In view of the decreasing demand for products and the reduction of customer orders, chemical manufacturers in the world are still cutting production. As of the end of last year, Germany's BASF has idled its production facilities by 25%; Dow Chemical's operating rate in the fourth quarter of last year was only 64%, the lowest in 25 years; LyondellBasell began last year One after another closed some of its olefin plants and switched to the production of more profitable products. Not long ago, it announced that it would close its high density polyethylene plant in Texas by the end of July this year.
While reducing production, chemical manufacturers have optimized their production processes. In order to optimize the supply of raw materials for refineries and petrochemical enterprises, the Japanese Ministry of Economy, Trade and Industry has implemented three cooperative projects, including Idemitsu Kosan and Mitsui Chemicals, Fuji Oil and Sumitomo Chemical, Idemitsu Kosan and Japan Energy's raw material supply projects. Its purpose is to achieve the integration of production by the neighboring refinery companies and petrochemical producers, thus achieving a win-win situation.
The well-known software companies AspenTech Inc. and UK Process Systems Inc. stand out from the competition for chemical companies to increase their global competitiveness. They can help users reduce energy, raw material consumption, and catalyst-related unnecessary expenses during economic downturns. AspenTech pointed out that before the global financial crisis, there was little driving force for innovation in process engineering. However, chemical manufacturers are currently re-examining their production facilities. Some companies have already put forward demand for engineering reengineering, striving to improve their competitiveness in the continued deterioration of the economic environment. AspenTech has developed production optimization software based on the needs of the times, using these software tools to perform predictive simulation and optimization of the supply network, which can establish a flexible mechanism for the production process, so as to achieve the effect of improving energy efficiency and reducing the environmental footprint.
What makes it difficult for some large-scale chemical manufacturers is that the production facilities that were originally built for certain production targets have to operate at low operating rates. In particular, some of the devices commonly used in chemical plants are often constructed with specific designs to handle specific reactions, such as large-scale continuous tank reactors, which means that these devices can only be in non-optimized conditions in most production modes. Under the operation. With the use of optimization software, these devices are expected to operate in an optimized manner that better adapts to changes in demand. Mass production is also expected to be optimized, especially for the production of specialty chemicals.
U.S. Process Systems has developed a predictive model that allows customers to operate in different operating modes. A key application area is the production process of refined terephthalic acid, which can reduce the amount of raw materials for paraxylene and acetic acid by simulation, and has considerable benefits in terms of saving raw material costs. Moreover, these models can play a role in economically certifying potential large-scale investment decisions, and can optimize daily production as raw material prices fluctuate, and different process operations can be used to simulate.
In the mass production process, some software can be used to control the production of equipment of different grades of products, minimize the quality error, and increase the output at the same time, so that the number of deviation products can be reduced at different time periods.
In view of the fact that some companies have cut large-scale investments and canceled or delayed projects to seek new development opportunities, adopting process optimization can also increase the investment repayment rate (ROI), provide a low-cost solution for improving the company's operations, and even become idle. Some companies that produce devices have identified the direction of investment in innovation. It is reported that for some projects with previous ROI thresholds of 3% to 40%, the ROI can be increased to about 80% using process optimization.
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