Industry Presentation - Chemical

Chemical Industry – Overview

Process Flow
Plant Layout
Types of Assets
Challenges / Critical Parameters
Solutions / IoT in Chemical
Q&A

Index
The chemical industry comprises the companies that produce industrial chemicals. Central to the modern
world economy, it converts raw materials (oil, natural gas, air, water, metals, and minerals) into more than
70,000 different products. The plastics industry contains some overlap, as most chemical companies
produce plastic as well as other chemicals.

The main sectors of the chemical industry are as follows:

1. Basic inorganics: acids, alkalis and salts, mainly used elsewhere in industry and industrial gases, such as oxygen,
nitrogen and acetylene
2. Basic organics: feedstocks for plastics, resins, synthetic rubbers, and synthetic fibres; solvents and detergent raw
materials; dyestuffs and pigments
3. Fertilizers and Pesticides
4. Plastics, resins, synthetic rubbers, cellulosic and synthetic fibres
5. Pharmaceuticals (drugs and medicines)
6. Paints and varnishes
7. Soaps, detergents, cleaning preparations, perfumes, cosmetics and other toiletries
8. Miscellaneous chemicals, such as polishes, explosives, adhesives, inks, photographic film and chemicals

Chemical Industry - Overview

 Chemical processes may be run in continuous or batch operation.

The manufacture involves the assembling of raw materials, mixing,

dispersing, thinning and adjusting, filling of containers and
warehousing.

Process Flow
 Loading and Power, boilers and
Process units Tank farms Flares
unloading facilities incinerators

Substations, large
Central control Analytical
Cooling towers electrical switch Warehouses
houses laboratories
yards

Fire hoses, fixed

Incoming utility
monitors, reservoirs Waste treatment Maintenance Administrative
metering and block
and emergency fire areas buildings and areas buildings
systems
pumps

Plant Layout
 Planetary Heat Rotary
Reactor Filter Flaker
Mixer Exchanger Vacuum Drier

Ribbon Distillation Packed

Storage Tank Scrubber Evaporator
Blender Column Columns/Bed

Vibratory Fluid
Autoclave ISO Tank Chimney
Bed Dryer

Types of Assets
Equipment monitoring and predictive analytics - Unplanned downtime
and high unpredictable maintenance costs are common problems
throughout the chemical industry.
Predictive quality / create a “golden batch” - Many chemical
manufacturers have insight only into the operating conditions for a set
number of batches, which limits their ability to optimize conditions.
Energy management - Energy makes up a large chunk of the cost of
chemicals manufacturing, and compliance with increasingly stringent
regulations is difficult and expensive.

Challenges / Critical Parameters

Predictive asset management - Maximize asset utilization and minimize unplanned downtime

Process management and control - Minimize production variability and improve quality

Energy management - Reduce energy costs and assess alternative energy sources

Safety management - Monitor assets, processes, people and products on a continuous and real time basis

Production simulation - Improve operator training, manufacturing planning and timely plant
commissioning
Demand forecasting - Adjust production schedule in line with changing customer needs

Solutions / IoT in Chemical Industry

Thank You