SULPHURIC ACID PLANT AUTOMATION WITH MESSUNG'S NX-ERA SERIES

1
(No Transcript)
2
(No Transcript)
3
THE LEADING EDGE
Messung is a Leading Industrial Technology Expert
in India, seeking to be a dynamic organisation
driven by pioneering zeal, a passion for new
ideas and pursuit for excellence to bring
progressive solutions that deliver the
competitive edge for customers. Continuing its
legacy of innovations in Industrial Automation,
the Messung Group has diversified into various
businesses. Messung empowers businesses and
industries with the foremost technologies and
high performance products backed by deep domain
knowledge and reliable support. We work closely
with customers, understand their needs and
challenges identifying opportunities and
technologies to bring the most relevant solutions
that contribute to their success. Even in
business, our social consciousness and sense of
environmental responsibility remain firm and
uncompromising. Our competencies are as diverse
as our portfolio - which today spans the fields
of Automation Controls, Electrical Engineering
and Workplace Technology. In these, and many more
emerging fields, we are constantly expanding and
enhancing our market expertise to achieve - and
deliver - the Leading Edge in the Food Beverage
(FB) industry.
4
SULPHURIC ACID PLANT AUTOMATION WITH MESSUNG'S
NX-ERA SERIES(A CASE STUDY)
5
ABOUT SULPHURIC ACID PRODUCTION

• Sulfuric acid is the largest-volume industrial
  chemical produced in the world.
• Concentrated sulfuric acid (93-98 ) is used in
  the manufacture of fertilizers, explosives, dyes,
  metal and petroleum products.
• The production of sulphuric acid is a delicate
  process that must be completed in a safe and
  efficient manner.
• Automation needs to be carefully designed to
  control the different stages of the process as
  per stringent parameters, and to provide
  continuous monitoring for better management of
  the plant.

www.messungautomation.co.in
6
THE CUSTOMER

• An agri-input Company focused on manufacturing,
  distribution and retailing of a wide range of
  crop yield enhancing and protection products.
• Product portfolio includes crop protection, crop
  nutrients, seeds, veterinary feed supplements.
• To secure supply of sulphuric acid, one of their
  key ingredients, they ventured into manufacturing
  of sulphuric acid.
• They produce sulphuric acid as well as other
  sulphuric acid-based chemicals like LABSA, DMS
  and Oleum that have wider applications across
  industries like agrochemicals, veterinary feed
  supplements, pharmaceuticals, synthetic
  detergents, etc.

7
KEY FEATURES OF THE SULPHURIC ACID MANUFACTURING
PLANT

• The raw material for sulphuric acid manufacture
  is clean SO2 gas. It comes from
• (i) burning molten by-product sulphur
• (ii) roasting or smelting metal sulphide
  concentrates, and
• (iii) decomposing contaminated organic chemical
  process sulphuric acid catalyst.

8
KEY SOLUTION GOALS

1. To produce Sulphuric Acid by controlling the
   boiler pressure, steam flow and acid level in the
   process tanks using NX-ERA NX3004 PLC NX-ERA
   JET I/O Modules 1500 Tags SCADA
2. To develop a logic to measure Pressures,
   Temperatures, Levels, Flow and SO2 Analysers at
   various stages of process.

1. To control the pumps and monitor the RUN/TRIP
   status
2. Also, to control the Steam pressure and drum
   level of a boiler PLC, SO2 concentration and Tank
   temperature using PID controllers in PLC.
3. To measure flow and calculate the inlet and
   outlet steam flow
4. To develop a logic to raise alarms, generate
   reports and trends in SCADA.

9
THE SOLUTION
Messung engineers studied the plant and its
requirements, and came up with a cost-efficient
solution consisting of 2 nos. of SCADA
system MODBUS RTU communication for
Thermocouple Sensors PID controllers 10 nos.
www.messungautomation.co.in
10
POWERING THE SYSTEM NX-ERA JET PLC
The Programmable Logic Controller utilised for
this sulphuric acid plant was the NX-ERA JET PLC.
It is a high-performance CPU for
medium-to-small-size Machine and Process
applications. Can be also combined with the main
products of the series, such as CPUs, backplane
racks, communication and fieldbus modules. Turns
into a selection of input and output modules
where requirements such as hot swapping and
advanced functionalities such as OTD (One Touch
Diag) and EPS (Easy Plug System) are no longer
necessary. The result is a group of compact and
economical modules capable of providing highly
competitive solutions, with no loss of electrical
characteristics such as isolation, performance
and accuracy.
www.messungautomation.co.in
11
NX-ERA JET PLC FEATURES
Integrated power supply I/O points Reliable
and compact I/O modules Embedded I/Os - 14
DI/10 DO Encoder interface Stepper motor
interface Multiprotocol support Expandable up
to 184 I/O points For more flexibility and
agility in the development of applications,
NX-ERA Jet counts on WEBSERVER Offers high
speed counters and PTO for simple motion
applications
www.messungautomation.co.in
12
BENEFITS FOR THE CUSTOMER
SCADA systems (2 nos) Enables the customer to
obtain information leading to better process
traceability, and storage of performance data
which is essential to correct quality and process
issues. SCADA is programmed to raise alarms,
generate reports and trends.
PID Controllers (10 nos) Automatically regulate
process parameters such as boiler pressure, steam
flow and acid level, etc., and keep the actual
output as close to the target/setpoint output as
possible.
Programming and configuration environment based
on IEC 61131-3 standard The software has
resources for all stages of the life cycle of an
automation and process control project, ensuring
efficiency throughout the development,
commissioning and maintenance.
www.messungautomation.co.in
13
BENEFITS FOR THE CUSTOMER
MODBUS RTU Communication for Thermocouple
Sensors Standard Modbus-RTU protocol with
high-speed RS-485 communication Thermocouple
linearization and sensor break detection ensure
reliable measurements Self-calibration lowers
maintenance costs by reducing periodic manual
calibration checks Software Watchdog timers
provide a configurable failsafe output state for
use when host I/O communication is
lost Self-diagnostics monitor microcontroller
activity to detect operational failures (lock-up)
and execute a reset to restore communication.
System supplied at affordable price
www.messungautomation.co.in
14
THE OUTCOME
Production of sulphuric acid has increased since
the automation system was installed. The client
is able to produce high-quality sulphuric acid
with almost negligible impurities. Also, the
client is able to access the status of different
parts and processes of the plant on a single
screen so he can view and monitor the whole
process easily. The client can also view the
history and trends of all parameters so as to
make improvements, pre-empt problems, and ensure
safe, smooth, reliable and profitable operations
consistently.
www.messungautomation.co.in
15
ABOUT

• If you're looking for best-in-class PLCs and
  automation system components to build a
  future-ready system, who better than Messung,
  leading PLC manufacturer in India.
• Messung Industrial Automation Control division
  also offers PLC panels for remote control, SCADA
  applications, VFD drives and servo drives.
• Messungs programmable controllers, Remote I/Os,
  HMIs and SCADA solutions have enabled industries,
  OEMs and automation system integrators achieve
  top-of-the-line performance and efficiencies.
• Messungs Process Automation, Servo Motion
  Control Automation, and General Purpose
  Automation solutions have proven themselves
  across the gamut of industries with their
  flexibility, efficiency and long service life.

16
Thank you

• Contact us
• MESSUNG SYSTEMS PVT. LTD.
• 501, 502 503 Lunkad Sky Vista, Viman Nagar,
  Pune, India - 411 014.
• T 91 20 6649 2800 E sales_at_messung.com