SIRIUS@Max
Stamicarbon IPCOS Real tIme Urea Solutions
Download the Sirius@Max brochure (PDF) from our download section
Sirius@Max is the result of the combination of Stamicarbon’s leading Urea process knowledge and IPCOS’ state-of-the-art Advanced Process Control (APC) technology called INCA, specifically designed for Stamicarbon Urea plants.
The benefits are obvious:
- Improved plant stability
- Increased urea production (1% to 4%)
- Reduced Energy consumption (> 0.5%)
- Reduced emissions
- Increased uptime
- Minimal alarms (operators can focus on essential operations)
- Minimal operator interventions
- Improved equipment reliability due to consistent, best-practice operation
The Sirius@Max solution is implemented using a phased methodology. The first phase focuses on the optimization of the base layer controls, whilst the second phase focuses on the implementation of the Advanced Process Control solution.
Watch the Sirius@Max movie
Layered approach
Optimized base layer control provides more stable operation throughout the entire Urea plant, and helps reduce the impact of disturbances on the plant with minimal operator intervention. The Sirius@Max Urea APC solution will optimize the operation of the unit minute to minute, every hour of the day, ensuring maximum efficiency and stability.
IPCOS and Stamicarbon help you achieve optimal operation of your urea plant, by pushing it closer towards the active constraints like:
- Limitation on condensation capacity in Synthesis/LP-section
- Available CO2-compression capacity (max. RPM compressor)
- Stripper flooding
Optimized base layer control provides more stable operation throughout the entire Urea plant, and helps reduce the impact of disturbances on the plant with minimal operator intervention. The Sirius@Max Urea APC solution will optimize the operation of the unit minute to minute, every hour of the day, ensuring maximum efficiency and stability.
Sirius@Max at Work?
Sirus@Max contains a Yield Optimization Module, which is based on a detailed rigourus model of your urea plant. This module computes the optimal yield point online. The optimal yield point changes with the active constraints and process conditions. This means that it has to be calculated in real time. It can be proven that the optimal yield point coincides with the point of minimal specific steam consumption. Sirius@Max can therefore guarantee maximal throughput under the optimal energy conditions. These ideal operating conditions are enforced on the plant via the Advanced Process Controller. The APC controller is also responsible for stabilizing the plant by reducing the process variations. In addition, the APC system will drive the plant towards the most economical constraints (e.g. not exceeding pressure in the recirculation section) Ramping the plant up and down in a very efficient and almost handsfree way is one of the possibilities of the Sirius@Max system. This is very usefull before and after granulator cleaning actions.
Via an OPC server these optimal control signals are communicated with the DCS. With the use of an OPC interface any common and modern DCS is able to integrate with the Sirius@Max system.
About Stamicarbon
The evolution of urea is synonymous with our company. We were the first to license urea production 60 years ago. Since then a huge and complex industry has evolved worldwide – and Stamicarbon has been integral to its development at every step of the way. Our technology has been successfully licensed in over 80 countries and every continent except Antarctica – from gas-rich areas like the Middle East and former Soviet states to the world’s biggest consumers of fertilizers – the vast land masses of China and India. Ever since the company’s foundation, innovation has been a priority at Stamicarbon – from early inventions like the CO2 stripper, to granulation technology, to our unique pool condenser/reactor concepts. We’re proud of our history, from our early years serving the coal industry, to the development of urea licensing at home, and then abroad - including a more consultative approach to this multi-trillion dollar business. The world needs feeding – and demand for urea increasing annually. Commercial opportunities abound as the world’s consumption of fertilizers continues to grow, and availability of arable land remains limited.
Have a look at the Stamicarbon website.
