Bosnia(BA)English (United Kingdom)
Print
PDF

Automation solution for fertilizer production plant

Reference_automation_elcom_AZOTARA_2008_v1

Customer: Global Ispat Coke Industry Lukavac, B&H

 

Process description
Gaseous ammonia, which comes from the plant 180 at a pressure of about 2.5 barand temperature of about -14 ° C is liquefied in the compressors and stored in the SR-1 with liquid ammonia, which comes directly from plant 180. Nitric acid is produced by first mixingammonia and air in a tank. In the presence of a catalyst, a reaction occurs which converts the ammonia to nitric oxide at plant 200. The nitric oxide is furtherreacted in the presence of water to produce 56% nitric acid. Nitric acid and ammonia are used to make ammonium nitrate at plant 313. The two materials are mixed together in a tank and a neutralization reaction occurs, producing ammonium nitrate. This material is then granulated with the other components . Method of granulation involves putting the solid materials from plant 311 into a rotating drum which has an inclined axis at plant 313. As the drum rotates, pieces of the solid fertilizer take on small spherical shapes. They are passed through a screen that separates out adequately sized particles. A coating of inert dust is then applied to the particles. Finally, the particles are dried, completing the granulation process.

 

Challenge
Implementation of a cost efficient and user friendly process control system with as ess as possible classical cabling which have to result in a very fast and easier cabling, engineering and commissioning of a very high level. A very detailed diagnostics and maintenance management for the components of the process control system was a must. Installation of a reliable fail-safe system to protect the plant in case of process malfunction. Integration of SIVICON camera monitoring into PCS7 environment.


Solution
The solution is a PCS7 v7.0 SP1 architecture with a completely network based topology. 5 Clients and 2 redundant servers are connected via industrial Ethernet to 1 controller AS416-2. Process instruments are connected to the system via Ex barriers or Profibus PA. Installation of process instrumentation with HART capability enables fast commissioning and maintenance. Remote I/O cards are connected to system via ET200M and ET200S.

 

Project overview

  • Sections in Atex zones
  • 150 motors
  • 50 on/off valves
  • 50 control valves
  • 250 analogue instruments
  • 1500 digital signals
  • Control system PCS7 V7.0 SP1
  • process controller AS416-2
  • 1 redundant OS server pair
  • 5 OS clients
  • ET 200M and ET200S
  • Based on network topologies
  • Industrial Ethernet and Profibus
  • DP/PA
  • Almost all instruments and control
  • valves with HART capability
  • SIVICON camera monitoring

 

Thumbnail imageThumbnail imageThumbnail imageThumbnail image
Thumbnail imageThumbnail imageThumbnail imageThumbnail image
Thumbnail imageThumbnail imageThumbnail imageThumbnail image
Thumbnail imageThumbnail imageThumbnail imageThumbnail image
Thumbnail imageThumbnail imageThumbnail image