News. Petrochemicals & Derivates Industrial Weighing and Measuring. Reduce costs by increasing process efficiency

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1 Petrochemicals & Derivates Industrial Weighing and Measuring 4 News Reduce costs by increasing process efficiency Weighing specialist METTLER TOLEDO has helped oil, gas and petrochemicals services contractor RBG Limited to significantly reduce the amount of residual oil contamination in solids recovered from offshore production operations in the North Sea. Integrated into RBG s Solids Management System, METTLER TOLEDO s FlexMount weigh module, with an ATEX-certified load cell, ensures accurate weighing of produced solids to assess batch composition prior to dosing with cleaning agents. Correct weighing of solids is essential as it allows RBG s system to accurately manage batch size in order to dose the waste with the correct quantity of chemical. Accurate chemical dosing leads to optimised performance and reduces chemical usage. Oil recovered from the waste is reintroduced into the process, commented RBG s Implementation Manager James Calderwood. This improves yield and also removes contaminants from the waste, making it suitable for overboard discharge. Removing the recovered oil has significant cost savings for the client, as the waste would otherwise need to be shipped from the offshore platform to a specialist disposal contractor onshore he added. The Solids Management System also provides an assurance that future legislative requirements for controlled overboard discharge can be met. The system s benefits were recognised in 2007 when it was short listed for an Innovation Award by the Offshore Contractors Association. RBG has constructed three such systems and plans to construct more in the coming year. The 0958 FlexMount weigh module used in RBG s Solids Management System is highly versatile and can be adapted to virtually any application. The unit supplied to RBG was specially modified to suit the hostile North Sea environment and it is the first time such a unit has been used for this type of portable process weighing application. Courtesy ADPO Courtesy RBG Limited

2 Tank weighing The FlexMount modules are very easy to install, regardless of the application, and their self-checking function allows economical system integration and a wide range of thermal expansion and contraction. Many arrangements are available to suit tanks, silos or hoppers with three or more legs in circular, square or rectangular patterns. The units ATEX certified stainless steel load cells are hermetically sealed to IP68 for the harshest industrial environments. The top plate of the units is rigidly located for easy installation and an anti-uplift bolt restrains the tank or silo and prevents it from tipping over. This feature is especially useful in protecting against wind pressure in exposed, exterior locations. The module was supplied to RBG with METTLER TOLEDO s stainless steel IND429 weighing terminal. Protected to IP69 in accordance with DIN for water ingress, the portable terminals are Ex certified for Zone 2 hazardous areas. A wide range of options are available for connecting the terminals to computers and printers, with the interfaces located in a protected position at the back of the terminal, accessible via IP69K-protected sockets. Wireless LAN communications options are also available. METTLER TOLEDO s Industrial Weighing Division is active in the food, pharmaceutical, chemistry, transport, logistics and offshore industries. It provides bespoke application solutions, software and service in areas such as raw materials, production, packaging and transport, mainly by direct channels but also via OEM/system integrator/sy partners and distributors. For more information please visit the company s website at FlexMount weigh modules Publisher Mettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Anti-lift device restrains tank from tipping Carbon steel and stainless steel design Accuracy: 3000e OIML & NTEP 5000e class IIIM FlexMount capacity range: 113 to 4400 kg (250 to lb) Hazardous Area: ATEX and FM approvals Zone 1/21 or Division 1 Production MarCom Industrial CH-8606 Nänikon Switzerland Subject to technical changes 07/2008 Mettler-Toledo AG Printed in Switzerland IND429xx The IND429xx weighing terminal is designed to meet the requirements of the chemical industry. The stainless steel housing and the IP69K protection make it the ideal solution for the harshest environment. IND429xx is approved for hazardous area Zone 2/22. 2 METTLER TOLEDO Petrochemicals & Derivates News 4

3 High precision for low moisture content Rapid moisture determination in plastic pellets The moisture content of plastic pellets prior to molding is key for optimal quality of molded parts. Allowable moisture content is as low as 200ppm and below and decides whether the pellets can be processed or not. METTLER TOLEDO s halogen moisture analyser determines very low water contents with high accuracy, is fast, reliable and easy to handle at the same time. Avoid excess moisture Plastics adhere to any shape, offer an unlimited range of functional possibilities and are the preferred material of industrial designers. Before processing, the raw material delivered as granules or pellets is dried to the moisture content specified by the supplier. Drying is needed as most pellets absorb moisture easily from ambient air during storage. Excess moisture remaining in the pellets will evaporate at the temperatures reached during molding and cause structural damage and surface irregularities of the finished parts. Depending on type of plastic and additives used, allowable moisture content is in the range of 200 ppm for ABS, PA6, POM and even less for polycarbonate. tion. Within 15 minutes and without the need of chemicals or trained personnel the HR83 provides the information needed to continue processing. * 1000ppm = 0,1% MC (moisture content) Key benefits Short analysis time: time to result is reduced to few minutes Increase uptime of injection molding machines Outstanding reproducibility and reliability Fulfill quality system regulation No chemicals needed In factory-at-line METTLER TOLEDO provides the entire solution for the HR83, including: Qualified installation (IQ, OQ, PQ) with IPac moisture Temperature calibration of HR83 exactly at point of use Application methods for most plastics Efficient process control with the HR83 Moisture analysis as part of the molding process is essential for effective processing and optimum product quality. Halogen moisture analysers from METTLER TOLEDO determine this important parameter fast, accurate and on-site on the production floor. The HR83 monitors moisture content up to the third decimal place (0.001% MC*). The results are highly reproducible and are perfectly matching those obtained by the reference method Karl Fischer Titra- METTLER TOLEDO Petrochemicals & Derivates News 4 3

4 The formulation of industrial polymers needs traceable accuracy. We deliver it. METTLER TOLEDO s formulation solution meets the requirements of the polymers manufacturing industry. Users are efficiently supported in their daily work by the multifunctional networked software FormWeigh.Net. The most important source of errors in the whole process operator mistakes are brought under control whilst implementing tracking and tracing of the process steps. We need a system to control and manage the weighing steps of our formulation process. Dong Mei, Production Manager of Compounding Plant. The polycarbonate project of Bayer Polymers (Shanghai) Co., Ltd is one of the biggest chemistry projects in Shanghai s Jin Shan Chemistry District. The compounding plant is the core of this project yielding about metric tons per year. In the production process, where formulation was manual, a performing system for recipes management, dispensing and charging was required. The operators weigh the materials and write by hand the recorded values onto the color ticket. The batch of weighed material is then transferred with the color ticked to the charging room. The charging operators will verify that the material from the dispensing room correspond to the color ticket and if no mistake is detected proceed with production. All protocols are recorded in writing. After production is completed, the color ticket is taken back to the production management and the data is reported in the production software. Customer s original requirements: The color ticket (production order) is prepared by the production department and given to the operators in printed form. The recipe has been developed in the laboratories. FormWeigh.Net formulation solution 4 METTLER TOLEDO Petrochemicals & Derivates News 4

5 FormWeigh.Net formulation processes managed and controlled efficiently As a result of an intensive exchange between Bayer s and METTLER TOLEDO s specialists, it was decided to implement METTLER TOLEDOI s FormWeigh.Net to manage the formulation processes at Bayer Polymers compounding plant. The whole system comprises a data server, a management client, two dispensing rooms and one charging room. METTLER TOLEDO Petrochemicals & Derivates News 4 5

6 FormWeigh.Net formulation solution New work flow with FormWeigh.Net A traceable system surpassing customer s initial requirements 1) The raw materials and end products are defined and entered to FormWeigh.Net by the system supervisors. The formulas and recipes are programmed according to the lab department specifications. The production shift leaders issue daily production schedules. 2) In the dispensing room the operators follow the instructions generated by FormWeigh.Net (running on an ID30 industrial PC) to weigh in the raw material according to the formula. Raw materials are identified unequivocally via barcode reader. After confirmation of correct mate- rial selection, FormWeigh.Net gives clearance to operators for weighing into the appropriate container. A local printer generates a label (with barcode) to be affixed onto the corresponding container. After completion of recipe, all the containers are forwarded to the charging room for production. 3) The charging operators report via barcode reader all the delivered materials to FormWeigh.Net (a local ID30 industrial PC is also in the charging room). The software gives production clearance only after materials can be matched to order recipe. 6 METTLER TOLEDO Petrochemicals & Derivates News 4

7 4) The weighing report as well as the charging report are stored onto the data server and can be uploaded and printed at the management client after charging is completed. Key benefits Reduce manual data input to minimum and avoid mistakes. The quality of the recipe is secured through FormWeigh.Net. Improve efficiency. No more manual records. All the information is transferred in real time. Process under control. All the production steps are monitored efficiently by the system, including material, recipe, order, dispensing and charging. Automatic quality control. All the data is recorded in the database and it is easy to review. Human intervention is minimized, saving costs. The quality is tracked and becomes traceable. Ease of operation. More than 30 operators were familiar with system operation shortly after installation. Customer s testimonial METTLER TOLEDO s FormWeigh.Net formulation solution for our compounding plant integrates our weighing equipment. It helps us improve the work flow and avoid some uncontrolled factors. The most important thing is that this system gives us great support for our production management. We can also record and analyze batch data allowing us to improve the understanding of our manufacturing process. I believe that we will have deeper cooperation with METTLER TOLEDO in the future. Production Manager Compounding Plant METTLER TOLEDO Petrochemicals & Derivates News 4 7

8 Boundless liberty in hazardous areas materialize weighing application dreams Changing industry landscapes, such as more volatile market demands and intensified competitive pressure, may force you to manage production with greater flexibility. This requires production flexibility, adaptability of product quality and elevated resource management even in explosive environments. To help achieve this, you need to have equipment in place to support your plan. With weighing equipment from METTLER TOLEDO, it is easy to dance to the music. Flexible, intelligent, safe With the freely programmable solution ID7sx SYS Pac, flexibility is just like a walk in the park. The capability to quickly change the application to accommodate changes in production makes the SYS Pac an indispensable utility. The ability to adapt to different product quality requirements is another virtue of the SYS Pac. Either connect an analog load cell weighing platform for low-demand production tolerances or a digital platform where high resolution and high accuracy are required or both together. Your quality requirements set the pace. The ID7sx SYS Pac solution is safe for explosive areas classified as Zone 1/21 and Class I, Division 1. ZONE 1/21 ID7sx weighing indicator DIVISION 1 USA Mettler-Toledo, Inc Polaris Parkway Columbus, OH, Tel. (1) Canada Mettler-Toledo, Inc Argentia Road, Unit 6 Mississauga, Ontario, L5N 8G6 Tel. (1) Mettler-Toledo AG Sales International CH-8606 Greifensee Switzerland Tel Your METTLER TOLEDO contact: For more information