Industrial Application of Computer Systems - Literature review Example

INDUSTRIAL APPLICATION OF COMPUTER SYSTEMS Student’s Name Institutional Affiliation Table of Contents 1 Table of Contents 2 Abstract 4 The following literature review analyses different computer systems in relation to Ethylene cracker gas plant. Major developments in the computer engineering and innovations that are more reliable, have taken place, including advanced technology. Therefore, many scholars have tried to study these developments and their applicability in different areas of industry. The review focuses specifically on the computer hardware, software, designs and their applications. The specific systems covered include Ethylene production plants, SCADA systems, Human Machine Interface and the PLCs. Finally, a paragraph has been provided at the end to summarize the entire literature review. 4 Introduction 5 Ethylene Cracker Gas Plants 5 Cracking Furnaces of Ethylene Plants 5 Capacity of the CB&I and Linde Furnaces 6 The Design of the Linde’s Cracking Furnace 8 The SCADA System According to Nolte, it is incredible that a big company with many functions can operate effectively by controlling and supervising its activities manually (Nolte et al, 1980). Such big firms or sometimes small ones, require automated systems of controlling, supervising, collecting, analyzing data and generating reports. One of the common systems that are mostly embraced by many firms is the SCADA system. This is an industrial computer system used in controlling and monitoring process in a company (Shetty2010). SCADA is an acronym that stands for Supervisory Control and Data Acquisition 10 The Concept of SCADA System 10 Source: DFS 11 The SCADA Software Processing 12 The Basic Components of SCADA System 13 The Designing of the SCADA System 14 SCADA system has changed over time, with the growth and development of computer technology. The designing of the system depends on which generation is being used. There are three generations of SCADA system (McCrady, 2013). These include the monolithic, distributed and networked generations. They come as first, second and third generations respectively (McCrady, 2013). 14 In the monolithic system, the computing concept is centered onto mainframe systems. In this, there is no any network and centralized systems stand-alone (Krutz, 2005).Therefore, there is no connection to other systems. The Wide Area Networks (WANs) are designed to ensure there is communication to the RTUs in the field only. Even if in some cases the use of WAN protocols existed, but this was very lean and could not support any functionality apart from the required scanning or controlling points in a remote device (McCrady, 2013). 14 At same time, this is not feasible with other to inter-mingle other data traffic types with the RTUs communications on a network. In addition, connectivity to the master station is very limited. It is done through the proprietary adapter or even controller, which is plugged into the backplane of the central processing unit at the bus-level (McCrady, 2013). This ensures there is redundancy in the entire system. 14 Human Machine Interface 17 Human Interface Devices 18 A Brief Outlook of HMI Design 19 Human Machine Interface Software 20 Programmable Logic Controller (PLC) 20 The Basic PLC Hardware Devices 21 The Basic PLC Software and Memory Architecture (IEC 61131-3) 22 Designing or Programming a PLC 23 Conclusion 24 References 25 Abstract The following literature review analyses different computer systems in relation to Ethylene cracker gas plant. Major developments in the computer engineering and innovations that are more reliable, have taken place, including advanced technology. Therefore, many scholars have tried to study these developments and their applicability in different areas of industry. The review focuses specifically on the computer hardware, software, designs and their applications. The specific systems covered include Ethylene production plants, SCADA systems, Human Machine Interface and the PLCs. Finally, a paragraph has been provided at the end to summarize the entire literature review. Introduction Over the years, technology has been advancing tremendously. This has affected many areas positively. At the same time, technological firms have strived to incorporate this fast growing technologies development in their systems. Cracking furnaces for Ethylene gas plant have not been left behind. There have been many changes in the Ethylene production world over (Fiset, 2009). Fiset states that since the start of Ethylene production and the building of the first plant in the early 1950s, more generations have been brought forth with varying features. Ethylene Cracker Gas Plants Cracking Furnaces of Ethylene Plants Cackling furnaces are helpful especially in the Ethylene plants. Fiset states that these furnaces play a great role in ensuring that the manufacture of products is done successfully in various companies, including production of Ethylene (Fiset, 2009). At same time, they determine the level of production, profitability and the efficiency of the Ethylene plants (Natural Gas Conversion Symposium et al, 2007). This has been contributed by the integration of technology in the entire process by different companies. However, there are only a few companies who are able to provide and design furnaces, which are reliable in all stages of production and offer operational flexibility (Leffler, 2008). Nevertheless, he states that there are companies with a wealth of experience in building and designing twin-cell furnaces, which have the capacity to produce massively in many modern plants (Oil & gas, 1992). Capacity of the CB&I and Linde Furnaces A good example of the company that has built reliable furnaces is the CB&I, which has had several generations of furnaces. This company has seven generations of Short Residence Time and pyrolysis furnaces (Budde et al, 2005). The first furnace of this company was developed in the middle of 1960s (Natural Gas Conversion Symposium et al, 2007). This was because of growing demand of Ethylene in the world. Among the seven generations of furnaces, the last four have a unique, two-pass radiant coil design. This design is mechanically simple to operate. CB&I company has built many furnaces than any other company in the world (McCrady, 2013)! He continues to state that most of these furnaces have met the highest level of standardization by achieving design capacity and meeting yield guarantees for customer satisfaction. However, this is a matter of debate. CB&I represent more than 40% of the entire global demand of Ethylene capacity (Bolton, 2006). Bolton adds that the furnaces are believed to operate for long hours, with an estimated time of more than fifty days. In addition, the company has built the proprietary transferline exchangers, "Quick Quencher" and "Bath Tub". This two are believed to offer higher yield as well as longer run-length. Its SRTs designs have integrated turbine that is incorporated with furnace to ensure that plant energy balance is improved (Fiset, 2009). At the same time, most of the company’s recent designs are fitted with NOX burners or De-NOX catalytic systems, to ensure that emissions are improved (Natural Gas Conversion Symposium et al, 2007). However, McCrady expresses that CB&I am the only company with the most advanced technology in designing and building of Ethylene furnaces (McCrady, 2013). He widely covers the events of Linde Company, which has been in this industry for more than seventy years. This is also emphasized by Shetty, who contend that this company has been the leader in designing Ethylene furnaces for many years (Shetty, 2010). According to statistics, the company’s technology has been used to design more thann40-large scale Ethylene plants. These plants have the capacity of over 18 million tons of Ethylene and have been operating for more many years. Shetty adds that Linde Company has been introducing new technology in almost every plant they design. This has however been seen to be objected by Rabiee (Rabiee, 2013). Despite this disagreement, Rabiee asserts that the company has incorporated creativity in the process of furnace designing, which has contributed to its success in engineering. The design has been made in such a way that the two processes of cracking furnaces and separation are compact. Nof explains how the process is applied by Linde Company, where the feedstock for the Ethylene plant is fed to the furnace after passing through the pre-treatment stage of the cracking process (Nof, 2009). He adds that the cracked products are then directed to the separation section of the system. It is at this stage that valuable products are finally recovered and then purified. Apart from Ethylene, the valuable by products recovered in the process include propylene, hydrogen, methane, acetylene, butene 1, butadiene, gasoline and aromatics such as benzene, toluene and xylene (Natural Gas Conversion Symposium et al, 2007). There are some considerations in the designing of cracking furnaces. These include ensuring there is maximum security in operation, efficiency in energy usage, low production and costs, maximizing on plant reliability, easy operation and good maintainability (Nof, 2009). The design has the technical concepts with continuous implementation and improvement of design technology. According to Rabiee, the process of producing Ethylene is usually complex (Rabiee .2013). This is because of many components generated by the thermal cracking. He argues that in this process, a company must include the separation stage to ensure that the right quality of the final product is achieved. McCrady observes that in Linde’s Ethylene separation process and optimization for various feeds have been done (McCrady, 2013). These include the gas crackers, liquid crackers as well as the dual crackers. The latter is capable of holding 100% gaseous or liquid feedstocks. The two contents can as well be mixed in the process (Budde et al, 2005). The Design of the Linde’s Cracking Furnace According to Leffler, the cracking technology of the Linde Company has been applied, with reports of success from small plants with Ethylene capacity of 200 KTA (Leffler, 2008). He continues to add that this technology has also been tested with mega plants having 1500 KTA capacity of Ethylene production. In addition, Bolton contends that there has been extensive research about this technology on mega Ethylene plants with a capacity more than 2000 KTA of Ethylene production (Bolton, 2006). This has proved that the steam technology cannot be compromised based on safety, constructability or mechanical reasons. The block flow diagram of Ethylene production process Source: Linde. Ethylene is a hydrocarbon gas, which is the first in the olefin series. It is one of the most important base materials in the manufacture of plastics and rasins (Budde et al, 2005). In the industry of chemistry, Ethylene is an important building block (McCrady, 2013). This product acts as link between petroleum refiners and chemical companies (Budde et al, 2005). In addition, Ethylene plant is also known as ‘olefin plant’ since the products of Ethylene production is of olefin series. In most cases, the common process of obtaining Ethylene is through steam cracking (McCrady, 2013). However, there are other ways such as”Triolefin” process, which disproportionate propylene into Ethylene as well as butylene. Others include hydrogenation used in of ethyl alcohol and the cracking of feedstock (McCrady, 2013). These processes are found in various regions or countries around the world. The above scholarly collection indicates vividly that steam crackling of Ethylene remains to be the most favored method of Ethylene production (McCrady, 2013). At the same time, there is agreement that a lot need to be done by various companies to ensure that their systems are reliable and deliver the highest standard of services to the customers (Budde et al, 2005). Research on the effectiveness and designing of Ethylene furnace should continue in order to ensure that more reliable and high quality products are relieved (Budde et al, 2005). The SCADA System According to Nolte, it is incredible that a big company with many functions can operate effectively by controlling and supervising its activities manually (Nolte et al, 1980). Such big firms or sometimes small ones, require automated systems of controlling, supervising, collecting, analyzing data and generating reports. One of the common systems that are mostly embraced by many firms is the SCADA system. This is an industrial computer system used in controlling and monitoring process in a company (Shetty2010). SCADA is an acronym that stands for Supervisory Control and Data Acquisition The Concept of SCADA System SCADA system is designed as a centralized system that controls and monitors the entire site or other systems, which are distributed or spread within a large area (Shetty2010). This could be in an entire country or within an industry. In this system, most of is control actions are regulated automatically by the Remote Terminal Units (RTUs). However these actions are also performed by the programmable logic controllers (PLCs). In addition, most control functions are restricted to supervisory or overriding level of intervention. A good example may well be illustrated where a PLC can regulate the flow of cooling water as part in of an industrial process, but at the same time, SCADA system can allow operators to make some changes on the set points of the water flow. The system can then enable alarm conditions to be shown and recorded, such as loss of flow or high temperatures. Finally, the feedback control goes through the PLC or the RTU, while at the same time SCADA system does monitor the entire performance of the loop. A simple diagram of SCADA system with a single computer Source: DFS The SCADA Software Processing SCADA software, which is a program that is put on a master terminal unit in a PC, is designed by application different approaches. The type of approaches include the centralized, distributed and client or server processing (Shetty2010). In the centralized processing, a single computer is used to do all the monitoring. In this regard, all information in the database is stored in a single computer. However, there are several weaknesses on this type of processing (Drioli, 2011). One of them is that the initial cost is usually expensive and when one is upgrading, it becomes difficult since the system is not flexible, rather fixed. In addition, redundancy is also expensive. This is because the entire work ought to be duplicated (Drioli, 2011). On the other hand, in the distributed processing, the SCADA system has to be divided into a number of small computers, which are usually PLCs. The approach is intended to overcome the challenges experienced when one applies the centralized processing. However, just like the centralized processing, it also has some weaknesses. Some of these include the fact that the communication flow between computes is usually complex. Further, while processing the data, as well as the databases, this has to be copied to other computers which lead to low efficiency (Drioli, 2011). Finally, there is no clear and systematic approach to be applied when one want to obtain data stored in plant devices. This means that there is limitation to accessing some data in the process. The final approach, the client server processing, is almost the same as the one usually used in the concepts of networking. In this process, there two types of nodes. The first are the server nodes, which are used in serving other nodes in the networking system. The second are the client nodes, which are the used in requesting the service from the main server. A good example is where a PC is used to display information from in a network form other computers. In this process, the display code (client code) requests information from the server, where one has to look in the database to ascertain the data, which will then be displayed the client. This approach is more convenient since it minimizes the network workload. Therefore, the process will take place in a more efficient and faster manner, as opposed to other processing (Drioli, 2011). The Basic Components of SCADA System SCADA system is composed of several elements (Shetty, 2010). These include the Human Machine Interface, which is used to present process data to a human operator. It is through this way, that the operator is able to regulate the entire system as well as monitoring it. The second component is the supervisory, also called the computer system. The work of this component is to ensure that all data is gathered in the process and commands sent to the same process. Another component is the remote terminal units (RTUs). The work of this component is to connect the sensors to the process. The sensors signals are converted to digital data, which is then sent to the computer or supervisory system. SCADA system also includes the filed devices such as programmable logic controllers (PLCs). This particular component is mostly used in the system since it is more versatile, economical, configurable and flexible than most of the special purpose RTUs (Shetty, 2010). The final component of SCADA system is the communication infrastructure, which offers the connectivity to the computer system and in the remote terminal units. The above components are interdependent for proper functioning of the SCADA system. The Designing of the SCADA System SCADA system has changed over time, with the growth and development of computer technology. The designing of the system depends on which generation is being used. There are three generations of SCADA system (McCrady, 2013). These include the monolithic, distributed and networked generations. They come as first, second and third generations respectively (McCrady, 2013). In the monolithic system, the computing concept is centered onto mainframe systems. In this, there is no any network and centralized systems stand-alone (Krutz, 2005).Therefore, there is no connection to other systems. The Wide Area Networks (WANs) are designed to ensure there is communication to the RTUs in the field only. Even if in some cases the use of WAN protocols existed, but this was very lean and could not support any functionality apart from the required scanning or controlling points in a remote device (McCrady, 2013). At same time, this is not feasible with other to inter-mingle other data traffic types with the RTUs communications on a network. In addition, connectivity to the master station is very limited. It is done through the proprietary adapter or even controller, which is plugged into the backplane of the central processing unit at the bus-level (McCrady, 2013). This ensures there is redundancy in the entire system. First Generation SCADA Architecture Source: DFS Distributed SCADA system takes advantage of the first generation development especially in the local area networking and the system miniaturization technology in the distribution of the process across several systems (McCrady, 2013). In this design, there is the use of multiple stations, which perform specific functions. They are connected to LAN and then share data in a real time. Unlike in the first generation processors, the stations usually use smaller and less expensive computers. The primary function of the distributed system is to communicate with the field device and is usually used as communication processors (Rabiee, 2013). They are also used as operator interfaces by offering the Human Machine Interface in system operation (McCrady, 2013). At the same time, some serve as the database serves or the calculation processors. Further, the distribution of a single SCADA system works across several system and provides processing power for the entire system (Pierce, 1991). In this regard, the networks which connect the entire system are usually under the LAN protocols. This means that it is not able to reach beyond the local environment. The LAN protocols are of the proprietary with the vendor creating its own protocol (Dale et al, 2013). This limits the other vendors in effectively connecting to the SCADA LAN (Rabiee, 2013). A Typical 2nd generation SCADA system Source: DFS The last designing is the networked SCADA systems (Shetty, 2010). This is mostly used in many cases than the previous two. It is however almost similar to the distributed system but the difference is that networked system is not controlled by a vendor rather providing an open architecture (McCrady, 2013). In the system, there is still the use of several networked systems, which share master station functions. The use of the open system architecture and utilization of open protocols and standards has helped in the distribution of SCADA functions within the WAN as well as in the LAN (Herbordt, 2005). Its operation is such that a user can conveniently connect the third party devices such as printers, monitors, disk drives among others, to the network or to the system itself (Shetty, 2010). One of the major improvements in the networked SCADA systems is the use of the WAN protocols including the internet protocol (IP) in communicating with the master station and other equipment. This process makes it possible for a portion of a master station used in communication with other devices to be separated from master station within the WAN (McCrady, 2013). A simple networked SCADA system. Source: DFS Human Machine Interface Human Machine Interface is the information media used to exchange mutual communication between the user and the electrochemical system (Fiset, 2009). This process allows the user to make settings by the use of touchable keys and images in a user-friendly window. Therefore, it provides a fast control of manufacture automation as well as replacing traditional control panels, which require a widespread wiring process. These interfaces are used in controlling and monitoring processes in an industrial set up (John, 2010). They are mostly found in factories, water treatment plants, oil refineries, subway systems or any other place that needs visual and real time control of data. Human Interface Devices In this regard, there are several devices or components found in the Human Machine Interface. These include the automation panels, operator panels, industrial panel PC and monitors (John, 2010). Automation panels come in various series such as control panels that might have flexible expansion. Thin client panels are also available with compact design or the wide screen series (Doron, 2002). The latter have built- intelligent keys used for intuitive UI. These types of panels come in different sizes depending on the manufacturer. Further, depending on the display size, as well as the availability of a wide range of CPU selection, then one can be in a position to meet different needs of applications (Shetty, 2010). Some of the processors include AMD, Core I and Intel Atom. Operator panels are the other categories of the HMI components. The type of panel also depends on the manufacturer. These are control panels used by the human operator himself. Operator panel’s series have been designed with more changes being done as per the demands in the automation industry. There are those that come with the RISC processors. At the same time, for these devices to fulfill the requirement of different applications, the support of industrial communication protocols is necessary. A good example is the WebOP Designer 2.0, which is software that helps in designing and providing application solutions to improve efficiency and saving time in an industrial environment as well as offering easy control of machines (John, 2010). At the same time, there are those operator panels, which are IP66 certified with LCD screens of different sizes. These devices are suitable when one is using different thermal or motion controller’s sensors or inverters. The other two categories include the industrial panels PCs and monitors. The former panels are very powerful, robust and a computing platforms used mostly in factory floors. It is prudent to note that industrial panels can be designed to perform and achieve cost ratio, which is optimum for any application in an industrial set-up. Depending on the manufacturing firm, these panels are built using heavy-duty stainless steel or aluminum front panels, offering an excellent design (Shetty, 2010). On the other hand, the industrial monitor panels come in different sizes depending on the series as well as the manufacturing company. The EPM series are used in various settings and provide a wide range of options and sizes such as 12 to 23 inches. In addition, they have various capabilities and excellent display. However, each series may feature a given industrial-grade LCD panel that posses a more brilliant display, designed for factory application. A Brief Outlook of HMI Design The design of Human Machine Interface process takes three interconnected stages. These include the interaction specification, specification of interface software and finally prototyping. In the interaction specification, the design is user, scenario, activity and resiliency oriented, while in the software specification, constrain enforcement and the ‘use cases’ aspects are applied. At the same time, protocols of interaction are used to minimize the occurrence of errors while operating. Finally, the prototyping practices consist of interactive designs based on libraries of elements of interface such as decorations, controls among others. Human Machine Interface Software Over time, different kinds of human interface software have been developed to meet the demands of industrial needs. One of this is the Intelligent Operator Panels (WebOP) which is used for segmented applications in various industries. Further, the application of the iDoor Technology is one of the latest technologies to be introduced in the industry (Shetty, 2010). It offers users flexibility of configuring different requirement of the I/O based on various applications, through the utilization of mini PCIe format and use of standardized interfaces and modules. Some of the modules in the iDoor Technology include analog and digital I/O, Fieldbus protocol communication, memory, and smart sensor. Many firms have integrated their software with other devices such as tablets and Smartphones. They enhance the ease of control and general operation (Shetty, 2010). Other series have been developed, offering more touch screens fitted ion multiple colors and dimensions. At the same time, more series are there in the market offering convenient and fast control functions for machines in industrial automation. A good example is the Screen Editor Software where the user is able to make changes in his images as well as graphs. Further, with macro command, one can set a suitable protocol of communication (Shetty, 2010). Programmable Logic Controller (PLC) PLC is an industrial computerized control system, used in monitoring the state of any input device and then offering decisions, which are based on a customized program in controlling the state of the output devices. There is no any process in an industry that cannot be enhanced with PLC systems. These could range from machines functions to production lines. In addition, there are many benefits of using PLC systems, but the most outstanding is the fact that this system is able to replicate or change the process or operation while at the same time collecting and communicating important information. Further, the PLC system is a modular. This means that one can be in a position of mixing and matching different types of inputs as well as outputs devices to suit one’s application (Shetty, 2010). The first model of PLC (084) was developed in 1969 by Dick Morley. However the successful model of PLC (184) was developed in 1973 by Michael Greenberg (Shetty, 2010). The Basic PLC Hardware Devices The basic PLC architecture involves some of the main components including the power supply, the processor module as well as the I/O modules (Rabiee, 2013). The basic components of processor module include the memory and the Central Processing Unit (CPU). Further CPU contains microprocessor and an interface that connects to a programming device (Rabiee, 2013). It may also have interfaces to input or output devices or other communication networks. In addition, the power supply of the PLC system is usually a separate module while the I/O modules are also separate from the main processor. I/O modules consist of analog, discrete (on/off) as well as some special modules such as high-speed and motion control counters. Further, it should be noted that field devices are interlinked into I/O modules (Shetty, 2010). The I/O modules can be in the same chassis just like the processor. They may also be in more than one chassis (Collins, 2007). This depends on the type of processor or the amount of I/O. For a long time, the I/O modules were in separate chassis with the processor but in the current PLC systems, some I/O modules are in the same chassis as the processor (Schneider, 2012). This is because there are some PLC systems that allow more processors in the same chassis. Further, for the smaller PLCs, they are mostly fixed on DIN rails. Finally, the nano-PLCs or micro-PLCs, which are the smallest PLCs, consist of processor, power supply as well as the I/O devices in a single package (Rohner, 1996). A panel, with built-in operator interface, may be contained in micro-PLCs. The amount of I/O is usually limited in micro-PLCs and cannot be expanded (Rabiee, 2013). The Basic PLC Software and Memory Architecture (IEC 61131-3) One of the program and memory models that follow the modern concepts of software engineering is the IEC 61131-3 standard. It includes features such as structured programming, interfaces of formal software, hierarchical organization, program encapsulation and top-down design (Nof, 2009). Some of the common elements in this model include the configuration. This is the entire software body (data and program). Configuration must correspond to the present PLCs in the system. It equates data and program to a single PLC. However, if many PLCs are involved then each has its own configuration. Access paths are used by configuration to communicate with the rest of the IEC configurations and to control systems. The other element is the resource that offers support functions in the process of executing of programs. It means that one or several resources form configuration. It is advisable to note that in most cases a resource exits in PLC, but it may as well be found in a single computer to support programs. The main work of a resource is the provision of an interface between the physical I/O of the PLC and a program. The other feature is the program, which includes interconnectivity of functional blocks where each may be displayed in any of the language of the IEC. It is also known as a program organization unit. A program is able to write and read to I/O channels (Nof, 2009). A program can read and write to global variables, I/O channels as well as communicating with other available programs. On the other hand, a task is vital in PLC, as it is used in controlling programs and function locks. The execution of programs and function blocks means that both can be processed at once (Rabiee, 2013). The main work of task is to execute a program after the latter has been assigned to it. However, for this to take place, the task should be configured so that it can continuously execute a program. The execution can also take place after a trigger. Finally, there are different types of variables. However, they are categorized in to Local, Global and Directly Represented Variables (Rabiee, 2013). The definition of local variable is done at the software element, which is the only way it can be accessed. These variables can as well be defined for a program, configuration as well as function block. All elements available in global variable are accessible so long as it is defined for a program, resource or configuration. They can also be accessed in all function blocks. Further, DRVs refers to the I/O and memory locations in PLC (Rabiee, 2013). Designing or Programming a PLC The process of programming a PLC involves the use of a PC with special software. The ladder logic is usually used in programming a PLC in many cases (Nof, 2009). This type of programming uses symbols as opposed to words when emulating the logic control in the real world. The symbols are then interlinked to the using lines to show the flow of current, through relay-like coils and contacts. There have been additions of symbols to enhance the system’s functionality (Nof, 2009). A program, once completed, looks like a ladder but in the actual sense, it symbolizes an electrical circuit. The right and left rails show the ground and positive of a power supply. Further, the rungs symbolize the wiring within different components (Doron, 2002). In terms of the PLC, these components are virtually represented in the CPU Conclusion The above literature findings indicate that much has been done to understand different computer systems that enhance the operations in an industry. However, much still is yet to be studied in the field of designing functionality of software at different levels . At the same time, there is need to apply more research on innovative ways of how functionality of computer systems can be improved to become even more efficient. Most of the authors, however, agree that that are only a few companies globally that come up with innovative designs especially in the building of new furnaces in Ethylene production. There is also need for different firms to integrate computer automation systems in their operation. This will enhance productivity and minimize cost of production. References Bailey, D., & Wright, E. (2003). Practical SCADA for industry. Amsterdam: Elsevier. Bolton, W. (2006). Programmable logic controllers. Amsterdam: Elsevier/Newnes. Budde, F., Felcht, U.-H., & Frankemlle, H. (2005). Value Creation: Strategies for the Chemical Industry. Weinheim: Wiley-VCH. Collins, K. (2007). PLC programming for industrial automation. Liskeard, Cornwall: Exposure. Dale, N. B., & Lewis, J. (2013). Computer science illuminated. Burlington, MA: Jones & Bartlett Learning. Doron, A. (2002). Use of programmable logic controller and human-machine interface software to improve homework achievements. Drioli, E., & Barbieri, G. (2011). Membrane engineering for the treatment of gases: Volume 2. Cambridge: Royal Society of Chemistry. Fiset, J.-Y. (2009). Human-machine interface design for process control. Research Triangle Park, NC: Instrumentation, Systems, and Automation Society. Herbordt, W. (2005). Sound capture for human/machine interfaces: Practical aspects of microphone array signal processing. Berlin [u.a.: Springer. John, K.-H., & Tiegelkamp, M. (2010). IEC 61131-3: Programming industrial automation systems: Concepts and programming languages, requirements for programming systems, decision-making aids. Berlin: Springer. Krutz, R. L. (2005). Securing SCADA Systems. Hoboken: John Wiley & Sons. Leffler, W. L. (2008). Petroleum refining in nontechnical language. Tulsa, Okla: PennWell. Loy, D. (2001). Open control networks: LonWorks/EIA 709 technology. Boston, Mass. [u.a.: Kluwer Acad. Publ. McCrady, S. G. (2013). Designing SCADA application software: A practical approach. London: Elsevier. Natural Gas Conversion Symposium, Noronha, F. B., Schmal, M., & Sousa-Aguiar, E. F. (2007). Natural gas conversion VIII: Proceedings of the 8th Natural Gas Conversion Symposium, Natal, Brazil, May 27-31, 2007. Amsterdam: Elsevier. Nof, S. Y. (2009). Springer handbook of automation: With DVD-ROM and 149 tables. Berlin: Springer. Nolte, W., Institute of Electrical and Electronics Engineers., IEEE Aerospace and Electronic Systems Society., & IEEE/AESS Symposium. (1980). The Human- machine interface in airborne systems: IEEE/AESS symposium, Dayton, Ohio Oil & gas: Australasia, South East Asia. (1992). Sydney: Prince-Tecpress Pub. Group. Pierce, B. C. (1991). Basic category theory for computer scientists. Cambridge, Mass: MIT Press. Rabiee, M. (2013). Programmable logic controllers: Hardware and programming. Tinley Park, IL: Goodheart-Willcox Co. Rohner, P. (1996). PLC: automation with programmable logic controllers: A textbook for engineers and technicians. Sydney: UNSW Press. Shetty, D., & Kolk, R. A. (2010). Mechatronics system design. Stamford, CT: Nelson. Schneider, G. M., Gersting, J. L., & Brinkman, B. (2012). Invitation to computer science. Boston, MA: Cengage Learning. Teukolsky, R. (2007). Barron's AP computer science: Levels A and AB. Hauppauge, NY: Barrons Educational Series. Wiebe, M. (1999). A guide to utility automation: AMR, SCADA and IT systems for electric power. Tulsa, Okla. PennWell. Top of Form Bottom of Form Read More

In addition, the company has built the proprietary transferline exchangers, "Quick Quencher" and "Bath Tub". This two are believed to offer higher yield as well as longer run-length. Its SRTs designs have integrated turbine that is incorporated with furnace to ensure that plant energy balance is improved (Fiset, 2009). At the same time, most of the company’s recent designs are fitted with NOX burners or De-NOX catalytic systems, to ensure that emissions are improved (Natural Gas Conversion Symposium et al, 2007).

However, McCrady expresses that CB&I am the only company with the most advanced technology in designing and building of Ethylene furnaces (McCrady, 2013). He widely covers the events of Linde Company, which has been in this industry for more than seventy years. This is also emphasized by Shetty, who contend that this company has been the leader in designing Ethylene furnaces for many years (Shetty, 2010). According to statistics, the company’s technology has been used to design more thann40-large scale Ethylene plants.

These plants have the capacity of over 18 million tons of Ethylene and have been operating for more many years. Shetty adds that Linde Company has been introducing new technology in almost every plant they design. This has however been seen to be objected by Rabiee (Rabiee, 2013). Despite this disagreement, Rabiee asserts that the company has incorporated creativity in the process of furnace designing, which has contributed to its success in engineering. The design has been made in such a way that the two processes of cracking furnaces and separation are compact.

Nof explains how the process is applied by Linde Company, where the feedstock for the Ethylene plant is fed to the furnace after passing through the pre-treatment stage of the cracking process (Nof, 2009). He adds that the cracked products are then directed to the separation section of the system. It is at this stage that valuable products are finally recovered and then purified. Apart from Ethylene, the valuable by products recovered in the process include propylene, hydrogen, methane, acetylene, butene 1, butadiene, gasoline and aromatics such as benzene, toluene and xylene (Natural Gas Conversion Symposium et al, 2007).

There are some considerations in the designing of cracking furnaces. These include ensuring there is maximum security in operation, efficiency in energy usage, low production and costs, maximizing on plant reliability, easy operation and good maintainability (Nof, 2009). The design has the technical concepts with continuous implementation and improvement of design technology. According to Rabiee, the process of producing Ethylene is usually complex (Rabiee .2013). This is because of many components generated by the thermal cracking.

He argues that in this process, a company must include the separation stage to ensure that the right quality of the final product is achieved. McCrady observes that in Linde’s Ethylene separation process and optimization for various feeds have been done (McCrady, 2013). These include the gas crackers, liquid crackers as well as the dual crackers. The latter is capable of holding 100% gaseous or liquid feedstocks. The two contents can as well be mixed in the process (Budde et al, 2005). The Design of the Linde’s Cracking Furnace According to Leffler, the cracking technology of the Linde Company has been applied, with reports of success from small plants with Ethylene capacity of 200 KTA (Leffler, 2008).

He continues to add that this technology has also been tested with mega plants having 1500 KTA capacity of Ethylene production. In addition, Bolton contends that there has been extensive research about this technology on mega Ethylene plants with a capacity more than 2000 KTA of Ethylene production (Bolton, 2006). This has proved that the steam technology cannot be compromised based on safety, constructability or mechanical reasons. The block flow diagram of Ethylene production process Source: Linde.

Read More