from
+4.2%
production increase
FIELD RESULTS
Nitric acid plants
direct DCS operation.
Software that autonomously optimizes and operates all 20+ DCS set points from inlet ammonia flow rate to NOx emissions.
Liquid ammonia evaporation →
Compressor train →
Converter →
Heat utilization →
Absorption →
NOx abatement →
Steam network →
Cooling water distribution
7 plants, no two alike.
Even the plants already pushing above design capacity gained more.
Years Built
1970s – 2010s
Capacity
300 – 950 TPD
Design capacity utilization
94 – 103%
Technologies
Mono-high-pressure; mono-medium-pressure; dual-pressure
DCS vendors
Schneider Electric, Honeywell, Yokogawa, Emerson
Production increase in TPD, plant by plant.
Production rate improved without adverse effects on other process parameters, including the NH3 consumption norm.
+62.9
+46.7
+23.7
+16.6
+16.1
+15.4
+14.8
All results are actual plant measurements taken at the acid flow meter on the line to the product tank.
Paths to higher production.
Typical production improvements from AI Software, APC and Capital projects.
PATH
AI process control
Advanced process control
Capital projects
Turbine inlet air chilling installation
Converter basket replacement
Steam turbine upgrade
Air compressor retrofit
PRODUCTION INCREASE
4.2 – 6.3%
0.5 – 2%
3 – 10%
3 – 4%
3 – 5%
4 – 5%
6 – 10%
AVG. ROI, MONTHS
3
9
14 – 36+
14
21
28
36+