Batch Operations | Chemical

Control and Instrumentation to Achieve the Highest Yield for All Batch Processes

Many companies constantly tweak processes to achieve a “golden batch,” without fully understanding how it happens. Resulting process errors negatively impact goals for batch optimization, efficient equipment utilization, and new product development. Emerson’s analytics for batch solutions reduce process variability, minimize transition times, and enhance utilization, enabling consistently maximized yields.

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Expert Solutions for Batch Operations

DeltaV Real-Time Scheduling System for scheduling and capacity increases.

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Proven Results

Custom Pressure Relief Value Solution Mitigated
Downtime Issues and Enhanced Efficiency in Ammonia Production

Frequently Asked Questions About Batch Processing

What’s wrong with the “golden batch” approach?

For many companies, a batch process is a black box. Follow the recipe, hope for the best, and you get what you get. When an exceptionally good batch is produced, the question becomes, “How do we do this every time?” Unfortunately, there is rarely sufficient data to determine why this particular batch was ideal, leading to continuance of this trial-and-error methodology of identifying where and how elements of the process change.

Is it possible to make batch processing more predictable and controllable?

The answer is yes, because with the right control strategy, batch processing is not a black box. A first step is to determine how the process is progressing. Is the batch reaction rate too slow? Is some variability to a feedstock affecting the process? Do we need to make a mid-stream temperature or pressure adjustment to get things back on track? These are all part of Emerson’s approach, and using it properly results in much improved consistency from batch to batch. This is much more effective than trying to pick apart a single golden batch result.

Why is batch manufacturing so inconsistent?

This can be related to many causes, such as feedstock variability, inadequate instrumentation leading to inconsistent processing, and lack of operator training with manual processes. Emerson’s batch control strategy finds and eliminates these sources of inconsistency, making the process more reliable and predictable.