DCM Shriram Ltd. is a leading business conglomerate, a spin-off from trifurcation of the reputed erstwhile DCM Group in 1990. DCM Shriram has manufacturing facilities of fertilizer, chlor-vinyl, and cement in Kota (Rajasthan), India. The business portfolio of DCM Shriram comprises primarily of:
Urea & SSP fertilizers, sugar, farm inputs marketing such as DAP, crop care chemicals, hybrid seeds
Caustic soda, chlorine, calcium carbide, PVC resins, PVC compounds, power and cement
Value added business
Fenesta building systems
Business Need: The company was looking for a best-in-class process solution for its ammonia plant, which was the hub of many fast, interactive, and continuous processes. This included complex operating conditions which were highly demanding and reactions involving gases/steams. The company was looking for a supplier who could provide end-to-end solutions supporting multiple inputs and outputs. Apart from a supplier with a deep understanding of the processes in the plant, DCM Shriram was also looking to improve the product quality while reducing the variability, increase the profits, reduce the process constraints, maximize efficiency, and reduce energy costs. Apart from this, the company was also looking to reduce time using automated model development and test control application, and train operators with off-line Model Predictive Control (MPC) solution.
Solution Implementation: DCM Shriram chose Emerson Process Management - Advanced Process Control (APC). This provided an end-to-end solution to the company's business needs by understanding the nuances of the plant, addressing all the pain points, and solving the issues efficiently. To handle the constraints and interactions simultaneously and provide predictive capabilities, DCM Shriram chose Emerson MIMO (multi-input, multi-output) Dynamic Model. The APC implementation methodology involved two phases. Phase 1 was the feasibility study with benefit analysis and Phase 2 involved functional design specification, step tests, model identification & testing, site commissioning, and training.
Achievements: Emerson's APC solution accelerated the plant performance to give maximum throughput and increased profitability. It helped the organization achieve these goals by improving product quality, maximizing efficiency, and reducing energy costs. And finally, it helped solve the constraint optimization problem to enable plants to operate with maximum profitability.