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 Home  Industry Overview  Chemical
OVERVIEW

Xyntek’s real-time turn-key automation consulting, design, and implementation services & industrial IT solutions, have helped many of the top 100 Chemical & Chem-Pharm corporations achieve their business goals & ROIXyntek’s services & solutions to the chemical industry, focus on real-time turn-key automation solutions, to a wide range of continuous & batch processes, and discrete manufacturing industries across the globe, from Puerto Rico, to Ireland, England, Belgium, and Switzerland.  Xyntek’s unmatched success in installing many real-time batch and continuous process control automation solutions at major Chemical facilities across North America and the globe, has involved operations with as many as 30,000 real time instruments and many complex batch recipes.  Xyntek’s solutions have been based on a variety of different Distributed Process Control Systems (DCS), and Programmable Logic Controllers (PLC).  However, for our professionals, the tools & the syntax of the software platform are secondary, but the primary goal is understanding and defining the process, user requirements, and the detailed design, while working in close with the A&E firm, the process design engineers, the instrumentation engineers, & the plant manufacturing and operations team.   The tools continuously change and become easier to use; however, unless sound controls & IT principals & architecture are put in place from the beginning, the process & business objectives will not be met.  Xyntek also stays with the systems, in order to ensure process controls optimization after plant start-up.   Data is collected, and is used to re-tune loops, and optimize the use of the process control systems.

METHODOLOGY

Xyntek’s professionals understand the need for increased productivity, ensuring industrial safety, reducing inventory cost, global competition, and the need for optimization of the process, while keeping the operating costs down.  All of Xyntek’s automation solutions are based on stringent understanding of your business, process, financial goals, and technical requirements. Xyntek will become part of your team in order to develop your user requirements, level I and level II hardware & software design specifications, procure hardware, develop software, perform system testing, FAT’s, system installation, on-site startup, loop tuning, optimization, validation, total system documentation, on-site support, and system optimization.

CASE STUDY
Automated Batch Control System Design and Implementation

Xyntek assisted the top US specialty chemical manufacturer in designing and implementing an automated batch control system with extensive recipe management.  The process involved the batching of 12 raw ingredients, a mix cycle, a cool cycle, and an extrusion cycle.  The control architecture and programming was based on Allen-Bradley SLC-500 processors, and the MMI was developed with Wonderware.

Batch Control Solution - K-90 Conversion

Xyntek has assisted one of the world’s premier specialty chemical companies in converting their existing Honeywell TDC system for four reactor lines to the Moore APACS+ system and modified the current 4-mation code for one of their reactor lines.  The project also involved creating vision applications and InBatch configuration that entails creating process models and creating recipes.

Batch Control Solution - De-Bottlenecking of a DCS System
One of our clients, a leading chemical company, desired to make upgrades to their current DCS system in order to increase the efficiency of Sytropor beads production. Xyntek assisted them with Graphical User Interface (GUI) screen adjustment; design of control logics, MODICON communication logics, and cross ACM logics; testing and troubleshooting. The upgraded system resulted in 30% increase in production capacity from 225 million pounds to 300 million pounds of Sytropor beads per year.
Batch Control Solution - APS/RTAP Upgrade from Fisher Provox System
Xyntek has helped our client stay on top as the leading North American supplier of solvents and intermediates to the Paint and Coating Industry by replacing an outdated PROVOX/QUARTEC control system with a 4-mation control and APS/RTAP HMI. The upgraded system provided the following items:
  • Creation of new variable dribble valve to replace the previously used fixed dribble valve and a new weight and flow totalizer blocks
  • Latch communication between ACMÃ??????Ã?????Ã????Ã???Ã??Ã?¢??s to verify pumps, valves, control loops, etc.
  • Transfer pump and water request logic
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