Alcan Achieves Early Start Up with AMS
Alcan had a tight schedule to expand its bauxite to alumina mineral processing refinery from 2.2 to 3.8 million tons. Alcan’s challenge included balancing the capital cost, minimizing the number of construction personnel on-site, integrate the green-field and brown-field facilities without affecting current operating facilities whilst achieving project budget, schedule and quality.
EmersonEmerson is a diversified global manufacturing company that brings technology and engineering together to provide innovative solutions to customers in the industrial, commercial and consumer markets through its Process Management, Industrial Automation, Network Power, Climate Technologies, and Commercial & Residential Solutions businesses. Year founded: 1890Revenue: $24.5 billion (2014)NYSE: EMR
Alcan International, a Canadian world leading mining company and aluminium manufacturer.
- CONNECTIVITY PROTOCOLS
6LoWPAN IPv6 Other frequency PROFIBUS
Alcan decided to expand using a Pre-Assembled Module (PAM) concept which enabled all modules to be built offsite in Thailand and Vietnam. By using Emerson's DeltaV and AMS Device Manager to pre-commission FOUNDATION fieldbus devices, Alcan significantly reduced man-hours and experienced cost savings. Software Components - DeltaV and AMS Device Manager
- DATA COLLECTED
Device Diagnostic Status, Labor Costs, Maintenance Requirements, Man Hours, Operating Cost
- SOLUTION TYPE
- SOLUTION MATURITY
Mature (technology has been on the market for > 5 years)
- OPERATIONAL IMPACT
Impact #1 [Efficiency Improvement - Maintenance]
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Impact #2 [Efficiency Improvement - Installation]
Technicians are able to query instruments remotely during commissioning to confirm device functionality.
Impact #3 [Cost Reduction - Energy]
The amount of energy used in production processes can be lowered and made more efficient.
- QUANTITATIVE BENEFIT
The project was executed 10 months early.
Termination costs reduced by 30%.
The system reduced 30% engineering cost such as loop drawings.
- USE CASES
Process Control & Optimization (PCO)Process Control and Optimization (PCO) is the discipline of adjusting a process to maintain or optimize a specified set of parameters without violating process constraints.The PCO market is being driven by rising demand for energy efficient production processes, safety and security concerns, and the development of IoT systems that can reliably predict process deviations.Fundamentally, there are three parameters that can be adjusted to affect optimal performance:- Equipment optimizationThe first step is to verify that the existing equipment is being used to its fullest advantage by examining operating data to identify equipment bottlenecks.- Operating proceduresOperating procedures may vary widely from person-to-person or from shift-to-shift. Automation of the plant can help significantly. But automation will be of no help if the operators take control and run the plant in manual.- Control optimizationIn a typical processing plant, such as a chemical plant or oil refinery, there are hundreds or even thousands of control loops. Each control loop is responsible for controlling one part of the process, such as maintaining a temperature, level, or flow. If the control loop is not properly designed and tuned, the process runs below its optimum. The process will be more expensive to operate, and equipment will wear out prematurely. For each control loop to run optimally, identification of sensor, valve, and tuning problems is important. It has been well documented that over 35% of control loops typically have problems. The process of continuously monitoring and optimizing the entire plant is sometimes called performance supervision.