How Applying Sigmafine at Chemical Sites Improves Operations
The petrochemical industry produces most of the commodities required by large market sectors such as agriculture, packaging, construction, automotive, and more. While population growth and global GDP are currently increasing demand, several factors (e.g. the political landscape, oil price fluctuations, feedstock availability, and environmental laws) are requiring chemical plants to make decisions more thoughtfully than ever before. Those decisions require chemical plants to be armed with accurate, consistent, accessible data – all made possible by Sigmafine.
Sigmafine is state-of-the-art data validation and reconciliation software that relates raw process data, material transactions, and business data in one model constrained by first principles equations. The result is a refined, consistent, and accurate set of data that supports informed decision processes.
Sigmafine supports accountants in large petrochemical facilities, even in combination with refineries. Validated and reconciled data are combined with material information to provide production and consumption reports, inventory stocks, site balance by material, and plant/process unit yields.
Harmonizing Intercompany Material Exchanges
In large sites with many companies or complex joint ventures where many materials are produced and consumed, it’s often difficult to agree upon a set of production and consumption figures. Sigmafine solves this problem by modeling all intracompany and intercompany material transfers, flow meter data, and inventory measurements to provide the ERP system a consistent, daily balance of all productions and consumptions. It eliminates end-of-month misalignments by providing a traceable, auditable, and transparent source of material balance data.
Tracking Quality and Composition
Sigmafine increases plant knowledge by calculating up-to-date estimates of the composition and qualities (e.g. density, viscosity, and sulphur content) of materials that are stocked in inventory or have been fed to process units. It empowers daily – and even hourly – monitoring, which enables operations teams to quickly fix production inefficiencies and update production planning throughout the month to optimize logistics and reduce costs. Finally, it assesses raw material and production costs based on unit feed qualities.
Be it a distillation column, a cracking furnace, a multi-stage compressor, or a full ethylene production plant, Sigmafine can provide detailed modeling of your facility alongside KPIs such as efficiencies, process duties, energy consumption, heat loss, and flaring estimation. To do so, Sigmafine is typically configured with mass and energy balance supported by a thermodynamic package with an extensive database of chemical components. Sigmafine can then run unattended and provide operators validated performance indicators on a regular basis (even more frequently than hourly) to expedite reaction time and improve process operations. KPIs are then used by process departments for plant analysis and by maintenance to monitor equipment performance.
Applying Sigmafine to Improve Plant Operations
Modeling flexibility and a wide range of data analyses make Sigmafine the ideal solution to achieve:
- Accurate production accounting, even with complex joint-ventures or multi-affiliate sites
- Up-to-date performance monitoring of both the plant and its equipment
- Accurate energy management and emissions monitoring
- Accurate material composition and quality tracking
Integrating Sigmafine with SAP
Sigmafine comes with an integration framework component, allowing data to interface with external systems, including SAP. The most common SAP modules integrated with Sigmafine are:
- PPPI: Post reconciled figures of productions, consumptions, and losses compared with planned/business figures
- SD: Download inbound raw material receipts and outbound final product shipments from SAP
- WM/MM: Align physical or logical SAP inventories with Sigmafine inventories
Benefits of Sigmafine
Improved data quality in the oil and gas refinery industry is primarily associated with:
- Validating and automating production accounting
- Validating auditable estimates of raw materials, intermediates, and product inventories
- Validating KPIs for improved process control and system optimization
The Business Impact of Implementing Sigmafine
Customers who have implemented Sigmafine have achieved:
- Daily production accounting automation
- Equipment and Site-wide performance monitoring
- Yield accounting
- Loss monitoring
- Results distribution throughout the organization
- Improved production planning and logistics
Sigmafine References in Chemicals
Customer: ENI Versallis
Abstract: Learn how ENI Versalies uses Sigmafine mass balance, quality tracking, and integration framework to plan and optimize selling and shipping activities, monitor plant efficiencies, and perform accurate daily consumption and inventory declarations in SAP
Used for: Supply chain & logistic optimization, production accounting, and equipment monitoring (via validated efficiencies)
Benefit: Automatic plant/production/yield accounting and inventory; systems integration; corrected production performance calculation; automatic daily monitoring or qualities of inventories; production performanceMES Project Quality Tracking
Customer: Dow Corning
Abstract: Learn how the conglomerate Dow Corning uses Sigmafine to completely automate daily production accounting through SAP validation and posting.
Used for: Production accounting and automatic validation and posting to SAP
Benefit: Automatic production accounting and inventory validation; full integration of the production accounting system in to SAPLearn More
Customer: Olefin Plants
Abstract: : Explore how large-scale Olefins sites tackle accurate asset performance simultaneously with corporate-level production accounting using Sigmafine and its thermodynamic extension, configured to perform coupled mass and energy balance.
Used for: Performance monitoring, real-time validated KPIs, loss monitoring (mass and energy). and unmeasured flow estimation
Benefit: Plant capacity maximization; transparent energy management of furnace, crackers and power generationLearn More