Chemical Process Upgrade and Automation

Predicting the need to double the plants output capacity within one year, the customer converted six highly manual batch process into an computer automated mixing system which yielded fantastic results.

Challenges:

• Developing existing piping & electrical configurations
• Combining multiple RM streams into one inlet
• Converting stand-alone equipment & obsolete controls architecture to a system which integrates production planning, recipe database, and process controls

Benefits:

• Reduced batch time by 50%
• Eliminated cumbersome hose connections
• Allowed for simulations raw material additions
• HMI touch screens allow operators to see & initiate sequence of events from a single screen
• Maintained consistent quality from exact batch replications

Project Included:

• Mass & Vortex style flow meters
• Shell & Tube heat exchangers
• Variable Frequency Drive Motors and Pump
• Level transmitter and controls
• Automated flow control valves
• HMI touch screen interfaces
• Control system integration between process & packaging area
• CIP systems
• Load cells tank weighing systems
• Integrated RM delivery system through manifolds to multiple mix tanks
• Hazardous Area Classification
• Upgraded process area emergency safety system