Productivity & Yield Improvement in Discontinuous Processes Chris Morse - Honeywell

Transcription

1 Productivity & Yield Improvement in Discontinuous Processes Chris Morse - Honeywell

2 Raw Material Costs in the Chemicals Industry Raw Materials after feedstock significant cost element for Chemicals Manufacturers Optimization of raw material usage reduces cost of goods sold Automation of Raw Material additions using Experion increases efficiency & productivity Techniques shown applicable to atch & other discontinuous processes Typical Financial asis for Chemicals Manufacturing 2 25 Honeywell International All Rights Reserved

3 Raw Material Automation - Challenges Physical/Chemical material characteristics vary Automation equipment requires tuning for different materials Manual actions are prone to error Processes/Formulations change over time Certain materials e.g. catalysts or modifiers are high cost items Raw Material Addition accuracy has significant QA impact 3 25 Honeywell International All Rights Reserved

4 Experion Functions Available to Help REG PV REG CTL LOG DIG COMP Experion atch Manager - Scalable for many sequential processes Sequential Control Modules - Raw material additions Advanced Sequence Visualization - Operator sees status & problems Control Modules - Advanced totalizer & controller facilities - Auxiliary Calculation Procedure Analyst - Raw Material Usage Report HPM Tools ExperionTools 4 25 Honeywell International All Rights Reserved

5 Experion atch Manager Cycle Time Reduction Server ased Mixer Cycle Time atch 52 Start Mixer Start Material Material 2 Mix Sample Discharge Reactor Start 6-2 secs Controller ased Mixer Cycle Time atch 53 Start Mixer Start Material Mix Sample Discharge Cycle Time Reduction Reactor Start Controller step transition times 2 Sec 2 Sec Server step transition times Material 2 2 secs 5 25 Honeywell International All Rights Reserved

6 Flowmeter Feed Addition Tank T Material Qty Units Material A 87. Kg Material 9.8 Kg Material C 24.5 Kg Flowrate Mat A Mat C Mat Pre Optimized Flows Open Valve T Setup/Start Totalizer Material A Material Material C Challenges: Material flows differ affecting cut-off point Wide variation in quantities same equipment Flow measurement characteristics vary by material FT Autoclave Flowrate Mat A Mat C Mat Target Value Optimization Levers: Up to 4 pre-targets per totalize Switch between multiple totalizers in an SCM Reduce cycle time of totalizer min 5 msec Optimized Flows Pre Pre Target 4 Target 2 Pre Continuous Process Target Honeywell International All Rights Reserved Start Pump Open Valve A//C Close Valve A//C Stop Pump Close Valve T Pre Target x Reached

7 Flow Control Material Addition Tank T Material Qty Units Material A 87. Kg Material 9.8 Kg Material C 24.5 Kg Open Valve T Setup/Start Totalizer Flowrate Material A Mode = Auto SP = Full Flow Start Pump Material A Material Material C Addition challenges: Minimise dosing time with accurate cutoff Post target cutoff content of line can affect cost/quantity Maintenance of flow & cutoff values FI Autoclave Continuous Process 7 25 Honeywell International All Rights Reserved FC Pre Target 2 Mode = Auto SP = Trickle Flow Pre Target Optimization Levers: Slope determined by OPROC Mode = Man OP = % Experiment with controller modes & flow set points for minimum addition target deviation Drain line & offset against line content may be equipment specific value Maintain values as Material or Equipment value not recipe parameters Mode = Auto SP= Full Mode = Auto SP = Trickle Mode = Man OP = % Stop Pump Close Valve T Mode = Man OP=% Pre Target 2 Reached Pre Target Reached OPCV = % Line Drain Time Complete

8 Gain in Weight Addition Weight Tolerance Un-Discharged Tare 2 Tare Challenges: Stabilization Time Reaching a Stable weight value Tank S 32% Dry Matter Calculate Target Open Vale T Start Pump In flight error varies with time & material Residual material on sides of hopper Material lot to lot variation W Open Valve S Close Valve W Target Reached Intermediate Storage 5 m 3 Final Storage m 3 Paper Machine Coating Station Mixer 2 m 3 Optimization Levers: Tune out instability Wait for Stabilization No Compensate for in flight error & material differences in a calculated target Yes In Tolerance? Stop Pump Close Valve S Alert Operator to un-discharged material 8 25 Honeywell International All Rights Reserved

9 Material Quantity Target Tuning Material A Addition over 5 atches Normal Variation with Giveaway +ve Tolerance Recipe Target 24.2Kg -ve Tolerance Improvement: Maintain Accuracy for each atch +ve Tolerance Recipe Target 24.2Kg -ve Tolerance In spec but with material giveaway & possible quality impact In spec & consistently closer to target for better yield and quality Applying Material A ias to next batch over 5 atches Mean ias over atches ias correction calculated for each batch applied to recipe target. ias monitoring for Equipment Problem Detection Mean ias over atches ias calculation tries to correct low delivery but the root cause is an equipment problem. Deviation will eventually occur Mean bias over several batches alert raised if absolute value gets too high before spec deviation 9 25 Honeywell International All Rights Reserved

10 Next atch Compensation & Real Time Release Mixer Operation +ve Tolerance Normal Target Value -ve Tolerance Monitoring Material A Material Mix Assumptions Positive difference vs target Negative difference vs target Calculated compensation vs normal target Accurate measurements are available Sample Set atch Status No End: Release/Quarantine/Reject In Tolerance? Yes End: Release atches feed to a downstream process Quality values can be calculated or inferred Real Time Release no quality deviations detected. atch moves to next stage downstream/packaging 25 Honeywell International All Rights Reserved

11 Reduced Sampling = Further Cycle Time Reduction Sampling Once Per atch atch 53 Start Mixer Start Material Material 2 Mix Sample Discharge Reactor Start Reduced Sampling Deviations Only Cycle Time Reduction Monitoring Phase Checks for raw material qty deviations atch 53 Start Mixer Start Material Mix Discharge Reactor Start Checks other quality variables which can be automated e.g. mix time Alerts operator to quality problems Material 2 Monitoring Sets status of batch: Released/Quarantine/Rejected MAY have Supervisor Access 25 Honeywell International All Rights Reserved

12 Procedure Analyst - Materials Usage Reporting Material Usage Report Show target, actual and deviation material amount on a per batch basis between specified start and end dates Search for target value deviations Any material addition SCM can be recorded for reporting 2 25 Honeywell International All Rights Reserved

13 Raw Materials Optimization Calculating the Value Assumptions: Production is 34 days/year 24 hours/day Production Rate 48 Tons/day Revenue $5/ton Raw Material Costs 35% of revenue Annual Revenue $244M Annual Raw Material Costs $85M % Reduction in Raw Material savings $85K 3 25 Honeywell International All Rights Reserved

14 Questions to Ask Can our raw material additions be automated? Can material addition measurements be improved? How could variations in raw material additions be smoothed out? What data is available for raw material usage? Can quality checks be automated? Is there a better way of adding some materials? 4 25 Honeywell International All Rights Reserved

15 What is the value of % Raw Material Savings? 5 25 Honeywell International All Rights Reserved