Key points
The chemical processing industry is in a state of rapid change, driven by demands to accelerate growth and meet stringent decarbonisation and environmental policies. Combined with a workforce that is already stretched thin and aging equipment, achieving these goals can be a challenge.
To make progress, the industry needs an overhaul in how data is captured as well as interpreted and shared across teams. Creating this real-time system of data collection and actionable insights requires digital transformation that is powered by solutions deployed on the plant floor, and into the cloud.
Many processing plants are operating with equipment designed before the industrial internet of things (IIoT) revolution.
These legacy machines were not designed to collect and aggregate data necessary to deliver meaningful insights into equipment performance and operational efficiency.
Today’s advanced systems incorporate smart sensors, measurement devices and automated valve systems that unlock data trapped by traditional processes.
Cloud-based advancements like edge computing and analytical technologies provide the real-time visibility and visualisation necessary to inform immediate and long-term process optimisations.
Combined, these smart plant technologies can drive new levels of operational efficiency and sustainability.
However, some chemical manufacturers find large-scale implementation to be a challenge that is difficult to overcome.
Approaching digital transformation through a scalable strategy can prove return on investment (ROI), ease adaptation and create a reliable proof point to support full-scale implementation.
Developing a scalable technology strategy
Many companies are at different stages of their digital transformation journeys and require customised solutions to meet their individual goals.
Staging a digital implementation within a less critical setting, such as a laboratory or pilot environment, provides real data and targeted recommendations to help determine the ROI of a large-scale transformation.
Real-time data is captured through smart fluid control, valve actuation and pneumatics solutions connected by high-speed, feature-rich edge controllers that unlock process data and move it to analytics software.
These programs translate the aggregated data into actionable insights displayed on user-friendly dashboards that teams can access from inside the facility or remotely.
When developing a pilot program, it is important to hone in on a specific challenge or issue such as energy efficiency, waste reduction or increasing resource circularity. As part of the process, data collection should be tailored to meet these goals, enabling the program to clearly demonstrate the potential ROI of the digital transformation.
Within this controlled setting, testing teams can evaluate system components and control functionality. This ensures the most important data is captured and the dashboard can effectively contextualise the information into actionable steps.
Functionality can vary by system, and evaluating these capabilities is a critical step in determining the near and future-state effectiveness of the system.
For example, some controls can perform thermodynamic calculations according to specific technical standards, and some can even support process simulation algorithms and machine learning routines to provide immediate process insights directly at plant level.
Proving these benefits at the pilot level makes it possible — and less risky — to use the same sensors, control valves, edge computing and analytics for rapid and immediate scale-up. This approach also serves as hands-on experience for the steering team that can facilitate scale-up at the appropriate time.
Because of these benefits, the pilot program is an important phase in scaling digital solutions throughout the processing facility.
For comprehensive results, many facilities find a 90-day pilot is necessary however, partnering with an automation technology supplier can help to streamline setup by providing access to systems and software, such as process simulation tools and predictive maintenance software, that some plants may not have within their internal resources.
This partnered approach can often demonstrate results in as little as 30 days, making it possible to implement a pilot program even within tight deadlines.
Additionally, deploying the pilot with an automation partner provides the added benefit of expert support which can help mitigate errors and ensure successful program development.
Scaling up digital technology for rapid growth
After a company has proven its pilot project, fully scaling digital technology across an entire enterprise is the ultimate goal. However, optimising key applications as a first step can help to accelerate growth while maximising value.
For example, after completing the pilot program, the same technologies and tools can be scaled to a single machine, a line or throughout a single plant site and then expanded incrementally based on KPIs.
Regardless of where digitalisation is deployed, a flexible plan that streamlines implementation and minimises downtime is critical to success.
For plants outsourcing the implementation path, scalability, openness and cybersecurity of software and services can further support deployment success.
Features such as smart commissioning technologies make it possible to bulk commission and deploy across many devices at once, saving time and associated labor costs.
Templates based on existing components and process control data simplify system migration while also ensuring existing data is captured and integrated. This templated approach ensures consistency as legacy systems are phased out and new, advanced systems are phased in.
Many chemical manufacturers understand the need for digital transformation but are unsure where to start or they may feel limited by a lack of legacy data. Partnering with automation technology suppliers with digital transformation expertise can help to overcome these obstacles.
With expert guidance, flexible technology architecture can be applied to existing machines and software and scaled to accommodate new equipment as operations grow, or goals shift.
Increasing efficiency and driving sustainability
As the chemical industry faces more stringent sustainability requirements, with a goal of carbon neutrality by 2030 and the production of at least two million T/y of recycled and renewable based polymers, reporting generated by real-time monitoring, simple KPIs (including simple OEE based on real time data that can be used as a benchmark among batches, production units, plants and competitors) and smart analytics are more critical now than ever before.
Digital transformation provides the data necessary to meet decarbonisation goals and enhance energy efficiency. In fact, industrial facilities that use energy management technologies with monitoring, measurement and reporting software can reduce overall site energy use by as much as 15% and, at the same time, control and reduce energy peaks that significantly increase the energy bill.
A comprehensive digital transformation system can incorporate devices such as smart fluid controls and pneumatics solutions that can precisely measure performance and continuously send real-time data to edge controllers.
Visualisation tools can provide clear insight into each stage of the chemical process to pinpoint resource usage and areas of waste.
Advanced equipment monitoring and predictive maintenance can reduce energy peaks generated by sliding, malfunctions and leaks, as well as prevent downtime and minimise unnecessary start-ups.
The combination of real-time monitoring and clear performance indicators can be used to conduct root-cause analyses to optimise equipment and processes.
Visualisation tools provide an environment to test efficiency enhancements before they are deployed to determine where changes will make the greatest impact.
And analytics software provides clear information that empowers operators to take corrective action. Some software solutions have even included preconfigured reports based on industry standard sustainability benchmarks that can be immediately deployed upon implementation.
Achieving digital transformation success
When it comes to chemical processing, innovation and process improvement never stop. Investing in data-driven systems will generate new levels of visibility and actionable data flows that can continue to be scaled as facilities expand and processes transform.
Whatever stage chemical companies are at in the digital transformation process, it’s important that any new investments increase performance and sustainability. Connecting production lines, plants and entire global enterprises gives chemical processing facilities the advantage necessary to increase efficiency and achieve sustainability goals.
Deploying these systems through a scalable strategy ensures digital solutions are tailored to meet the needs of the facility and have been proven to deliver results — now and in the future.
