Control system for resin condensation reactors with recipe module and process simulator
How do you commission a resin condensation plant while ensuring high product quality, process repeatability, and operational safety? In this project, we implemented a reactor control system with a recipe management module and a process simulation platform, which enabled rapid plant start-up and reduced the risk of losses already at the commissioning stage.
Goals
- High product quality and repeatability
- Process safety ensured through automation of individual production steps
- Fast deployment of the control system
- Easy and intuitive recipe modification
- Flexible and rapid expansion of the product portfolio
Challenges
- Short commissioning time of the installation
- Strict safety requirements in the chemical industry
- Implementation of a process simulation platform
Solutions
- CSim process simulator
- Wonderware / AVEVA Batch Management
- System Platform
- Siemens S7-1500 controller
- InTouch visualization system
Benefits
- Precise control of production process parameters
- High product quality and repeatability
- Improved operator comfort
- First batch meeting high-quality standards
- No losses during commissioning
The investor offers a wide range of products used in construction, furniture manufacturing, and interior design industries. Thanks to its experience, technological expertise, and innovative approach, the company delivers high-quality solutions.
Continuing its strategy of delivering premium-grade products, the investor implemented a new resin production facility used, among others, for manufacturing laminated panels.
As in most greenfield projects, the main challenge was to build a facility that meets design assumptions while ensuring high product quality and repeatability. Due to growing consumer demand, a short commissioning time was also a key priority.
At the beginning of the project, during discussions with the investor, we defined priorities, potential challenges, and an action plan aligned with project milestones. This enabled structured execution and successful delivery in accordance with the agreed schedule.
Commissioning works at the investor’s site
Project challenges
In the chemical industry, the production process is complex and takes place under strictly defined conditions. This requires compliance with numerous process safety requirements, covering both operational safety and personnel protection.
The strong emphasis on maintaining a high level of safety led to the development of a process simulation concept — a digital twin. This solution played a key role in the success of the project.
The simulator developed by Control-Service engineers is a mathematical model replicating the real production process. The software was fully integrated with the target SCADA application and the production control and management system. It enables both production execution and operator training in a virtual environment using the final user interface.
By simulating all process values, the software accurately reproduces the operation of the real resin condensation system, including the interface for recipe creation and modification. This allows fine-tuning of parameters, optimization of plant operation, and elimination of errors and raw material losses during commissioning.
Beyond production-related benefits, the simulator integrated with the final system also enables training of maintenance personnel in analyzing control system code and responding quickly to emergency situations.
Additionally, to support maintenance teams, we implemented a diagnostic system that reports potential irregularities in equipment operation.
Achievements
The tested and validated software enabled the implementation of a control system that precisely manages production process parameters. As a result, users can achieve high product quality and repeatability already from the first production batch.
A key factor in the success of such implementations is the involvement of teams on both the investor’s and integrator’s side. The achievement of project goals was made possible through close collaboration, strong commitment, clearly defined objectives, precise process engineering, and readiness to take on ambitious challenges.
In retrospect, the project proved to be an interesting challenge for both parties and an opportunity to leverage algorithms, programming tools, and years of accumulated experience. This enabled a fast deployment and commissioning of a control system that met the client’s expectations.
The project initiated an ongoing global cooperation with the investor, with whom we continue to develop solutions for subsequent projects implemented in other locations.
