Polyolefin Online Classification and Online SPC in LabWare LIMS. Christian Unger OLPA Department Borealis
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1 Polyolefin Online Classification and Online SPC in LabWare LIMS Christian Unger OLPA Department Borealis
2 Borealis at a Glance Leading provider of chemical and innovative plastics solutions that create value for society More than 50 years of experience Unique Borstar technology to develop polyolefin solutions that are tailored to customers needs 5,100 employees in over 20 countries Ownership 64% IPIC / 36% OMV Joint venture in Middle East and Asia: Borouge (Abu Dhabi) 2
3 PE and PP Producers 2011: Borealis/Borouge 8 th in World, Borealis 2 nd in Europe Capacities 2011 based on ownership share % World Western Europe 3
4 Polyethylene and Polypropylene QC testing Melt flow rate Pellet size & shape Density Mechanical properties Contamination 4
5 Polyethylene and Polypropylene offline samples Operator takes sample Sample is taken to QC lab QC testing PRODUCTION BATCH ~ t BATCH SAMPLE ~ 1-25kg SAMPLE ALIQUOT < 1kg 5
6 Product flow and quality control in a Borstar PO plant LOOP 1 st GPR 2 nd GPR DRYER BLENDER SILO FARM PP PURGE BIN EXTRUDER Online Instrumentation Room or container Online Polymer Analysis (OLPA) NMR Rheometer Optical inspection NMR Powder samples Pellet samples QC lab powder testing Xylene solubles, Ethylene content QC lab pellet testing Melt flow rate, Xylene solubles, Ethylene content, Mechanical properties, Optical inspection 6
7 Example: Rheometer trend 7
8 Example: Film inspection 8
9 Online Polymer Analysis (OLPA) vs Offline testing Offline testing OLPA Process control & trending Low sample frequency Sample preparation & analysis take time (Density: 2 hours) Continuous results (trends) Immediate results Online classification Lot release delays (mechanical properties: 24h) Real time lot release Classification based on homogenised sample (a few kg) Full final blend statistics 9
10 Automatic Online Classification (OLC) Fully automatic collection of OLPA measurement results (AspenTech InfoPlus.21) Automatic processing & statistics calculation (IP.21 OLC module) Integration into batch classification procedure in LabWare LIMS Average Minimum, maximum, standard deviation Online coverage factor Installed by LabWare and AspenTech in 2007 Replaces Excel sheets, VB macros, DCS printouts 10
11 OLC overview Analysis data Analysis data Batch details Analysis data Instrument PC DCS IP.21 plant server Instrument PC Batch statistics IP.21 OLPA server (OLC module) LabWare LIMS 11
12 OLC overview IP.21 OLPA server (OLC module) LabWare LIMS Background service Datapoints Statistics for LIMS automatic file import OLC sample Event trigger OLC subroutine Batch sample 12
13 OLC overview IP.21 OLPA server (OLC module) LabWare LIMS Background service Datapoints Statistics for LIMS automatic file import OLC sample Event trigger OLC subroutine Batch sample 13
14 OLC overview IP.21 OLPA server (OLC module) LabWare LIMS Background service Datapoints Statistics for LIMS automatic file import OLC sample Event trigger OLC subroutine Batch sample 14
15 OLC overview IP.21 OLPA server (OLC module) LabWare LIMS Background service Datapoints Statistics for LIMS automatic file import OLC sample Event trigger OLC subroutine Batch sample 15
16 LIMS batch sample Classification result Online results 16
17 Online SPC in LabWare LIMS & AspenTech IP.21 Lab result Lab result AVG Sampling time +/- time window LabWare LIMS LIMS sample: lab results (entered by operator) Online SPC settings (custom table) Tolerance Time offset Time window Event trigger subroutine Lab result + test number + sampling time + limits Automatic import online average / STDEV + info text (OK/NOK) AspenTech InfoPlus.21 Online SPC Module Get average result from online tag Report if the online measurement is stable (calibration allowed) Report if the online measurement is within limits 17
18 Online SPC in LabWare LIMS & AspenTech IP.21 Offline lab result Online SPC results + Calculated result 18
19 Presenting online results using Enhanced Visual Workflows Online data (.txt file) LIMS data (SPC samples) 19
20 Presenting online results using Enhanced Visual Workflows 20
21 Presenting online results using Enhanced Visual Workflows 21
22 LabWare LIMS Online classification experiences LabWare LIMS flexible enough to support complicated Online Classification procedure Online quality data structured and presented in an organised way (SPC, Offline and Online batch data) Extracted online quality statistics in LIMS are supporting product consistency improvement projects Availability of LIMS has become more important (24/7 uptime) Amount of results in the LIMS database has increased significantly >100 extra results in LIMS per batch 30% of the results table consists of OLC statistics results Regular performance tuning required (subroutine optimisation, background services, indexing) 22
23 Millions Results created per year ,03 6 3, ,40 0,47 1,19 1,93 2,15 2,23 2,22 2,59 3,05 3,48 4,28 4,96 OLC statistics Batch + Process results Million total results since Million OLC statistics results 23
24 Thank you Unless otherwise specifically stated, this presentation, any part of it, or any information contained herein may only be copied, disclosed or used within the Borealis group of companies. Borealis AG and its affiliates give no warranty and make no representation as to the accuracy, completeness or fitness for any particular use of the information contained herein. 24
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