Emerson's PlantWeb® Delivers 2% Availability Improvement for New Chemical Waste Treatment Plant | Automation.com

Emerson's PlantWeb® Delivers 2% Availability Improvement for New Chemical Waste Treatment Plant

February 152005
AUSTIN, TEXAS (February 15, 2004) -- When SICIT 2000 of Vicenza, Italy, planned automation of their new $30 million plant for the production of protein hydrolyzates, they chose PlantWeb® digital plant architecture from Emerson Process Management. After 10 months of operation, the plant reported a 2% increase in plant uptime and a 5% improvement in operating efficiency, exceeding predictions and guaranteed results.

The plant uses proprietary expertise and experience developed over many years to process 400 tons per day of animal waste from local tannery operations in Vicenza into useful and valuable products. The fat is separated into products used for soap manufacture. The remaining protein-rich amino acid material is hydrolyzed in reactors at 140°C and 3.6bar to produce a solid of peptides and calcium sulphate, used as a fertilizer, and a protein-rich liquid. High in nitrogen and carbon, this is a valuable fertilizer material and is supplied as a raw material to both the tanning and building plaster industries.

Essential factors in the choice of PlantWeb architecture were the increased plant availability enabled by using the AMS™ Suite: Intelligent Device Manager to process online diagnostic information from intelligent field devices, and the ability to improve product uniformity by using DeltaV™ digital automation system advanced control products.

Plant flexibility, availability and reliability are essential to SICIT 2000. The PlantWeb field-based approach supplied by Emerson included the DeltaV system networked to Micro Motion® Coriolis flowmeters, Rosemount® temperature and pressure measurement transmitters, and other intelligent field devices. Within the DeltaV system, the AMS Device Manager software delivers information from device diagnostics to enable plant personnel to predict issues and take remedial action before they interrupt plant operations. Another DeltaV product, DeltaV Tune, quickly and easily tunes PID and Fuzzy control blocks and simulates process response to recommended tuning.

As a commercial organization, operational plant efficiency and control of material costs were important aspects too. Emerson predicted and guaranteed economic benefits that would be delivered by the technology of the PlantWeb digital architecture.

Benefits at Vicenza were first demonstrated in the project phase, and operational benefits followed as soon as the plant started up.

In the project phase, use of PlantWeb resulted in 5% savings. Many factors contributed: the use of FOUNDATION fieldbus technology led to 30% savings in plant wiring; and during commissioning and start-up, plug and play technology was estimated to save 60% in time and effort. The simplicity and ease of use of the DeltaV system with AMS Device Manager facilitated these savings.

Operational savings were established when the plant was online using the new systems. SICIT 2000 had noted that the DeltaV auto-tuning techniques helped reduce the loop tuning time by 90%; better loop performance immediately improved product quality and homogeneity.

More significantly, the quantity of the different reactant materials required was reduced with DeltaV Tune, producing operational savings. The solids mixing time was reduced 30% through tighter control of the material proportions; the result was an increased yield of the protein liquor by 30%, and a 2% improvement in thermal energy efficiency per ton of output.

SICIT 2000 calculates that overall equipment effectiveness, a measure of operating efficiency, has increased by a full 5%, meeting and exceeding the initial predictions of the Emerson engineers in their performance guarantee.

The new plant has already increased the plant availability by 2% compared to the old plant, even during the initial period after installation. SICIT 2000 has found the DeltaV Historian reports to be a major help in complying with the necessary HACCP (Hazard Analysis and Critical Control Point) rules, and these have also enabled quicker plant performance analysis, saving an estimated 30% of engineering time.

The benefits to future plant operation from more efficient performance analysis, and from predictive diagnostics information feeding into maintenance planning, will be significant. Emerson’s technologies and services will help ensure that an efficient and high availability by-product treatment and recycling system helps the tanning industry continue to flourish in Vicenza.

About SICIT 2000
SICIT 2000 SpA (www.sicit2000.it) was originally founded in Italy in 1960 for the production of amino acids and peptide mixtures and their derivatives, fully complying with European Community regulations. The SICIT 2000 plant in Vicenza treats collagen-based raw material to produce amino acids, peptides and their by-products. The plant works under HACCP (Hazard Analysis and Critical Control Point) rules.

About Emerson Process Management
Emerson Process Management (www.emersonprocess.com), an Emerson business, is a leader in helping businesses automate their production, processing, and distribution in the chemical, oil and gas, pulp & paper, power, food and beverage, pharmaceutical, semiconductor, and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management, and maintenance services. Its brands include PlantWeb®, Fisher®, Micro Motion®, Rosemount®, Daniel®, DeltaV™, Ovation®, AMS™ Suite and CSI.

About Emerson
St. Louis-based Emerson (www.gotoemerson.com) is a global leader in bringing technology and engineering together to provide innovative solutions to customers in process control; electronics and telecommunications; industrial automation; heating, ventilating and air conditioning; and appliances and tools. Sales in fiscal 2004 were $15.6 billion.

PlantWeb, Fisher, Micro Motion, Rosemount, DeltaV and AMS are marks of Emerson Process Management. FOUNDATION is a mark of the Fieldbus Foundation. Other marks are the property of their respective owners.
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