Automation key to Turkey bioethanol plant

Mustafakemalpasa-Bursa, Turkey - Turkish company  Tarkim has linked operational gains to the automation system in operation at its bioethanol production plant, which processes corn and wheat to produce ethanol to be used as a fuel additive. The unit in Mustafakemalpasa-Bursa  has has been operating for over two years and during that time there have been no off-specification product or quality concessions made and only two or three unexpected shutdowns.

The Tarkim facility employs Emerson automation architecture, which has contributed to a 28% increase in production at the plant from the planned level. The automation vendor's support on the start up phase also helped Tarkim to start up one month earlier than scheduled, achieve cost savings of 220,000 and book early revenues.

The control system is based on Emerson’s PlantWeb digital plant architecture. This includes a DeltaV digital automation system communicating with 381 field instruments, 108 control valves and 124 on/off valves using HART communications protocol. There are over 1200 input/output points. Emerson also supplied redundant controllers and power supplies.

“There are literally hundreds of limits for parameters which are set by the DeltaV digital system," said Levent Kalin, Tarkim factory manager. "These are checked regularly and alerts generated for any that are outside limits. When there is a problem, a fast solution gains us time for production. Consequently, our unit costs are approximately 10 per cent lower than we expected.”

The ethanol production process consists of several operations performed in series. Consequently, downtime at any unit impacts on the output from the others. With unscheduled downtime being a critical factor, Emerson's AMS Device Manager is used to help identify potential problems before they develop into events that could close the line.

“We were pioneers when we entered this sector,” said Ahmet Tüzün, Tarkim general manager. “Our global aim is to become an expert and pioneer company not only in bioethanol but widely in the biofuel sector; to keep our existing position and to expand the sectors we serve not only in Turkey but also in other geographical territories.”