have a major impact on the environment, posing a serious threat to public health. Concurrent with the global growth of manufacturing operations to keep pace with market trends, many countries are taking measures to deal with environmental problems.

摘要:

Controls temperature in, and acquires data from, various internal components of plastic film manufacturing equipment. An easy to use, high cost-performance data acquisition and monitoring system can be assembled by using Ethernet compatible instruments and DAQWORX package software.

摘要:

Industrial Combustion sources such as thermal cracking furnaces and, process heaters play a critical role in the process industry.

摘要:

In limestone-gypsum flue gas desulfurization systems, the consumption of a desulfurization agent (lime) is controlled using online pH analyzers.

摘要:
  • Compressor start and stop
    The inlet valve and blow-off valve are controlled efficiently.
  • During steady-state operation
    The inlet valve is controlled to regulate the blow-off flow rate of the compressed air. (Flow control)
摘要:

For safe and efficient operation, the quality of feedwater, steam, and condensate in boiler plants must be controlled and maintained in the most favorable conditions.

摘要:

Industrial Combustion sources such as thermal cracking furnaces and, process heaters play a critical role in the process industry. Because the large amount of fuel such as gas or fuel oil which is consumed in these processes, their combustion efficiency directly affects the performance and operational costs of the production facilities.

摘要:
  • In the YS170 and SLPC, single-element control needs to be configured within the user program.
  • The YS1700, however, offers the primary direct mode so that the user program can switch on and off single-element control by changing a parameter.
摘要:

Operators must receive diagnostic information before a line block leads to a malfunction. Yokogawa provides predictive diagnostics based on trend analysis of the blocking factor, which improves maintenance efficiency and reduces maintenance costs.

摘要:

Steam is still one of the most popular methods of providing an energy source to a process and its associated operations. The more accurate and reliable measurements that are made, the more informed decisions can be taken that affect costs and product quality.

摘要:
  • Emergency interlock circuits for petrochemical plants and other facilities must be independent of the main control system.
  • The YS80 Rack Instrument interfaces not only with field devices and upstream control systems, but also with emergency interlock circuits guarding against process abnormalities.
摘要:

The DXAdvanced Paperless Recorder (hereinafter, the DX) lets you write arbitrary messages on the trend display screen that are useful for writing comments or memos. Moreover, with a combination of the DX touch screen model (DX1000T/2000T) and the custom display function, you can write messages, start/stop recording, and perform a variety of other tasks at the touch of a button.

摘要:

In the course of more than twenty years as an engineer involved directly in utility related projects in a number of industries, I have seen a great variety of energy efficiency projects and programs covering the entire spectrum of efficacy. The Deer Park, Texas, plant of the Rohm and Haas Company has a unique energy management program that has proven to be highly successful. This program has resulted in a 17 percent reduction in energy use on a per pound of product basis, saving 3.25 trillion btus and $15 million each year! This article discusses this program, its history, successes, and the unique characteristics that have contributed to those successes. 

摘要:

The REPSOL company had in mind the improvement of the control on one of their chemical reactors. A feasibility study for the implementation of an Advanced Control technique (Predictive Control for temperature control for chemical Reactors - PCR) for a batch reactor for Polyols production has been performed. The proposed technique PCR is based on a dynamic model of the unit which makes the prediction of the process variables behaviour.

摘要:

After a feasibility study, Repsol YPF decided to apply a model-based predictive controller to a batch reactor producing polyols. The predictive controller for reactors (PCR) is a set of control modules that are designed to face most of the reactor configurations. The important increase of production is a consequence of the better handling of the reactor temperature. Here's a description of the unit and control objectives, methodology, project steps, results and the corresponding benefits.

摘要:

From engineering to installation, commissioning, operations, and maintenance, FOUNDATION fieldbus offer significant cost reductions of 30 percent or more versus conventional analog systems. Many of these cost reductions come from the advanced functions that fieldbus offers versus analog technology.

摘要:

The automation suppliers that will be successful in the long term will be those that effectively address application or industry specific problems for end users with a value proposition that cannot be ignored. These problems exist throughout the process industries today, and they won't be solved by simply offering a product, but through a combination of hardware, software, services, application expertise, and knowledge.

摘要:

In ARC's view, customers need a compelling business value proposition to justify investment in any kind of automation. Vigilance and VigilantPlant were created with this in mind. Yokogawa's vision with VigilantPlant is to create an environment where plant personnel and operators are well informed, alert, and ready to take action. 

摘要:

Yokogawa has come a long way in making its message clear to the world of process automation. Last year, the company embarked on a full-scale global marketing campaign to make customers aware of the company's focus on system reliability, security, dependability, and robustness. Dubbed "Vigilance", the campaign created a unified message for the company and greatly helped expand awareness of the Yokogawa brand and corporate philosophy.

摘要:

Process automation end users are under more pressure than ever to do more with less. The current economic climate means that many automation capital projects are on hold. With capital budgets tighter than ever, users instead focus on operational budgets (where cost cutting is also a key concern), or on automation investments with a very rapid return on investment.

摘要:

In today's dynamic industrial marketplace, the only constant is change. Raw material costs, energy costs, market demands, environmental and safety regulations, technology, and even the nature of the labor force itself are constantly changing, and not always in predictable directions.

摘要:

September 2008

Yokogawa is helping a large chemicals site in China manage product transfer by road, ship and pipeline.

摘要:

ISA S88.01 provides great benefit to users and vendors by solidifying batch operating models and standardizing batch control terminology. On the other hand, as befits an industry-wide standard, ISA S88.01 leaves great flexibility for individual users to apply their own project practices and implementation methodology. Even when utilizing ISA S88.01 models and terminology, many pitfalls remain for those who implement batch controls and recipe management without thinking ahead. Real-world project experience has demonstrated a number of design and implementation "lessons" which might be overlooked to the eventual grief of the batch engineer.

摘要:

The S88.02 draft standard defines a means for depicting procedural control in master and control recipes. This depiction method is called a Procedural Function Chart (PFC). This standard depiction is based on the requirements of S88.01, technical report ISA-TR88.0.03-1996, user requirements, previous standards and commonly used procedure depiction methods in use today. PFCs can provide a common basis for the exchange of recipes, reduce the learning curve between control systems, and establish a common ground for improved human communication. This paper provides a brief overview of the development of PFCs, the rules for their use and some of the benefits expected by their adoption in the industry.

摘要:

The case study in this paper illustrates the value of integrating front-end scheduling with a batch control system. Recipe changes, and addition of recipes, occur frequently in the target process. However, since both scheduler and batch packages were designed with the ISA-S88.01 model in mind, these packages could be tightly coupled (well integrated) – and, as a result, it is easy to add or change recipes. The front- end scheduler is not limited to performing scheduling; it also provides an easy-to-grasp real-time production status display which can help enhance efficiency and productivity.

摘要:

As batch processes are automated, it is common to leave certain less essential field devices without automatic actuators. Thus, the initial control design must accommodate both automated and manual activities. Later, the manual field devices may be automated, either one-at-a-time or in related groups as equipment modules. These field changes, often occurring over a period of years, each require rework of the batch control logic, which can easily exceed the cost of the actuator. In response to this undesirable situation, a technique has been developed which permits the batch design to automatically modify itself, or evolve, to accommodate changes in field automation.

摘要:

Six Sigma is a quality improvement methodology applied to improving any type of process. It is a methodology endorsed by and heavily integrated into several major chemical companies.

摘要:

Key Performance Indicators (KPIs) are used in batch processing industries as measurements of production performance. Their use is one element in the current trend of real-time performance management. A single KPI used as the primary measurement of production can cause other dimensions of production performance lose importance. When multiple KPIs are used to measure a batch's production performance it can be difficult to reconcile differences between them for individual batches or for groups of batches. KPIs based upon meeting a target, or specification, measure absolute performance yet do not provide relative information regarding how a batch performed against its peers. The peer comparisons are important for monitoring variability of production performance, which is a critical factor in documenting ROI.

摘要:

The application of DCS-based "advanced controls" is a common method of achieving enhanced performance from continuous processes such as refinery units. However, it is less widely recognized, but nonetheless true, that modern DCS systems can include other software tools for the significant improvement of batch plant productivity, product quality, and economic performance. Due to the fundamental processing differences between the two types of plants, unique batch "advanced control" features are required which are different from those used for continuous plants.

摘要:

ARC believes that by implementing procedural automation, many process plants can minimize variability to help ensure smooth, efficient, and safe state transitions.

想了解更多技術&解決方案嗎?


聯絡我們
置頂