CCO appointed to R&D leader.

The appointment of Dr Nathalie Huther as the new Chief Commercial Officer (CCO)with High Force Research has been announced. This strategic hire follows the company’s most recent Management Buyout (MBO), initiating a new chapter of growth and expansion.

Dr Nathalie Huther

In the newly created role, Nathalie will lead High Force Research’s commercial strategy, overseeing business development, client relations, and market expansion. With over 15 years’ experience of commercial leadership in the chemical and pharma/biotech service sectors, Nathalie brings a strong track record of driving revenue growth and forging strategic partnerships.

"I am delighted to join High Force Research at such a pivotal time," said Nathalie "The company’s reputation for scientific expertise and customer-centric solutions is exceptional. I look forward to building on this foundation, strengthening existing partnerships, and identifying new opportunities for growth."

The appointment comes as High Force Research looks to strengthen its position following the latest MBO, led by Tristan Sillars (CEO), which has given the company greater flexibility to accelerate its growth strategy. "We are thrilled to welcome Nathalie to the team," he declared. "Nathalie’s expertise will be invaluable as we focus on expanding our commercial reach and delivering even greater value to our clients. The recent MBO has positioned us for growth, and Nathalie will play a key role in driving that forward."

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 @HFResearch #PAuto #Research #Scientific

Automation partner at ethylene complex.

A Leveraged Procurement Agreement (LPA) to support automation at Dow’s Fort Saskatchewan Path2Zero expansion project (CDN).

ABB has signed a Leveraged Procurement Agreement (LPA) to support as the automation partner for Dow’s Path2Zero project at Fort Saskatchewan in Alberta, (CDN). According to Dow, the project, which is currently under construction, will create the world’s first net-zero Scope 1 and 2 greenhouse gas emissions ethylene and derivatives complex1, producing essential building blocks needed for many of the materials and products on which society relies.

The project will involve a brownfield expansion and retrofit of Dow’s existing manufacturing site 330 km north of Calgary, which when complete aims to decarbonize approximately 20 percent2 of Dow’s global ethylene capacity. It represents one of the largest private sector investments in Alberta's history, according to the province’s government.

To achieve net-zero Scope 1 and 2 emissions, Dow has designed the site to recover and convert its cracker off-gas to hydrogen, which will be used as a clean fuel in the site’s furnaces3. In addition, carbon dioxide emissions will be captured and stored permanently, reducing existing emissions and abating most emissions from the addition of the site’s new capacity.

The collaboration will explore how ABB’s solutions will support the decarbonization of Dow’s manufacturing facilities by driving energy efficiency, automating processes, and using digital tools to optimize operations. As part of the LPA, ABB will explore expanding the existing ABB Ability™ System 800xA® Distributed Control System by adding approximately 25,000 new Select I/O channels and conventional I/Os. ABB will also supply all the hardware, design and engineering of cabinets.

“We are proud to apply our automation expertise and collaborate with Dow to make strides towards a lower carbon future,” said Per Erik Holsten, President of ABB Energy Industries. “Industrial energy consumption accounts for about a quarter of energy-related CO2 emissions4. As the global economy and population grow, so will demand for materials and goods, increasing the importance of using technology to enable more sustainable manufacturing.”

To meet Dow’s automation requirements and ‘design once, build many’ philosophy, ABB will also look to deploy its Adaptive Execution™ methodology to write a standard solution across future sites that helps reduce risks, manage costs and deliver high-quality solutions on time.

With work having started in December 2024, the site is expected to increase approximately 1.8 million metric tons of ethylene capacity in a phased approach through to 2030. It will also create up to 5,000 jobs during peak construction and approximately 500 full-time jobs once operational.

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@ABBgroupnews @abb_automation @Dow_Canada #Pauto #Canada

Modernising control systems & software.

Artificial intelligence and cloud-based solutions to aid control system and software upgrade at chemical giant’s largest manufacturing facility in Europe.

Multinational chemical company LyondellBasell has selected Emerson to modernize control systems and software at its Wesseling complex in Germany. The implementation of advanced automation technology will help to enhance operation of an ethylene cracker and butadiene production plant. Emerson digital tools and project engineering services will help to ensure a smooth transition during the planned plant shutdown in 2024.

The Wesseling site is LyondellBasell‘s largest manufacturing facility in Europe. As part of a global modernization program, LyondellBasell is standardizing its control system technology. Emerson was selected for the project after demonstrating that it could implement all hardware and software upgrades during the two-week turnaround period.

Emerson’s DeltaV™ distributed control system and DeltaV Live software will be deployed to operate the ethylene cracker safely and efficiently, with the company’s AMS Device Manager software supporting the start-up process and ongoing management of field instrumentation. The advanced automation solutions will significantly reduce engineering time for implementing control strategies aimed at improving efficiency. DeltaV Live software will provide modern user interfaces that simplify management of the plant, enable operators to identify issues earlier and maximize worker productivity.

Virtual DeltaV systems will be used throughout the project to support development, testing and training. An operator training solution using Emerson’s MIMIC™ process simulation software will help operators to familiarize themselves with the new control system prior to start-up, minimizing the risk of potential issues and optimize operator efficiency. Emerson on-site engineers will provide start-up support and consult on the implementation of modern control strategies.

Essential to meeting the timeline will be a range of digital tools that streamline system modernization projects. This includes Emerson’s REVAMP software, which uses artificial intelligence (AI) algorithms to automate the task of identifying existing control system code to be used in the generation of DeltaV system configuration, eliminating errors and reducing engineering time. Cloud-based tools will support collaborative project planning and execution, streamlining the design, engineering and testing phases, while a range of digital tools will simplify the connection of existing I/O to the new control system.

“Emerson is committed to helping our customers to modernize and digitally transform their production facilities to enable operational improvements,” said Claudio Fayad, vice president of technology for Emerson’s process systems and solutions business. “AI, machine learning, cloud-based solutions and Emerson’s extensive project expertise will all help LyondellBasell simplify their control system upgrade, reduce project time and mitigate risk.”

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@EMR_Automation @LyondellBasell #PAuto #Germany

Reactor control.

The AGI Glassplant Pilot Reactor Controller has been launched for easy control, automation and monitoring of any pilot reactor and associated devices via a single software interface. Designed for the pharmaceutical, chemical, CRO/CMO, agrochemical, and flavour and fragrance sectors, this modular and scalable system provides easy integration of third-party devices, offering secure and robust data connections to help reactors reach their full potential.

The controller is an easy-to-use, turnkey solution that is ideal for chemists and chemical engineers looking to scale up from lab to pilot plant or, conversely, down from production to pilot. Using OPC Unified Architecture, this next generation reactor controller offers universal connectivity with a vast range of reactors and peripheral devices – including circulators, stirrers, sensors and pumps – via a no-code software interface, allowing quick set up and process replication without specialist programming knowledge. Multiple users can visualize every connected device via an intuitive drag-and-drop interface, and data is collected, processed, compiled and logged in a single .CSV file for further analysis.

The flexible Hub and DAQ design is easily configurable to suit individual laboratory needs, with easy-to-access connection ports that can be customized to specific process requirements. Additional DAQs can be added as necessary, enabling scale-up and control of even the most complex processes. The system provides numerical and graphical live displays that can be customized to specific data interpretation needs, enabling real-time process oversight and control for close tracking and modification of reactions on the fly. The AGI Glassplant Pilot Reactor Controller also features integrated, user-programmable safety procedures – with high and low level alarms – as well as operator-defined safe standby procedures and a physical remote standby trigger for complete peace of mind.

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@agi_glassplant @kdmcomms #PAuto

Automating electrification of chemical production processes.

Pioneering technology uses light to decarbonise chemical production, helping manufacturers reduce both emissions and operational costs.

Emerson has been chosen by Syzygy Plasmonics to automate its innovative catalyst reactor technology that uses light instead of thermal energy, such as heat generated from burning fossil fuels, for chemical manufacturing. The all-electric production method is designed to replace fossil fuel-based combustion, helping reduce industrial greenhouse gas emissions and operational costs while advancing global sustainability goals. Syzygy estimates its reactor systems could eliminate one gigaton of CO² emissions by 2040.

Syzygy photoreactor used during catalyst testing
(Photo: Brandon Martin Rice University)

The Syzygy catalyst reactor technology will advance decarbonisation in a cost-effective way by electrifying carbon-intensive activities such as chemical manufacturing and reducing the carbon intensity of hydrogen, methanol and fuel production. Rather than rely on thermal energy, the Syzygy reactor harnesses the power of light to energise chemical reactions and reduce the carbon footprint in transportation fuels.

“We are excited to advance this opportunity with Emerson not only for its automation technologies and software but also its sustainability leadership and domain expertise in chemical engineering, electrification and hydrogen production,” said Syzygy chief executive officer Trevor Best. “As we expand beyond traditional paradigms of reactor technology and launch a new way to electrify chemical manufacturing, we wanted a technology partner who can help us scale our technology efficiently, safely and reliably.”

"Emerson is excited to collaborate with Syzygy Plasmonics on such promising technology that could have a significant impact on industries that are some of the most challenging to decarbonise," said Peter Zornio, chief technology officer at Emerson. “This aligns with Emerson’s culture of innovation that takes on our customers’ biggest challenges.”

Decommissioned photocatalytic reactor
used to train Syzygy employees

Syzygy has developed, scaled and integrated its core technologies, incubated at Rice University, into a universal photocatalytic reactor platform, which includes the Rigel™ photoreactor and the proprietary photocatalyst that enables light-driven chemical reactions at unprecedented efficiency.

Emerson will provide hardware, software and services for the Syzygy modular reactors, including its DeltaV™ distributed control system; industrial software for process simulation and data analytics; Rosemount™ instrumentation to measure pressure, temperature, level and flow; and Fisher™ valves to control pressure and improve safety.

Syzygy has three field trials planned for 2023. Leading global partners are driving strong market interest with trials located in North Carolina, California and South Korea.

Syzygy has received funding from the US Department of Energy and the National Science Foundation, and investments from Aramco Ventures, BP, Chevron Technology Ventures, Equinor Ventures, EVOK Innovations, Goose Capital, Horizons Ventures, LOTTE Chemical, LOTTE Fine Chemical, Pan American Energy, Sumitomo Corporation of Americas, The Engine and Toyota Ventures.

@EMR_Automation @Emerson_News @EmersonExchange  @SyzygyPlasmonic @HHC_Lewis #PAuto #CarbonReduction

Chemical vessel production.

A major chemicals company needed a highly accurate welding system that could manufacture vessels used in chlorine production

A highly flexible ABB robot is helping a major British chemicals company produce accurate laser welds on chemical production equipment. The solution, developed by Cyan Tec Systems, is designed around an ABB IRB 6700 industrial robot carrying a laser welder to produce highly accurate welding on production vessels used in the manufacture of chlorine.

“Over the last six to seven years, we have done a lot of laser applications for welding and cutting. Many of these have used ABB robots and we have built up a bank of experience and expertise, so familiarity with the solution was a big influencer in choosing a robot for the customer," said Cyan Tec's Richard Copson 

The end user was keen to solve logistical challenges by bringing the welding of the product in house from a European sub-contractor. As well as offering more control over the process, reshoring production would avoid the need to deliver raw materials to the sub-contractor and ship back the finished product.

Laser welding offers the high accuracy required in producing this type of process vessel. It gives better quality welds ensuring that the weld maintains high integrity and prevents any distortion that can result from the higher heat dispersion of other methods. It also offers faster throughput.

Because laser welding presents a risk of eye injury to human workers, a fully enclosed automated solution was required.

Cyan Tec Systems was asked to develop the solution. The company, an ABB Value Provider, has extensive experience designing and building robotic automation solutions for companies in industries including aerospace, automotive and nuclear.

The system required a machine that could carry out the immediate task required but which also had the flexibility to handle different welding tasks in the future. For this reason, Cyan Tec chose a robot solution rather than a gantry design. Although a gantry would have met the immediate requirements of the tasks, it would not offer the longer-term future proofing that the customer specified.

As the customer already had an ABB robot on its shopfloor, Cyan Tec looked at ABB robots that could fulfil the brief. This would ensure that the customer’s engineers could conduct basic programming tasks without having to learn a new language.

ABB could supply a versatile six axis robot but could also provide a track that the robot could run on. Fitting the robot to an ABB IRBT motion system effectively gave it a seventh axis, allowing it to run down the length of the component to produce an accurate weld. The version suitable for the IRB 6700 can provide a travel length of up to 19.7 meters in one-meter steps. With a simple, robust, and compact design, the track solution offers best in class path accuracy and a position-to-position time of less than 3.4 seconds for a four-meter length.

With a reach of over three meters and running on the track, the ABB IRB 6700 robot can weld accurately along the two-meter length of the component. The robot has a higher payload than that required for the application, but this also gives the flexibility to carry a heavier welding head or other effectors if requirements should change in the future.

The solution also incorporated a vision system on the laser head, allowing it to compensate in the event of misaligned component elements.

Cyan Tec used ABB’s RobotStudio simulation software to prove the layout and operation of the solution. Simulating the application, complete with a graphical animation of the robot’s operation and its interaction with the other solution elements, reassured the customer that Cyan Tec had chosen the correct robot with the right reach. It also proved that it would not foul other objects or collide with any of the ancillary machinery. RobotStudio also eliminated much of the risk involved in developing the application, as it avoids the need to reengineer the project if problems are discovered during the commissioning stage.

Because a Class 1 laser was used, which could potentially cause damage to eyesight if users are not wearing suitable eye protection, the robot needed to be in a laser proof enclosure. Cyan Tec designed a system that allows the customer to load one component for welding while unloading a finished component, speeding up the rate of production.

The enclosure incorporates two sets of welding fixtures, one for welding together two flat sheets into one. This is then unloaded, sent to a pressing section for formation into components and then reloaded into the enclosure on the other set of fixtures for final welding into the complete product. This final welding stage takes around two minutes for a completed product.

As well as the robot, track and enclosure, Cyan Tec integrated the laser source and ancillary components such as the tooling, laser chiller, fume extraction system and assist gas control.

“The experience we have with ABB robots means we don’t always need their help to design and develop a solution, but they are always on hand if we need to use different features or do things we haven’t done before. As an ABB Value Provider, it’s good to know that their support is always available if we need it.”

@ABBRobotics @ABBgroupnews @ABBMeasurement @abb_automation @CyanTecSystems #Robotics #PAuto 

Automation for polymars project.

Global technology and software leader Emerson is to provide automation technologies, software and analytics from its Plantweb™ digital ecosystem for the Golden Triangle Polymers Project, a world-scale integrated polymers facility on the Texas Gulf Coast (USA).* The total installed cost of the project is expected to be $8.5 billion and is a joint venture between Chevron Phillips Chemical Company LP and an indirect subsidiary of QatarEnergy. Operations are expected to begin in 2026.

Designed using the latest greenhouse gas (GHG) emissions reduction technology, the project aims to have approximately 25% lower GHG emissions than similar facilities in the United States and Europe.

“With its digital automation technologies, industrial software portfolio, and deep energy experience, we are relying on Emerson to help ensure a project of this magnitude operates safely and reliably, optimizes energy use and mitigates emissions,” said David Godard, project director for the Golden Triangle Polymers Project.

The Golden Triangle Polymers Project includes a 2,080 KTA ethane cracker as well as two 1,000 KTA high-density polyethylene units. Polyethylene is used to produce durable goods and essential packaging to protect food and keep medical supplies sterile.

“The Golden Triangle Polymers Project and the recently announced Ras Laffan Petrochemical Complex in Qatar are among the world’s largest ethane crackers, both leveraging Emerson’s digital automation technologies, software and expertise to promote safer, smarter and more sustainable operations,” said Ron Martin, Emerson’s president, Americas. “We are proud to support Chevron Phillips Chemical’s and QatarEnergy’s track record of building world-class, optimized facilities.”

Emerson will deliver integrated process control and safety systems that leverage advanced predictive technologies to reduce operational complexity and minimize project risk through its DeltaV™ distributed control and safety instrumented systems, and Rosemount gas analyzer and chromatograph solutions. The project also leverages Emerson’s Mimic™ and AspenTech HYSYS® simulation software for operator training, energy management, safety analysis and operational optimization. Emerson’s AgileOps operations management software and alarm management services will help staff monitor and maintain safety, alarms, and the control system to drive improved process and operational integrity.

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* The Golden Triangle Polymers Project is located located in Orange, (TX USA) about 113 miles east of Houston in the “Golden Triangle” region of Texas that encompasses the city of Orange.

@EmersonExchange @EMR_Automation @Emerson_News  @chevronphillips @HHC_Lewis #PAuto #Research #USA

Lab sensors for pH, conductivity, and dissolved oxygen measurements.

Endress+Hauser has launched five new laboratory sensors compatible with its Liquiline CML18 handheld laboratory analysis device. The Memosens CPL53E, CPL57E, CPL59E, COL37E, and CLL47E liquid analytical sensors now join the CPL51E to further amplify the company’s goals of trustworthy measurement, easy operation for end-users, and enhanced good laboratory practice (GLP).

The new sensors support data and quality management in the verification processes of online measurements, provide immediate and tamper-proof calibration history traceability, with easy data transfer using Bluetooth technology.

Using the bayonet connector, the handheld CML18 and Memosens sensors are plug-and-play, working out of the box with support for easily switching output parameters—such as pH, dissolved oxygen, and conductivity—at the measuring point. Users can begin making measurements without initial calibration because these accurate Memosens instruments are pre-calibrated at the factory.

Memosens 2.0 sensors are suited for laboratory measurement and random process grab sampling, ensuring that online measured values are always reliable. By using the same sensor type in the lab as in the process, you are assured of data and quality management in the verification process of online measurements.

CPL53E – digital pH sensor built for all-around use. The CPL53E glass PH sensor is built for all-around use in the lab, covering everything from lab sampling to random process grab sampling. Additionally, the CPL53E has a measurement range of pH 0 to 14, a process temperature range of –5 to 100 °C (23 to 212 °F) and an application range of 0 to 80 °C (32 to 176 °F). CPL57E – highly accurate digital pH sensor for low conductivity water. The CPL57E pH sensor is designed for low-conductivity water applications in all industry types. This glass sensor provides long-term stability because of additional salt storage, providing high measurement accuracy in pure water from pH 0 to 14, a process temperature range of –5 to 100 °C (23 to 212 °F) and an application range of 0 to 80 °C (32 to 176 °F). Like the CPL53E, the CPL57E is a virtually maintenance-free sensor. CPL59E – pH sensor built for harsh conditions. The CPL59E pH sensor is built to withstand harsh conditions in chemically aggressive fluids, specifically within the measurement range of pH 0 to 14, with a process temperature range of 0 to 135 °C (32 to 275 °F) and application range of 0 to 100 °C (32 to 212 °F). With an ion trap, the instrument provides high stability to oxidizing agents, protecting the sensor from drift that can result in inaccurate measurements. COL37E – an agile optical oxygen sensor. The digital COL37E dissolved oxygen sensor enhances oxygen measurement with a fast response time. With a measurement range of 0 to 200 %SAT and process temperature range of –5 to +60 ˚C (23 to 140 ˚F), the sensor is primed for use in checking oxygen values in aeration tanks, fish farms, and surface water. CLL47E – 4-electrode digital conductivity sensor. The CLL47E is a four-electrode conductivity sensor for random sampling and measurements in the lab with a measurement range of 5 μS/cm to 200 mS/cm and a process temperature range of 0 to 100 °C (32 to 212 °F). The instrument’s four platinum electrodes allow for coverage over a large variety of samples. This sensor provides high precision at measuring point in drinking water, cooling water, wastewater, and process media (such as cleaning solutions). The CLL47E is also suited for verifying online measuring loops, analyzing grab samples, and spot-checks at critical process points.

@Endress_US @Endress_Hauser @Endress_UK #PAuto #Laboratory

Lithium breakthrough.

A new technology that dramatically improves the production efficiency of lithium – the most crucial component of a Li-Ion battery has been launched by Sensmet. Their automated online measurement technology enables the optimal dosing of chemicals during lithium production, which improves revenues and reduces costs.

Traditionally, battery metal manufacturers had to rely on batch sampling and laboratory analysis to control their processes, but this is costly, labour intensive, and typically incurs a delay of 4–10 hours. In contrast, Sensmet’s technology; Micro-Discharge Optical Emission Spectroscopy µDOES®, is able to measure multiple metals, such as any battery metal and their impurities, in real-time. In addition to lithium manufacture, the technology is also suited to the ‘black mass’ recycling of battery metals. Strict online monitoring and control is implemented to reduce impurity levels and thereby prevent the cost and delay incurred by retreatment.

Keliber ran a pilot-scale test programme in 2022 to evaluate the µDOES® analyser in the continuous optimisation of precipitation chemical dosing during lithium production. Nearly 80 samples were drawn from the process with sodium and lithium concentrations analysed in parallel using both the µDOES® continuous analyser and a laboratory ICP-OES. The results showed an excellent degree of correlation between the methods. Keliber’s Sami Heikkinen said: “Chemical dosing based on reliable real-time data brings stability to the process, which is very important because it avoids drift and optimises both yield and quality while minimising cost.” They have recently announced their €588,00 lithium hydroxide facility.

The ability to conduct continuous, simultaneous measurements of multiple metal species in an aqueous matrix offers battery metal manufacturers the opportunity to improve process efficiency, lower costs, increase throughput, avoid waste and improve the quality of the final product.

@Sensmet_Ltd @_Enviro_News #PAuto 

Power management system for potash project.

Integration of power and process technologies into one of the world’s largest potash sites will increase electrical and substation visibility to support maximum uptime

ABB has been selected by BHP to deliver a power management system for the Jansen Potash Project in Canada, which will provide nutrient-rich potash fertilizer to enable more sustainable farming globally. The global resource company is progressing the US $5.7 billion Jansen Stage 1 Potash Project which is expected to achieve first production in late 2026.

ABB recently expanded its ABB Ability System 800xA Power Control Library software to in-clude more options to commun-icate with and control electrical devices throughout the power infrastructure for mining and mineral processing operations.

“ABB will not only ensure high levels of availability, process visibility and energy management but also demonstrate interoperability with a third-party control system on this important project,” said Max Luedtke, Global Head of Mining, Process Industries, ABB. “Our teams have been working in the Canadian potash mining sector for many decades and anticipate growing to even greater levels of domain understanding using new available data and alerts.”

The order includes ABB Ability™ System 800xA Power Control Library, a digital application to monitor industrial electrical systems. It will help BHP on its journey towards an automated, electrified and digitalized site where engineers can monitor and quickly troubleshoot disturbances. The system will cover the electrical substation equipment remotely, reducing the time taken for fault diagnosis and problem solving.

BHP’s 100 percent-owned Jansen Potash Project in Saskatchewan, Canada, is planned to be the largest potash producing mine in the world with an initial Jansen Stage 1 capacity of 4.5 million tons per annum (Mtpa) and potential for 16 to 17 Mtpa through future development. Potash, a potassium-rich salt used as a fertilizer to improve the quality and yield of agricultural crops, is an essential plant nutrient and is increasingly vital due to land scarcity and a growing world population. Around 70 Mtpa is currently produced globally with a current market reliance on Canada and emerging potash-producing regions.

ABB will ensure high levels of availability and efficiency of the energy supply to the process. BHP will also have access to data for the electrical substation and electrical assets and the bank of information available will build over time, allowing trends to be identified and actions taken.

@ABBgroupnews @abb_automation @bhp @admiralpr #PAuto  #Fertiliser

Partnership a roadmap to increase automation of its operations in Mexico.

Braskem Idesa Works with Emerson to Drive Operational Excellence, Achieve Sustainability Goals!

A strategic partnership with Braskem Idesa to provide digital automation technologies and engineering services across its operations to meet business performance metrics and achieve its sustainability goals has been announced by Emerson.  Braskem Idesa is a joint venture between Brazil-based Braskem, the largest producer of thermoplastic resins in the Americas, and Grupo Idesa, one of the biggest petrochemical companies in Mexico.

A multi-year digital transformation roadmap will leverage Emerson’s extensive petrochemical industry expertise and broad portfolio of advanced automation technology and software solutions to drive not only operational excellence but also support Braskem Idesa’s goal of reducing greenhouse gas (GHG) emissions scope 1 and 2 by 15% by 2028 and achieving full carbon neutrality by 2050.

“We identified several key financial and performance benchmarks and brought Emerson on board to participate in the creation of a detailed digital transformation strategy for achieving Top Quartile results,” said Stefan Lepecki, Braskem Idesa’s CEO. “Having a well-defined path forward has given us the confidence to pursue our sustainability and performance goals, with advanced, integrated technologies that help us support market demands.”

Taking advantage of Emerson’s Operational Certainty methodology, the roadmap provides a framework for scalable improvements in some of the four key transformation work streams:

• Information management, including creating a data architecture for real-time KPIs and decision-making. • Physical loss control, with enhanced energy management and loss control systems. • Production and energy optimisation with advanced control technologies. • Reliability and energy efficiency using data analytics, continuous emissions monitoring systems, LED lights and fugitive emissions reductions.

These work streams align with Braskem Idesa’s three-pronged strategy for the reduction of GHG emissions through energy efficiency, renewable energy use and low carbon intensity process technologies; renewable feedstocks and post-consumer recycling; and capturing carbon emissions to use as raw materials, value-added chemicals and as an alternative to future carbon taxes.

“Successful leaders are realising that sustainability initiatives are also good business,” said Mark Bulanda, executive president of Emerson’s Automation Solutions business. “Reducing waste and unnecessary raw material consumption, lowering energy costs and driving profitability, all while improving environmental sustainability, is absolutely possible with the right focus and resolve.”

•  See "Forward Focus..."  - the theme of the Emerson User Group Conference commencing 24th October 2022 in Grapevine (TX USA).

@EmersonExchange @EMR_Automation @Emerson_News @BraskemIdesa @HHC_Lewis #PAuto #Mexico

PoE for Coriolis for process efficiency.

The first Micro Motion Power-over-Ethernet (PoE) Coriolis flow measurement device for the food and beverage, life sciences and chemical industries has been introduced by Emerson. Their 1600 Coriolis Transmitter is designed to be a scalable solution for facilities wanting to make a gradual transition to remote flow data collection, monitoring and configuration.

“The Micro Motion 1600 transmitter offers customers a purpose-fit device in both form factor and capabilities for the demands of the food & beverage and life sciences industries as they strive to achieve more efficient, reliable and sustainable operations,” said Melissa Steigler, food and beverage industry director at Emerson.

With traditional Ethernet, optional PoE and an additional licensable configurable output, the 1600 delivers a powerful solution for customers looking for a flow measurement device that will grow with their process and is easily integrated into a control system.

PoE can deliver power and data over a single Ethernet cable, which means no new cabling will need to be installed, saving customers up to 50% in installation and maintenance costs. The Micro Motion 1600 transmitter can use just PoE or have a separate direct current (DC) power input, depending on wiring availability. The smallest PoE Coriolis transmitter on the market, the 1600 is available in aluminium or hygienic stainless steel. The compact size and lightweight design are an added space-saving benefit for skid designers.

The transmitter is equipped with a multi-language four-line local operator interface (LOI), a suite of advanced software solutions including Smart Meter Verification, Data Historian, Concentration Measurement and Advanced Phase Measurement, as well as an additional licensable channel that can be configured for analogue, frequency or discrete output and a USB-C service port. The reliable, high-quality data it collects allows for greater process efficiency, which minimises product and process waste, reduces emissions by giving visibility to entrained gas events, and results in a more efficient consumption of power.

•  See "Forward Focus..."  - the theme of the Emerson User Group Conference commencing 24th October 2022 in Grapevine (TX USA).

@EmersonExchange @EMR_Automation @Emerson_News @MicroMotion @HHC_Lewis #PAuto #Food

Control systems, software and engineering services for speciality chemicals

Specialty chemicals company LANXESS has selected Emerson as a Global Alliance Partner for automation technology, enhancing its existing long-standing relationship. By upgrading its control and safety systems, and digitally transforming its production facilities, LANXESS aims to optimise operational performance and support sustainability targets.

The companies have signed an initial five-year global agreement. Emerson will help drive the adoption of advanced automation technologies and enable more efficient project implementation that will allow LANXESS to achieve shorter time-to-market for new products.

"We are pleased to expand our collaboration with Emerson and work more closely to develop digital automation solutions that help improve operational performance. Emerson’s automation solutions will support us on our growth path and further drive the digital transformation of production at LANXESS," said Marcel Beermann, head of global procurement and logistics at LANXESS.

The agreement will be supplemented by joint projects to develop and implement applications and analytics software to identify opportunities for increased efficiency and performance, while also delivering on sustainability goals.

“LANXESS and Emerson have enjoyed a successful relationship for many years,” said Mark Bulanda, executive president of Emerson’s Automation Solutions business. “This new agreement enables us to accelerate implementation of advanced automation solutions and digitalise processes that increase operational efficiency, improve energy usage and lower emissions.”

@LANXESS @Emerson_News @EMR_Automation @EmersonExchange @HHC_Lewis #PAuto #Chemicals

Hygienic scale platforms.

In regulated, hygienic environments, ease of equipment sanitation is as important as the operational performance. It is increasingly important to streamline cleaning processes to not only eliminate contamination risk but also maximize productivity.

Mettler Toledo’s PBD659 and PBA639 hygienic weighing platforms enable manufacturers in the pharmaceutical, chemical and food industries to speed up cleaning processes and ensure regulatory compliance with an optimized hygienic design. The platforms strictly adhere to hygienic design guidelines, facilitate quick and easy cleaning, and meet higher weighing accuracy standards to expedite processing time and reduce production costs.

With PBD659 or PBA639, operators can boost cleaning speed by up to 40% with less effort compared to traditional weighing equipment. The following features of the platforms help operators to eliminate contamination risk in regulated environments:

• No cavities, crevices or open threads
• Open-frame stainless-steel design with rounded edges and minimal flat surfaces
• Hermetically sealed load cell with IP68 and IP69k water ingress protection

The PBD659 and PBA639 platforms are designed to withstand impacts and ensure peak performance in challenging environments. Optimally placed and independently adjusted overload stops and additional side impact protection enable increased uptime, reduced maintenance and maximized equipment longevity.

The smart load cell used within the PBD659 platform actively corrects and compensates for measurement errors caused by external and internal factors, which improves accuracy by up to 100% to 6000e for legal-for-trade applications and 60000d for non legal-for-trade applications, compared to traditional analog weighing systems to prevent bad batches and reduce product waste.

Global approvals, which enable cross-border consistency, include OIML, NTEP, CPA (metrology); FCC, CE (EMC); IEC/EN61010, UL (safety). For firms operating globally, PBD659 and PBA639 are sold worldwide and serviced locally in over 40 countries by competent personnel. The analog version of the hygienic platform (PBA639) is also available with global EX approvals for use in Zone 1/21, Division 1 and Zone 2/22, Division 2 hazardous environments.

@mettlertoledo #Pharma #Food #Weighing

Reduce emissions & increasing capacity in polyester plant.

Improving safety at a newly expanded purified terephthalic acid (PTA) facility at Merak (RI).

INEOS Aromatics Indonesia has completed $70 million of upgrades at its facilities in Indonesia, to significantly reduce emissions and increase capacity, which includes the installation of two vent gas analyzer systems from Servomex. These were designed in conjunction with INEOS to deliver enhanced safety and control of the oxidation reactor.

Each gas analyzer system includes a pressure reduction pre-sample conditioner enclosure and a SERVOTOUGH OxyExact 2200 – a high specification O² analyzer which offers an unrivaled combination of precision, flexibility and performance for optimum process and safety control.

Installing the larger oxidation reactor, reconfiguring the reactor’s heat recovery system and revamping the process air compressor train is expected to reduce the site’s CO² emissions per ton by 15 per cent. The move should also increase site capacity by 15 per cent from 500,000 tonnes to 575,000 tonnes per annum.

The project was successfully secured and delivered by Project Manager Ernesto Torres and Design Engineering Lead Cole Harbour.

Shelley Moore, Global Head of Systems at Servomex, said: “Our highly-valued team members of the Systems Engineering group based at Texas ensured the highest quality design and build of the systems and completed the project ahead of schedule to the delight of our customer. With the continued international strategic approach to winning and executing projects, Servomex is on track to continue satisfying customers and achieving our company goals.”

INEOS Aromatics Indonesia president director, Frank Yang added: “This new, multi-million dollar investment shows our commitment to its future growth. Installing the larger oxidation reactor supports INEOS’s commitment to producing essential products while reducing emissions to net-zero by 2050.”

The Merak plant has played an important part in the growth of the Indonesian polyester industry. It became part of INEOS as part of its $5 billion acquisition of the BP Petrochemicals business in January 2021. 

@Servomex @INEOS @codacomms #PAuto #Indonesia

Easily monitor process fluids in real time.

Many processes require fast reactions to changes or errors. LiquiSonic® from SensoTech GmbH reliably detects these deviations within seconds. Warnings can be issued via a variety of data interfaces - even by e-mail. Thus, users are always informed about the status of their process.

Chlorine and caustic soda are essential chemicals whose production is indispensable for downstream chemical processes. Due to the immense production volumes, small deviations and errors in the individual production steps can mean large financial losses. For this reason, complete and accurate process monitoring is important. LiquiSonic® offers a process monitoring system that meets these high requirements.

Precise monitoring of the starting materials already shows its advantages during the preparation of the brine. With LiquiSonic®, the concentration of the sodium chloride solution can be precisely adjusted down to 0.1 m%. Maximum saturation prolongs the life of the membranes during electrolysis and saves energy during subsequent concentration of the sodium hydroxide solution.

After electrolysis, the caustic soda solution (NaOH) still has to be freed from unwanted NaCl residues and then concentrated to the usual purity. With LiquiSonic ® , this process can also be monitored and controlled in real time. High plant efficiency and unbeatable product quality are the result.

After the chlorine gas has been produced, the challenge is to reduce its process-related water content. For this purpose, hygroscopic sulfuric acid is used as a drying agent. The smallest deviations in acid concentration cause poor drying results and high costs or long-term plant damage, eg, due to rust. LiquiSonic ® allows checking the sulfuric acid concentration with an unbeatable accuracy of up to 0.03 m%. Poor chlorine drying results are thus a thing of the past.

@PresseBox #SensoTech #PAuto 

Champion resellers and service partners!

Seeq Corporation has announced its 2021 Reseller and Service Partners of the Year. These partners have been selected for their excellence in providing value to customers, their continued investments in technical expertise with their Seeq-certified employees and training professionals, and for creating awareness of Seeq through collaboration in marketing activities and events.

Seeq enables engineers and scientists in process manufacturing organizations to rapidly analyze, predict, collaborate, and share insights to improve production outcomes. Seeq customers include companies in the oil and gas, pharmaceutical, chemical, energy, mining, food and beverage, and other process industries. Investors in Seeq include Insight Ventures, Saudi Aramco Energy Ventures, Altira Group, Chevron Technology Ventures, and Cisco Investments.

In 2021, Seeq announced a $50 million Series C funding round led by Insight Partners, was recognized by Frost & Sullivan’s North American Technology Innovation Leadership Award for Seeq Data Lab, and expanded its products and capabilities, including support for machine learning innovation.

“We are pleased to select four companies as our 2021 Reseller and Service Partners of the Year,” said Will Knight, Head of Worldwide Partner Sales at Seeq. “These awards recognize the impact these partners have on empowering our customers to create advanced analytics insights, and the standards they have set for excellence in delivering the next generation of process manufacturing improvements.”

Resellers of the Year Asia Pacific Nukon is Seeq’s 2021 Asia Pacific Partner of the Year. Nukon was selected among Seeq’s reselling partners for its focus on customer support and its tremendous growth in the Australian market, more than doubling its revenue over the previous year. The company provides a variety of OT and IT solutions and services to its clients in the consumer goods, infrastructure, utilities, and waste management industries.  “We’re honored to be selected as a Seeq Partner of the Year for the second year running,” says Alec Konynenburg, General Manager at Nukon. “Nukon prides itself on providing the best solutions for clients, and Seeq’s capability allows us to do this through their unique set of offerings. The Nukon and Seeq partnership is built on joint values and commitment to our customers, and we’re excited to continue to provide this value in 2022 and beyond.” Americas  Swan-Black is Seeq’s 2021 Americas Partner of the Year. Swan-Black was selected for its rapid growth in the Americas and globally, and its support for Seeq’s customers in the food and beverage and bioscience industries. Swan-Black has expertise in batch and continuous manufacturing processes, with a focus on applying advanced analytics to improve business outcomes.  “We are incredibly honored to be recognized by Seeq as Partner of the Year for the Americas,” says Joe Gardner, Practice Lead at Swan-Black. “The Seeq solution and the team’s support of our efforts empower us to deliver meaningful process data insights for our customers, leading to increased process efficiency and optimization. We look forward to our continued partnership with Seeq and the value it will bring our customers well into the future.” EMEA Crucial Solutions and Services (CSS) is Seeq’s 2021 EMEA Partner of the Year. CSS was selected for its support and leadership of Seeq’s customers in the Middle East, notably its collaboration on Saudi Aramco’s industrial digitalization initiatives. The company provides a variety of technology offerings to its clients in the oil and gas, petrochemical, and power and utilities industries.  “CSS is dedicated to providing customers with game-changing services and solutions that optimize their efficiency and enhance business growth,” says Sulaiman Alzuhair, Founder and CEO at CSS. “Seeq’s complementary products and capabilities enable CSS to achieve this mission and we are honored to be selected as the Seeq Partner of the Year for EMEA.” Service Partner of the Year BKO Services LLC is Seeq’s first Service Partner of the Year recipient. BKO was selected for its expertise in the oil and gas and power generation industries, its work on Shell’s upstream digital initiatives and Tranter’s use of advanced digital tools to manage its clients’ fleet of heat transfer equipment, and its investment in Seeq-certified employees. In 2021 alone, BKO added five certified partner analytics engineers and one certified instructor to its team. The company provides data engineering, machine learning, and OSIsoft application development services for the oil and gas, power, and other process manufacturing industries.  “As the true value of data analytics and machine learning become more apparent, technology must not only keep pace with the increasing availability of data, but effectively utilize it to improve operations and safety,” says Shaun Wright, CEO of BKO. “We are pleased and proud to be a Seeq partner and part of the radical mindset shift driving this rapidly emerging field of science and technology.”

Seeq’s worldwide growth is fueled in part by its partnerships and commitment to cloud-based computing. Seeq is available in the Amazon Web Services (AWS) marketplace, is an AWS Industrial and Energy Competency Partner, and supports many data storage services, including Amazon Redshift, S3, plus machine learning in SageMaker, and others.

On Microsoft Azure, Seeq has been available as a SaaS application in the Azure Marketplace since 2019, with support for many Azure cloud services including Synapse, Azure Data Lake, and Active Directory. Seeq also supports connectivity to Azure Data Explorer, Time Series Insights, and Power BI.

In addition to cloud partnerships, Seeq connects to an extensive set of data storage platforms from vendors including OSIsoft, Siemens, GE, Honeywell, Inductive Automation, AVEVA, AspenTech, Yokogawa, InfluxDB, Snowflake, and others.

@SeeqCorporation @BkoServices #PAuto 

Chemical show highpoint approaches.

The highpoint of ACHEMA Pulse is approaching: on 15 and 16 June 2021, decision-makers, international experts and the more than 950 exhibitors at ACHEMA Pulse will get together during the live days to provide information, inspiration and food for thought for all players in the chemical, pharmaceutical and food industries.

Around 400 hours of programme on three live stages, in 8 congress channels, 8 exhibitor channels and 6 parallel workshop channels await the audience. From visionary discussions on the digital process industry or the hydrogen economy, to practical talks on laboratory automation and recycling, to product presentations, there is everything to interest plant planners and operators, process developers and producers. Numerous company executives and experts from BASF, Bayer, Clariant, Covestro, Ekato, Emerson, Evonik, Excellence United, GEA, Genomatica, Linde, Merck, Microsoft, OPC Foundation, Romaco, Samson, Siemens, Syngenta and many others will share their insight on panels or in interviews. In addition, thought leaders from international research institutions will describe their visions for the chemical and pharmaceutical industries of the future. Live demonstrations will be broadcast on some topics such as the laboratory of the future, 5G or gas leakage. Thanks to the live format, participants can actively contribute to the discussions with their questions.

"The fact that both we as organisers, who are deeply rooted in the community, and the exhibitors and many partner organisations jointly design the program means that we cover the entire range of currently relevant topics," says Dr. Thomas Scheuring, CEO of DECHEMA Ausstellungs-GmbH. Thus, in addition to the highlight sessions, topics such as sustainable pharmaceutical packaging, flow chemistry, modularisation, vaccine development and production, or new raw materials for the chemical industry will be addressed both in high-level panel discussions and in expert presentations by exhibitors or interactive workshops. "No matter how deeply individual participants want to delve into a topic, the many different formats mean there is something for everyone," he explains.

With the Global Insights, ACHEMA Pulse also shines a spotlight on some regions that are currently undergoing transformation processes. These include, for example, the decarbonization of Singapore as a chemical location, the green raw materials wave in Scandinavia or sustainable agrochemicals in South America.

Those who miss parts of the extensive program in real time have the opportunity to watch the recordings in the platform until June 30 and can, of course, still get in touch with the contact persons for the topics. Only the workshops are exclusively live. 

Since May 31, more than 950 exhibitors have already been presenting products and solutions for the process industry on the ACHEMA Pulse platform. "The variety of offerings is really impressive," says Björn Mathes, Member of the Board of DECHEMA Ausstellungs-GmbH and project manager of ACHEMA Pulse. "The exhibitors have quickly settled into the platform and attractively showcased their innovations. We can see from the steadily increasing visitor numbers that this unique opportunity to gain a comprehensive overview of the current state of the art is gladly taken." 

Although there had been some faltering in electronic ticket sales at the very beginning, these difficulties have since been overcome. "Now we are excited about the upcoming live days and are looking forward to full virtual halls," says Björn Mathes.

• See also The pulse of processing (31/5/2021)

@ACHEMAworldwide @Pressebox #PAuto #Pharma

Module Type Package integrated in control systems.

Emerson has integrated the emerging MTP process automation standard into its control systems, as part of a continued effort to help manufacturers increase speed-to-market and reduce project and operations costs. Emerson is among the first automation vendors to support the User Association of Automation Technology in Process Industries’ (NAMUR) Module Type Package (MTP) standard for both distributed control systems (DCS) and programmable logic controllers (PLCs).

 Reduce risk and accelerate speed-to-market

“MTP is a significant step to help the manufacturing industries respond faster to changing markets," according to Sean Sims, vice president of marketing for the DeltaV platform, Emerson. “With our MTP implementation, Emerson is continuing a tradition of not only supporting but innovating on industry standards. Integration between our DeltaV™ and PACSystems™ automation systems as well as third-party automation systems will help create more modular, flexible manufacturing that improves speed-to-market for our customers.”

A key challenge for the process industries, particularly life sciences and chemical, is the time it takes to bring products to market or change operations to accommodate new products. With many process changes, engineers can spend weeks or longer integrating manufacturing skids and their respective automation systems. Working with industry leaders like Emerson, NAMUR has been developing MTP to create a common, open standard that requires less engineering and makes new equipment integration closer to plug-and-play. With its MTP tools, Emerson estimates manufacturers and system integrators could save weeks in project time and hundreds of thousands of dollars in engineering costs compared to traditional integration without MTP.

Emerson's MTP tools natively reduce engineering time and risk with near plug-and-play integration. PACSystems PLCs and DeltaV automation systems both support integration with third-party components or orchestration layer systems that have also implemented MTP support.

By incorporating MTP into its DeltaV and PACSystems automation systems, Emerson has eliminated the requirement for end users or system integrators to invest in additional engineering or special integration tools. Emerson’s MTP tools natively create a configuration file for its PACSystems PLCs and AMS machinery prediction devices that is automatically integrated into the DeltaV DCS. PACSystems and DeltaV systems both support integration with third-party components or orchestration layer systems that have also implemented support for MTP.

With MTP, organisations can reduce engineering time and risk for both capital and operational performance projects, making it easier to quickly deliver critical products to market. In the pharmaceutical and biotech industries, MTP helps enable ‘ballroom-style’ flexible manufacturing where skids can be interchanged with minimal re-engineering. More flexible manufacturing means production sites can switch skids faster to produce different therapies based on patient demand.

As part of the first MTP release, Emerson has also taken a significant step to make reliability data from its manufacturing units importable to the DeltaV system. Operators can use the asset health data from the AMS Asset Monitor edge analytics device to consider how the health of plant assets will impact operations and production.

@Emerson_News @EMR_Automation @HHC_Lewis #PAuto #LifeSciences

Automation for chemical and life sciences!

A series of presentations at ACHEMA Pulse (June 15-16 2021*) presented by Emerson will outline how advanced automation technologies can help chemical and life sciences companies make step change improvements in operational performance and environmental sustainability. As an exclusive partner of the virtual event Emerson will offer thought-leadership keynotes, customer case studies and technology presentations that inform participants how to successfully digitally transform operations to meet the challenges of decarbonisation, increasing efficiency, improving quality and reducing time-to-market.

Underpinning these sessions will be a range of customer experiences, with Covestro guiding participants through a distributed control system migration project at a batch production plant, BASF explaining the benefits of control system health monitoring, and Dow discussing the importance of applying functional margin, when proof-testing valves, to increase reliability and safety. A presentation by Evonik will provide insight into digital transformation in process plants, Dynea will discuss implementing wireless monitoring solutions, and Applikon will explain how to reduce drug research and development costs and reduce time-to-market.

Roel Van Doren

In the first of two keynote presentations, Roel Van Doren, group president global sales at Emerson, will explain how advanced automation technologies can help industrial companies address their environmental sustainability challenges, such as improving energy efficiency by optimising equipment performance and meeting the demand for clean fuels, such as hydrogen. In a second keynote, Peter Zornio, Emerson’s chief technology officer, will look at how emerging technologies are creating new industrial computing architectures that help to transform operations and drive efficiency improvements.

“Equipment reliability and process availability impact the ability of chemical companies to achieve performance targets,” explained Van Doren. “The presentations we are hosting address this challenge, outlining ways to mitigate process upsets and maximise uptime, digitally transform operations for greater reliability, and safely migrate to modern solutions while maintaining production. For life sciences companies, there is a need to reduce costs and increase the speed from clinical to production with high regulatory compliance. To support this, we will demonstrate how Emerson can help to streamline operations and debottleneck processes, and create effective solutions for data management, real-time product quality, reliability and operating costs.”

A key focus of the Emerson-led sessions will be ways of achieving environmental sustainability goals. This includes implementing solutions that enable the use of alternative fuels and low-carbon power sources, the reduction of energy and material use in production systems, and the management and removal of production emissions. Emerson experts will address the subjects of emissions monitoring, control and optimisation, driving energy and reliability performance through improved control, and accelerating the transition to a hydrogen future.

“Industrial companies must make a strategic shift in environmental sustainability,” said Van Doren. “We are therefore dedicating multiple sessions to addressing this challenge, including presentations that highlight decarbonisation opportunities, examine how optimising control loop performance helps improve energy efficiency, and outline the role of automation in meeting greater demand for hydrogen.”

• See also:  The PULSE of processing!

@Emerson_News @EMR_Automation @ACHEMAworldwide @HHC_Lewis #PAuto #LifeSciences #Pharma