Global technology and software company Emerson is helping Covestro, a world-leading producer of high-tech polymer materials, to enhance the operational performance and sustainability of its manufacturing facility in Barcelona, Spain. As part of a continuous plant improvement program aimed at reducing emissions from production and external energy sources to net zero by 2035, Covestro has optimized the esterification process used to produce polyester. By implementing Emerson’s DeltaV™ advanced process control software, Covestro has improved the efficiency of polyester production, leading to increased availability and throughput, and reduced water and energy consumption.
Covestro produces polyester resin at its Barcelona facility to be used within plastics manufacturing, but recently faced operational challenges with its batch-based production process. The need to optimize esterification and prevent unreacted glycol from plugging a downstream condenser while minimizing reflux water usage prompted Covestro to seek an improved control solution.
Due to the complexity of the process variables involved, attempts to achieve these improvements through adjustments to the existing batch process control configuration were unsuccessful. Covestro therefore turned to Emerson, and after careful analysis, its consultants recommended the implementation of DeltaV PredictPro, a multivariable, model predictive control (MPC) and optimization software solution, which is part of Emerson’s evolving DeltaV automation platform.
Courtesy of Emerson.