oxochimie oxochimie at osi conference 1999 oxochimie lavera - france françois germain plant manager...

OXOCHIMIE

OXOCHIMIE at OSI conference 1999

OXOCHIMIE Lavera - France

François GERMAINPlant manager

From yield optimization From yield optimization to manufacturing cost to manufacturing cost

controlcontrol

OXOCHIMIE


Oxochimie

Bienvenue en ProvenceBienvenue en Provence

Lavera en ProvenceLavera en Provence

Lavera siteLavera site

OXOCHIMIE


BPA CHEMICALSELF ATOCHEM

33.600 PEOPLE

43 Bn$ TURNOVER

17.000 PEOPLE

14 Bn$ TURNOVER

50 % 50 %OXOCHIMIEOXOCHIMIE100 PEOPLE

100 M$ TURNOVER

OXOCHIMIE - 1999OXOCHIMIE - 1999

OXOCHIMIE


What are we doing?What are we doing?

We are making basic chemicalsWe are making basic chemicals

Production de 300 000 Tonnes/yearProduction de 300 000 Tonnes/year of OXO-alcohols of OXO-alcohols

Applications for plasticisers, paints, Applications for plasticisers, paints, inks, solvents…inks, solvents…

5th world producer of Oxo-alcohols5th world producer of Oxo-alcohols

OXOCHIMIE


SummarySummary

1. Before PI1. Before PI

2. A fast track project2. A fast track project

3. Rapids benefits of PI3. Rapids benefits of PI

4. Reports4. Reports

5. Data reconciliation + demo5. Data reconciliation + demo

6. Link to manufacturing costs6. Link to manufacturing costs

OXOCHIMIE


Before PIBefore PI

RE-KEYING OF DATA

PRINTOUTS

LABORATORY REPORTS

TELEPHONE CALLS

HUMAN ERRORTime consuming to consolidate reports

When?

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The PI projectThe PI project

Initiated by Elf groupInitiated by Elf group Limitation with DCS historicalLimitation with DCS historical

(ABB MOD 300)(ABB MOD 300) Motivated team for installing the PI Motivated team for installing the PI

systemsystem Fast projectFast project Immediate resultsImmediate results

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Project planningProject planning

Dec 96:Dec 96: Project definitionProject definition

Jan 97:Jan 97: Project kickoffProject kickoff

Feb 97:Feb 97: Hardware purchaseHardware purchase

March 97:March 97: PI start upPI start up

Avril 97: Avril 97: User trainingUser training

June 97: June 97: Laboratory transfer on PILaboratory transfer on PI

Feb 98: Feb 98: Automatic daily reportsAutomatic daily reports

March 98: March 98: Manufacturing costsManufacturing costs

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PI implementationPI implementation

DCS: ABB MOD 300DCS: ABB MOD 300 Alpha server 1000A Alpha server 1000A

5 / 333 - VMS 7.15 / 333 - VMS 7.1 PI2 license 5000 tags PI2 license 5000 tags

(3800 used)(3800 used) existing PC network existing PC network

(W95)(W95)

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What they say about PI (1)What they say about PI (1)

Console operatorConsole operator« It is a great advantage of PI above « It is a great advantage of PI above DCS historical, Process Book gives DCS historical, Process Book gives facilities to configure appropriate facilities to configure appropriate scales, time ranges, tags… » scales, time ranges, tags… »

Shift supervisorShift supervisor« When you are back on the plant after a shift break, « When you are back on the plant after a shift break, we do identifie previous modifications . With 2 or 3 we do identifie previous modifications . With 2 or 3 clicks we get the right information… »clicks we get the right information… »

OXOCHIMIE


What they say about PI (2)What they say about PI (2)Day foremanDay foreman

« The system is user friendly »« The system is user friendly »

Lab supervisorLab supervisor« By mixing lab data and « By mixing lab data and process, we do understand the process, we do understand the quality variations »quality variations »

Logistic engineerLogistic engineer« With PI and associated tools, « With PI and associated tools, we really get the right data. Time we really get the right data. Time consuming is divided by 3 »consuming is divided by 3 »

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What they say about PI (3)What they say about PI (3)PI administratorPI administrator

« The PI system gave me hard « The PI system gave me hard days at start up,days at start up,but It is a pleasure to see people but It is a pleasure to see people happy with it »happy with it »

Site general Manager Site general Manager «PI is the good tool, we will install it «PI is the good tool, we will install it on the other plants »on the other plants »

OXOCHIMIE


Rapid benefitsRapid benefits

After training phase, Process book was largely used for trouble shooting mainly

Every incident is investigated with PI Increased reliability Daily optimization Obtain returns

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Plant reliability Plant reliability

95

96

97

98

99

100

1996 1997 1998 Q1 1999

%

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Daily reportingDaily reporting

Manufacturing report show yield variations and Manufacturing report show yield variations and performanceperformance

Laboratory reports include process dataLaboratory reports include process data

PI Data link + PI Perf equation usagePI Data link + PI Perf equation usage

Replacement of our rekeyed report by automatic Replacement of our rekeyed report by automatic PI reportsPI reports

OXOCHIMIE


Morning manufacturing reportMorning manufacturing report

OXOCHIMIE


Morning laboratory reportMorning laboratory report

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Other reportsOther reports

Monthly manufacturing report:Monthly manufacturing report:Totaliser tags: integration of daily ratesTotaliser tags: integration of daily rates

Identification and reconstruction of plant model Identification and reconstruction of plant model (unit by unit): mass balance(unit by unit): mass balance

Maintenance report: usage rate of equipmentsMaintenance report: usage rate of equipments

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Corporate application Corporate application tools usedtools used

X / Y add-in in Procbook for correlation study X / Y add-in in Procbook for correlation study

Comparison of laboratory analysis versus on Comparison of laboratory analysis versus on line analyzerline analyzer

Temperature profile analysis for tubular reactorsTemperature profile analysis for tubular reactors

SQC reports from laboratory (Excel 97)SQC reports from laboratory (Excel 97)

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Data reconciliationData reconciliation

Complexity of numerous units Complexity of numerous units

and linksand links

What is Datrec?What is Datrec?

DemoDemo

GAZ DE SYNTHESE

RHODIUMDISTILLATION

ALDHEHYDE

ISOBUTANOL

2 ETHYLHEXANOL

Gaz de synthèse

OXO brutN- butyraldhéhyde

N-butanol brut

Isobutanol

2 éthylhexanol

Isobutyraldéhyde

HYDRO 8500

HYDRO 4500

HYDRO 2500Nal

N-butanol brut 2500

N-butanol brut 4500

N-butanol brut 8500

DISTILLATION

8500STOCKAGE

BUTANOL BRUT

N-Butanol

ventes

H2H2 PSA

H2 CK4

H2 11b

H2 ATO

O2 Gaz nat Propylène

Complexity of units products links

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What is DatrecWhat is Datrec

Reconciliate dataReconciliate data

Detect faulty measurement deviceDetect faulty measurement device

Compute daily/monthly material balance for Compute daily/monthly material balance for the whole plant from raw materials to finished the whole plant from raw materials to finished productsproducts

Developed by Elf research center (Solaize)Developed by Elf research center (Solaize) Distributed by Honeywell and TechnipDistributed by Honeywell and Technip

OXOCHIMIE


General characteristicsGeneral characteristics

Treat any redundancy equation:Treat any redundancy equation:- Linear (mass balance)- Linear (mass balance)- Non linear (energy balance, constituent- Non linear (energy balance, constituentbalance)balance)

Estimate the missing measurementsEstimate the missing measurements Power of maths in user friendly interfacePower of maths in user friendly interface PI Interface PI Interface (through PI API)(through PI API)::

- instantaneous- instantaneous- average- average- integration- integration

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Results with DatrecResults with Datrec

Gets Gets accurateaccurate coherentcoherent and and reliablereliable data to data to generate yield and mass balancegenerate yield and mass balance

Improves data quality, feed back of faulty Improves data quality, feed back of faulty valuesvalues

Feeds sound data for manufacturing costs Feeds sound data for manufacturing costs calculationcalculation

OXOCHIMIE


PI / Datrec / Cost systemPI / Datrec / Cost system

PIDATREC

Daily balance

Production report

Monthly balance

Plant

VCS

COSTS

PCData

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DATREC DEMODATREC DEMO

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Manufacturing cost projectManufacturing cost project

Objectives:Objectives:

Calculate the variable costs of Calculate the variable costs of productions based on market prices.productions based on market prices.

Generate quantity repartition by Generate quantity repartition by product for each shareholderproduct for each shareholder

OXOCHIMIE


VCS OXOVCS OXO PRINCIPLESPRINCIPLES PI:PI: collect technical data + mass balance + analysis of collect technical data + mass balance + analysis of

deviationsdeviations DATREC:DATREC: reconciliate data reconciliate data PC:PC: chemicals consumption and prices chemicals consumption and prices VCS:VCS: Variable Cost systemVariable Cost system

. feed stock balance (production / stocks / sales). feed stock balance (production / stocks / sales)

. consumption by product. consumption by product- cost calculation of each product- cost calculation of each product- product cost for each shareholderproduct cost for each shareholder- variance reports- variance reports

OXOCHIMIE


Questions ?Questions ?

oxochimie oxochimie at osi conference 1999 oxochimie lavera - france françois germain plant manager...

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