Sustainable Digitalization in the Chemical Industry

Sustainable Digitalization in the Chemical Industry: Twin Management Approach Imagine a facility. One with a certain number of stirred tanks or reactors operating, each continuously running reactions or mixing processes according to specific recipes, a few technicians constantly taking analysis samples from each tank at set intervals and transporting them to the laboratory, samples accumulating and waiting in queue at the laboratory instrument, and production and packaging waiting for results from the laboratory… Sounds familiar, doesn't it? Actually, we don't need to imagine—I've just described a snippet of the daily routines in many of our processes. A very familiar scenario for any process professional. Most chemical productions are old processes that have been carried out for many years. The methods applied in production processes are also mostly established methods. This situation brings disadvantages along with advantages. For example, if there are no changes in raw materials and you make no modifications over many years, it's possible to carry out the same production with the same people. Because these people know the chronic problems of the facility and reactors. They can identify the sources of problems occurring in the final product. They have determined compensation methods for product issues themselves. Most of the time, problems are solved without needing to report to upper management. However, this process dependent on people, which could be counted as an advantage, can also turn into a disadvantage. The fact that processes are established creates the perception that manual operations are sufficient. Until a situation arises that is costly to compensate… In this case, another familiar scenario kicks in. While daily production routines continue, one day the reaction end is missed in polymerization and the product freezes. The reactor will be unusable for a period. In another scenario, temperatures are problematic due to seasonal transitions. Customer complaints about the final product are increasing. These problems are ones every factory experiences at certain intervals. For a production facility, digitalization makes its presence or absence deeply felt in such situations. Because digital sensors provide you with this meaningful data. This data encompasses real-time and historical data.  

A Digitalization Example: Inline Viscosity Measurement

For instance, in a polymerization reactor, temperature, viscosity and pH are the most important critical control parameters. Process viscometers, inline pH and temperature sensors enable reactions to be kept under control with real-time data. By pre-defining certain set values, alarms can be triggered before adverse conditions actually occur. When adverse conditions do occur, it enables the identification of root causes retroactively. All these data can be monitored at intervals of seconds or even shorter. This way, time-dependent changes that cannot be detected in hourly laboratory samples are also recorded. Digitalization, of course, generally occurs by transforming physical elements and processes that are usually working inefficiently. However, this does not mean that existing processes and infrastructure will completely disappear. On the contrary, a situation is created where the existing and the transforming are used simultaneously in a hybrid manner. Consider the mixing process in water-based paint production. For each product there is a pre-defined recipe and mixing time. The operation is as follows: water is loaded into the tank, the mixer is activated, powder and other liquid content are added according to the recipe and mixing is defined for the determined time. When the time ends, the laboratory is notified and a sample is taken for viscosity. After approval, filling begins. The pre-defined mixing times in recipes are generally set with safety margins and are generally longer than necessary. Considering the completion of mixing, the sample reaching the laboratory, the sample preparation process and the availability of the laboratory instrument, these times can become quite extended. Let's now digitalize the same mixing process. In most processes involving polymers, the most important parameter is viscosity. Let's imagine we mounted a process viscometer on the body of this stirred tank. From this point on, the change in real-time viscosity can be monitored on a second-by-second basis. The process will work as follows. Water and other components will be loaded into the tank. The gradual increase in viscosity will be continuously recorded by the system that viscosity depends on. When the predetermined suitable viscosity range is entered, operators will understand that the product is ready. At this point, tank emptying can now begin without any waiting. The quality laboratory can also come and take its witness sample during emptying. In Graph 1, you can see a time-dependent graph of data taken from a sample process viscometer for a mixing process. Based on this mixer example, we can list the contributions of integrating a process viscometer into the system as follows. These benefits generally apply to other digitalization actions as well: • Because measurements are continuous and on-site, problems can be detected the moment they occur. • It provides faster results compared to laboratory measurements. This shortens waiting times. It provides time efficiency. • It prevents human measurement errors. • It enables development in previously defined old recipes. It contributes to process development and continuous improvement efforts. • It provides data to automation systems and artificial intelligence tools. • It prevents losses resulting from over-mixing or unsuitable products. • Because process viscometers are mounted on production tanks or pipe lines, they enable measurement directly under process effects. This way, the rheology of the fluid during the process can be monitored. • In addition to viscosity in mixing processes, it enables the detection of the homogeneity of the fluid. As can be seen in Graph 1, the data line straightens at the end of the mixing. This can be interpreted as increased homogeneity and greater dissolution of solids. • If a time-dependent reaction is occurring, the start and end times of the reaction can be easily determined with a process viscometer. Gelation and sudden solidification processes can be prevented.

Sustainable Digitalization: Green and Digital

Despite all these advantages, investment decisions in digitalization tools can turn into processes that take a long time to decide on. This often stems from a misconception. Digital transformation does not, contrary to common perception, require radical transformations and high-tech investments in all processes. In other words, digital transformation doesn't have to be disruptive. Returning to the viscometer example: a process viscometer integration is a tool that facilitates production and quality processes. The quality laboratory continues its activities. Witness samples and final product samples continue to be taken and stored. The process viscometer is added to the system as a component that communicates with the automation system and SCADA. It is routine for us that this perception dominates in the production facilities we advise and are our customers. However, it also shows that digitalization is a process that must be managed correctly. Just like sustainability. Sustainability is meeting the daily needs of countries and societies while not overlooking the resources to be passed on to future generations and consumption needs. Based on this definition, the point that both digitalization and sustainability are trying to reach is similar. According to the EU, the objective of transforming Europe into a globally competitive, climate-neutral and digitalized economy and society is based on two fundamental pillars: green and digital transformations. These transformations, which we can define as twin transformations, can also be managed together by manufacturing companies. What we can call "sustainable digitalization" is an inescapable concept in order to be able to become an EU supplier. Managing this twin transformation together will be an advantage for facilities that are at the beginning of the road for both concepts. After all, these two concepts are linked by a cause-and-effect relationship. The contribution of digitalization, particularly in the chemical and polymer industry, to sustainability is high. We can group these contributions under the headings of: reduction of losses, increase in production efficiency and energy efficiency. To elaborate a bit more: • Digital measurement technologies reduce errors and waste through on-site and real-time measurements. It helps optimize raw material use. • Parameters that cause energy consumption such as temperature, pressure, mixing speed and flow rate can be properly managed with precise and real-time measurement. Energy efficiency is achieved. • With digital sensors, waste and wastewater amounts can be reduced. In automatic washing processes, unnecessary water consumption can be prevented with a sensor such as a turbidimeter in the drain line. The same sensors can also detect product leakage in heat exchanger, serpentine and condensate lines. • Digital measurement systems generate large amounts of data. Through data analysis, inefficiencies can be prevented. • It ensures repeatable product quality. It prevents non-conformities and non-standard product production. • It enables better inventory management and supply chain optimization. By monitoring raw material use and inventory levels in real time, producers can manage raw material procurement and minimize transportation needs, creating a more sustainable and efficient supply chain. In conclusion, production facilities can implement a twin management approach by setting common goals in their current investment plans toward being green and digital. Combining efficient use of today's resources with today's technologies will allow us to leave resources to future generations to produce tomorrow's technologies.   Dr. Hulki Özel Sales and Application Director Pikolab Engineering