Langenfeld, Germany (February 27, 2024) – Multinational chemical company LyondellBasell has chosen to partner with global software and technology leader Emerson to digitally transform the control systems and software at its production site in Wetherling, Germany. The implementation of advanced automation technologies will help improve the operations of ethylene cracking furnaces and butadiene production plants. Emerson’s digital tools and project engineering services will help smooth the transition during the plant’s planned shutdown in 2024.

AIP830-101/EIM Lyondell Industries’ plant in Wetherling, Germany, is its largest production site in Europe. Polyolefin products produced at the site are used in the manufacture of films, cable and pipeline coatings, fuel tanks, injection molds and household items. Photo credit: LyondellBasell

The Wetherling plant is LyondellBasell’s large production site in Europe. As part of its global digitalisation initiative, LyondellBasell is standardising its control system technology. Emerson won the project after demonstrating that it could complete all hardware and software upgrades within a two-week retrofit deadline.

Emerson’s DeltaV™ distributed control system and DeltaV Live software AIP830-101/EIM will be used for the safe and efficient operation of the ethylene cracker, while AMS Intelligent Device management system software will support the start-up process and ongoing management of on-site meters. Advanced automation solutions will significantly reduce engineering design time to implement control strategies aimed at increasing efficiency. DeltaV Live software will provide a modern user interface that simplifies plant management, allowing operators to detect problems early and maximize worker productivity.

AIP830-101/EIM

Simulation software for the DeltaV system will be used throughout the project for development, testing and training support. Operator training programs using Emerson MIMIC™ process simulation software will help AIP830-101/EIM operators familiarize themselves with the new control system before the unit is started, minimizing the risk of potential problems and optimizing operator productivity. Emerson’s field engineers will provide start-up support and consulting services on the implementation of modern control strategies.

To get things done on time, a range of digital tools to simplify systems modernization projects is essential. These include Emerson’s REVAMP software, which uses artificial intelligence (AI) algorithms to automatically identify existing control system codes used to generate DeltaV system configurations,AIP830-101/EIM  eliminating errors and reducing engineering time. Cloud-based tools will support collaborative project planning and execution, simplifying the design, engineering and testing phases, while a range of digital tools will simplify the connection of existing I/O to new control systems.

“Emerson is committed to helping our customers modernize and digitally transform their production facilities to improve operations,” said Claudio Fayad, vice president of technology for Emerson’s Process Systems and Solutions business. “AI, machine learning, cloud-based solutions and Emerson’s extensive project expertise will help LyondellBasell simplify control system upgrades, reduce project time and reduce risk.”