“Smart Reactor 4.0” is a Batch process application. Batch control operations, which can offer flexibility and performance, have been utilized to meet the production objectives of our chemical enterprise customer. In the manufacturing process, there were different needs ranging from simple single reactor, single product production to multi-reactor and complex production. We knew that a flexible, reliable method was needed for every need. An easy-to-use system needed an application to address operational needs and problems, adapt to changes in customer demands, and improve operations.
For the “Smart Reactor 4.0” Batch application, we have identified a production process that can be controlled in 3 ways: automatic, semi-automatic and manual. We have adapted these production modes to the batch process in a flexible, reliable and responsive manner.
In the automatic control process, all reactors were produced automatically according to the prescribed prescription and intelligent production methods. The automatic control process pulls the materials from the respective silos respectively according to the recipe to be produced and transfers them to the reactor to be produced. The reactor is subjected to the required heating, cooling and mixing batch processes according to the product and the production is completed.
In semi-automatic control mode, the material in the silos is pulled into the manual reactors and operated automatically according to the desired batch process. In this way, different productions can be made in different reactors and production flexibility is maximized. In the reactors, production is completed by passing the necessary heating, cooling and mixing batch processes according to the product.
In the manual control mode, the entire production process can be operated manually. In this mode, the operator manually monitors the production according to the desired product and ensures the completion of the batch process.
Since batch processes in the reactors differ according to the product to be produced, the operator is notified automatically about the production notifications, probable problems and alarms. Production processes can be monitored online on the web scada screen and mobile application in our “Smart Reactor” application and all notifications can be received simultaneously.
With the “Smart Reactor 4.0” Batch application, a flexible Industry 4.0 production system has been provided in-house to meet further production and return demands. Our solution enables more efficient production operations by reducing engineering and maintenance costs, maximizing accessibility and traceability through modern web and mobile interfaces, digitizing the production process, and managing recipes and workflows and easily accessing critical production information.
