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© 2008 OSIsoft, Inc. | Company Confidential Genencor and PI Johan Saerens
3 © 2008 OSIsoft, Inc. | Company Confidential GENENCOR INTERNATIONAL a Danisco Division A global leader in the development of biotechnology products for Bioproducts and Agriculture markets
4 © 2008 OSIsoft, Inc. | Company Confidential Genencor Locations FINLAND Jämsänkoski Hanko NETHERLANDS Leiden BELGIUM Brugge CHINA Beijing Wuxi JAPAN Tokyo SINGAPORE USA Rochester, NY Palo Alto, CA Cedar Rapids, IA Beloit,WI ARGENTINA Arroyito Buenos Aires Mfg. R&D Admin. > 4 million liters of fermentation capacity Beloit, Wisconsin
5 © 2008 OSIsoft, Inc. | Company Confidential ACTIVITIES – GENENCOR Genencor International Genencor International Manufacturing plant Production of Enzymes Market: Market: Feed Grain Processing Food Biofuels Textiles Sweeteners Cleaning Products
6 © 2008 OSIsoft, Inc. | Company Confidential Hot Cook Conventional EtOH Process Animal Feed with enhanced* nutritional value Phytase*
7 © 2008 OSIsoft, Inc. | Company Confidential 2 nd Generation BioEthanol: Not starch but biomass [cellulose]-based
8 © 2008 OSIsoft, Inc. | Company Confidential glucoamylasealpha-amylase pullulanase fungal amylase or beta-amylase glucose isomerase Maltose Glucose Fructose APPLICATION – STARCH DEGRADING ENZYMES
9 © 2008 OSIsoft, Inc. | Company Confidential Kyoto ? In Belgium the CO2 emission should be reduced with 11 MTon by 2012 Calculation prof. Soetaert (University of Gent) : –Enzymen produced in Genencor Belgium will result in an CO2 reduction in their application of 2 MTon (worldwide) –Comparison : the Thornton windmill park will reduce CO2 emission by 1,6 MTon
10 © 2008 OSIsoft, Inc. | Company Confidential Genencor High Level Production Process Fermentation Recovery Formulated Product Product Storage Where the enzyme is made. Where the enzyme is purified. Where the enzyme is stabilized/standarize d
11 © 2008 OSIsoft, Inc. | Company Confidential Genencor Brugge… Batch PROCESS
12 © 2008 OSIsoft, Inc. | Company Confidential Data aquisition up to 1996 : manual / internally developped software PRO –Batch oriented –Integrated with Lab data –Variable charts, definable by the operator –Profiles –Based upon Hour After Inoculation CONTRA –Manual input (90%) possible operator errors –Limited number of parameters (128/batch) –Based upon hours, no detailed data –No time reference. (totals over batches) –No interfacing with other programs (Excel..) –No data compressing -> slow –A lot of paper
13 © 2008 OSIsoft, Inc. | Company Confidential What do we want, check with the users Process engineer (they define where we can find money) –Batch oriented –Comparison between batches (GOLDEN batch principle) over the plant limits. –Fast & easy access to process data scale up continuous improvement, transfer between plants, lower the number of batches needed for a transfer (10 #) … –Be able to make any special calculation Production engineers (they make the money) –Production data concerning occupation / batch information –Warehouse management –Raw material management –Event registration
14 © 2008 OSIsoft, Inc. | Company Confidential What do we want, check with the users Capital engineers (they spend a lot of money) –Real time trendings –Possibility to evaluate equipment Utility officer / maintenance people (they really try to save the money) –Fast overview of his utility equipment status –Real time data from equipment –KPI / efficiencies of the systems to detect efficiency improvement
15 © 2008 OSIsoft, Inc. | Company Confidential And then came: OSI PI After a market evaluation of different products we came to OSI PI Not a lot of automation effort. Easily explained to the different end users –Use of process books –Use of excel interface –Use of batch functionality Batch oriënted Easy to use, maintain Great interface to automation systems (delta V, ABB, Metso, Honeywell,…) so site independent. Easy interface to LAB system (Unilab) Rather low maintenance / maintenance costs
16 © 2008 OSIsoft, Inc. | Company Confidential OSI PI use Functional Setup
17 © 2008 OSIsoft, Inc. | Company Confidential OSI PI use in GENENCOR +/- 50 000 tags world wide (small nevertheless efficient) Plant servers: choise for system availability All sites are having PI Batch working for fermentation. The LIMS-to-PI interface is expanded to all other sites. We are testing the SAP xMII tool; this tool is using a bidirectional interface to a PI server in the test environment. How do we proceed for future (MES, Interfacing to SAP, Rlink, ….)
18 © 2008 OSIsoft, Inc. | Company Confidential Process Engineers Flexible Batch process seed withdrawal droptank Sterilizer feedsystem fermentor
19 © 2008 OSIsoft, Inc. | Company Confidential Process engineers Golden batch : analysis of f.e. cellulose feed Gathering data from 2 batches and the running one –Get the batch reports –Find out which fermentors were used –What was the sterilizer used for cellulose –Find the TAG of the flowmeter –Find out the timing, when did the process start –The extract the data and analyse
20 © 2008 OSIsoft, Inc. | Company Confidential Process engineers Golden batch : analysis of time / temperature of sterilisation Now with PI –Fill in the batch numbers –Choose the parameters you want to see –Push the button
21 © 2008 OSIsoft, Inc. | Company Confidential Production engineers Detailed planning / analysis
22 © 2008 OSIsoft, Inc. | Company Confidential Capital engineers Engineers Detailed evaluation: pump curves, VFD controlled systems
23 © 2008 OSIsoft, Inc. | Company Confidential Capital engineers Chillers : energy optimization
24 © 2008 OSIsoft, Inc. | Company Confidential Maintenance Technicians
25 © 2008 OSIsoft, Inc. | Company Confidential Utility officer
26 © 2008 OSIsoft, Inc. | Company Confidential Conclusions Very useful especially with our batch systems Fast and quick responses Multiple interfaces make connectivity very easy PI used as a client tool and not a programming/IT task Very user friendly and consistent in upgrades to existing configurations Resulting in –Fast data gathering, fast introducing / transferring new products –Very good tool for analyzing the process resulting in less events, finding root causes and final fixes. –Preventive maintenance increases significantly up-time and reduces corrective actions (costs) –Optimizing processes based on good reliable data Still a lot of opportunities to explore
27 © 2008 OSIsoft, Inc. | Company Confidential Conclusions some numbers from Bruges plant… Plant to plant transfert of products: number of trials to result in the same output : reduced from 10 -> 3#gain : 500k€ /transfer resulting in > 2 M€/yr only forBruges plant Reducing corrective maintenance by preventive actions. Capacity gain in fermentation due to an increase in availability of the equipment from 92% to 96%. Justification data for optimizing the energy use: projects in 2008 resulted already in a yearly saving of >200 k€/yr on the electricity bill. OSI PI has delivered an essential part into these successes
28 © 2008 OSIsoft, Inc. | Company Confidential
© 2008 OSIsoft, Inc. | Company Confidential ROMPETROL’S REAL TIME INFORMATION SYSTEM: a road from PLANT OPERATIONS FIELD DATA to MANAGERIAL DECISIONS.
1 © 2008 OSIsoft, Inc. | Company Confidential Edison Mission Energy: PI for the Next Generation (of Generation) OSI Regional User Conference 10/09/08 Jerry.
Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. ROMPETROL’S REAL TIME INFORMATION SYSTEM a road from PLANT OPERATIONS.
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© 2009 OSIsoft, Inc. – Company Confidential 1 Empowering Business in Real Time Regional Seminar Series Presents: Jonathan Procopio, Project Engineer,
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Innovative by Nature TM Dr. E.N. Zyme Biology AP, Monta Vista High School – September 13, 2013 Disclaimer: This presentation is used as a SIMULATION activity.
Operational Excellence at Roche: PI Delivers Robert Fretz F. Hoffmann-La Roche Ltd. Basel, Switzerland.
© 2008 OSIsoft, Inc. | Company Confidential PI as an Infrastructure: Energy Management PI as an Infrastructure: Energy Management Dave Roberts OSIsoft.
How AEP is Approaching the Information Management Crisis by Leveraging OSIsoft’s Suite of Tools Bill Sigmon Sr. Vice President Fossil and Hydro Generation.
RtReports in Action Barry Higgins Automation & Control Engineer.
Ward VS, Brecht S, Astrid V. What does Genencor make? Production of enzymes Enzymes can break of nutrients. Enzymes are used in : -> Grain Processing/
2 © 2005 OSIsoft, Inc. – Company Confidential Nicoletta Aloi - IPLOM Massimo Galli – Pimsoft.
Confidential and Proprietary May 7, 2015 Real-Time Data Where You Can Use It.
NCMS - NOx Compliance Management System Presented by: Bill Soldat and Judah Moseson PI Users Group meeting San Francisco, CA April, 2000.
OXOCHIMIE OXOCHIMIE at OSI conference 1999 OXOCHIMIE Lavera - France François GERMAIN Plant manager From yield optimization to manufacturing cost control.
© 2008 OSIsoft, Inc. | Company Confidential Introduction to OSIsoft and the PI Infrastructure Allen Wernke.
Evolution of PI in an Expanding Utility’s Strategy John L. Ragone KeySpan.
Copyright © 2007 OSIsoft, Inc. All rights reserved. Ekho - MES Applications that leverages AF 2.0 Yannick Galipeau Inexcon Technologies Patrick Ramsey.
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