Data validation for Fertilizers

Applying Sigmafine in Fertilizers

The highly competitive fertilizer industry suppresses the product value yet the main feed stock is linked to the increasing price of natural gas thus prioritizing efficient asset utilization.

Top tier fertilizer producer’s solution landscape includes an optimum use of its process data, which must be consistent, accurate and timely available. Sigmafine turns process data into quality information which supports knowledge based decision requirements to improve business performance. Data quality matters!
Sigmafine is robust and scalable, efficient state-of-the-art data validation and reconciliation software which resolves the issue of unaccounted losses from your fertilizer facility; finding and resolving errors in raw plant data thus closing the mass balance used for production and financial accounting. Operationally this improves the management feedstock, intermediates and products.

Pimsoft is your business partner with worldwide experience and know-how for the implementation of automatic plantwide data reconciliation and balancing. This means: timely project implementation, elimination of measurement errors from operational and financial reports.

Production Accounting

Sigmafine supports the daily job of accountants for the full business chain, from raw materials, to production sites then to storage and distribution as well as accounting at the production site level, e.g. ammonia plant or urea plant. Validated and reconciled data are conditioned to provide reports of productions and consumptions, inventory stocks, site balance by material or plant / process units’ yield.

Full Business Integration
Full Business Integration

Sigmafine models (balancing as mass, energy, volume or components):

  • Intra-company material trades/transfers
  • Inter-company material trades/transfers
  • Flow meter data
  • Inventory data

Sigmafine provides consistent daily or batch balance of production / consumptions to the ERP. Traceable and auditable; completely transparent material balances. No more misalignments at month end!

Full Business Integration

Sigmafine Integration Framework component provides easy connectivity to external systems facilitating integration with most common ERP systems, including SAP. Common SAP modules integrated with
Sigmafine connectors include:

  • PPPI: post reconciled figures of Productions, Consumptions & Losses vs Planned/Business figures
  • SD: download from SAP inbound raw material receipts & outbound final product shipments
  • WM/MM: align SAP/Sigmafine inventories

Component balancing

Sigmafine Component analyses balances the components (e.g. Nitrogen, Potassium, Sulphur content, etc.) of materials stocked in inventories or fed to process units providing. Such balance may include environmental losses, thus providing validated estimates for emission reporting.

Model Data Quality monitoring

Being it an ammonia network, inventories, an ammonia converter, or the complete fertilizer production plant, Sigmafine can monitor the data quality based on the model structure and measurements to provide systematic monitoring of data used for accounting and reporting purposes. In countless installation of Sigmafine, we have seen an improvement with the starting measurements, showing that when data quality matters, also the behavior affecting the data quality improves. In the graph below, the improvement was realized within the first week of Sigmafine use at the undisclosed fertilizer site.

Data quality of the enter model structure and system of measurements
Data quality of the enter model structure and system of measurements

Performance monitoring

For such applications, Sigmafine is typically configured with mass and energy balance supported by a thermodynamic package with an extensive database of chemical components.

Sigmafine can run unattended and provide operators validated performance indicators on a regular time basis (hourly or even less) to act at proper time, improving process operation (e.g. keep product in spec by better operating looking at the reconciled fuel consumption).

Sigmafine equipment KPIs are used both by process department for plant analysis and by maintenance to know in advance how performance of equipment is changing over time and act accordingly.

Performance monitoring of Ammonia compressor
Performance monitoring of Ammonia compressor

Supported Applications

  • Reduce uncertainty in your KPIs
  • Apply first principles and concentration laws to achieve consistent data
  • Monitor and validate recoveries
  • Track valuable components across the process network

Comprehensive Mass and Component Balancing

Customers using Sigmafine have a solid mass, component and energy balancing system, which provides validated, secured, and auditable information to the financial systems; accurate information to operation managers for operations optimization using a unified set of data. Additionally, engineers and operators, can compute process recoveries or other KPIs with more certainty when using Sigmafine reconciled data.

The Sigmafine system may be configured to perform mass balances for the whole production complex with the use of the Component Balance Analysis rule for balancing key components e.g. P2O5 to estimate reconciled key elemental concentrations that comply with concertation laws of processing units across the fertilizer process network. Pimsoft starts by using the PI Asset Framework to create “process templates” of the different processes and related equipment (e.g., mill, mixers, separators, etc.). After the initial setup and configuration, the solution requires the development of a connectivity model that represents the material flows of the facility. During the last step, meters and analyzers are represented to receive information from the process data historian using out-of-the box connectivity.

Benefits

Improved data quality in the Fertilizer Industry are primarily associated with:

  • Production accounting from single process units to multi-purpose sites
  • Component balance for elemental balancing and emission monitoring
  • Performance monitoring at both plant and equipment level
  • Balancing of the full business chain
  • Water balancing, loss estimation and monitoring

Business Impact

Sigmafine customers may achieve, through the single Sigmafine implementation, automation of the daily production accounting, performance monitoring, loss monitoring as well as the direct connectivity and distribution of results throughout the organization this official information which are safeguarded and auditable. Additional benefits such as improvements in production planning and logistic can also be realized.

Sigmafine References in Fertilizers

Coming Soon!

Resources

Coming Soon!

Pimsoft Contact

Veletia Moodie, Milan Office, Industry Principal for Fertilizers

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