BASF: New High-Temperature Esterification Plant

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In order to increase its North American production of specialty esters, BASF (formerly Cognis Corporation) planned to build a new $14 million ester production facility in South Carolina. The centerpiece of this planned facility was a new high-temperature reactor and refining process. The reactor’s liquid ester product would then pass through a new $1.2 million automated pastillator to prepare for transport and bulk material handling systems.

CSA was brought in early on the project and handled project management, designing and installing all instrumentation and electrical equipment for the facility. We designed the layout of the new control room and wrote the specifications for all DCS hardware and software. We also wrote the specifications for all batch and continuous control strategies.

We configured the DeltaV system for batch and continuous control, developed and installed operator displays, and managed all electrical construction. And we provided operator DCS trainig.

When construction was complete, we handled on-site startup services. The new plant was completely successfully and to specification. Start-up went well, and the plant has greatly increased the company’s production.

Services Provided:

  • Project management
  • Design, specification, and integration services
  • Electrical construction management
  • Continuous and batch configuration of DeltaV system
  • Operator display development
  • Conventional I/O, Foundation Field bus, ASi, Profibus
  • Operator DCS Training
  • Control System: Emerson DeltaV