Sirius@Max® (STAMICARBON IPCOS REAL TIME UREA SOLUTIONS) is the result of the combination of Stamicarbon's leading urea process knowledge and IPCOS' state-of-the-art Advanced Process Control (APC) technology called INCA, specifically designed for Stamicarbon Urea plants. The Sirius@Max® solution is implemented using a phased methodology. The first phase focuses on the optimization of the base layer controls, whilst the second phase focuses on the implementation of the APC solution.

Layered approach Optimized base layer control provides more stable operation throughout the entire Urea plant, and helps reduce the impact of disturbances on the plant with minimal operator intervention. The Sirius@Max® urea APC solution will optimize the operation of the unit minute to minute, every hour of the day, ensuring maximum efficiency and stability. Sirius@Max® Urea APC solution help you achieve optimal operation of your urea plant, by pushing it closer towards the active constraints like:

• Limitation on condensation capacity in synthesis/low-pressure section
• Exceeding ammonia emission limits
• Available CO2-compression capacity (max. RPM compressor)
• Stripper flooding The benefits are obvious
• Increase overall plant stability: Due to the typical complexity (high degree of interactions and recycles) of a urea plant, the INCA APC controller is the perfect tool to reach the optimal, stable operating point in a straightforward way.
• Maximize throughput: Once the desired stability is reached, the INCA APC controller will be used to smoothly maximize the urea production by increasing e.g. CO2 flow without violating any of the operating constraints. A typical constraint can be the maximum pressure of the reactor or a too low cooling water temperature at the inlet of the low pressure carbamate condenser.
• Increase yield: By increasing the yield in the high pressure reaction section, less carbamate will be recycled which will result in minimization of the energy consumption of some 0.5 %. In addition reduced emissions, increased uptime, minimal alarms (operators can focus on essential operations), and improved equipment reliability can be achieved due to consistent, best-practice operation.

SIRIUS@MAX® at work:
Sirius@Max® contains a Yield Optimization Module, which is based on a detailed rigorous model of your urea plant. This module computes the optimal yield point online. The optimal yield point changes with the active constraints and process conditions. This means that it has to be calculated in real time. It can be proven that the optimal yield point coincides with the point of minimal specific steam consumption. Sirius@Max® can therefore guarantee maximal throughput under the optimal energy conditions. These ideal operating conditions are enforced on the plant via the Advanced Process Controller.

The APC controller is also responsible for stabilizing the plant by reducing the process variations. In addition, the APC system will drive the plant towards the most economical constraints (e.g. not exceeding pressure in the recirculation section). Revamping the plant up and down in a very efficient and almost hands free way is one of the possibilities of the Sirius@Max® system. This is very useful before and after granulator cleaning actions. Via an Open Process Control (OPC) server these optimal control signals are communicated with the DCS. With the use of an OPC interface any common and modern DCS is able to integrate with the Sirius@Max® system.

More inforamation about IPCOS:http://www.ipcos.com/en