© 2008 OSIsoft, Inc. | Company Confidential Genencor and PI Johan Saerens

© 2008 OSIsoft, Inc. | Company Confidential

Genencor and PIGenencor and PIGenencor and PIGenencor and PI

Johan SaerensJohan SaerensJohan SaerensJohan Saerens

3© 2008 OSIsoft, Inc. | Company Confidential

GENENCOR INTERNATIONAL a Danisco Division

A global leader in the development of biotechnology products for Bioproducts and

Agriculture markets


Genencor LocationsGenencor Locations

FINLANDJämsänkoskiHanko

NETHERLANDSLeiden

BELGIUMBrugge CHINA

Beijing Wuxi

JAPANTokyo

SINGAPORE

USARochester, NY Palo Alto, CA Cedar Rapids, IA Beloit,WI

ARGENTINAArroyito Buenos Aires Mfg.

R&D

Admin.

• > 4 million liters of fermentation capacity

Beloit, Wisconsin


ACTIVITIES – GENENCORACTIVITIES – GENENCOR

Genencor International Genencor International

Manufacturing plant

Production of Enzymes Market:Market:

Feed

Grain Processing

Food

Biofuels

Textiles

Sweeteners

Cleaning Products


Hot Cook Conventional EtOH ProcessHot Cook Conventional EtOH Process

Animal Feed with enhanced*nutritional value

Phytase*


2nd Generation BioEthanol:Not starch but biomass [cellulose]-based2nd Generation BioEthanol:Not starch but biomass [cellulose]-based


glucoamylasealpha-amylase

pullulanase

fungal amylaseor

beta-amylase

glucoseisomerase

Maltose

Glucose

Fructose

APPLICATION – STARCH DEGRADING ENZYMESAPPLICATION – STARCH DEGRADING ENZYMES


Kyoto ?Kyoto ?

In Belgium the CO2 emission should be reduced with 11 MTon by 2012

Calculation prof. Soetaert (University of Gent) :

– Enzymen produced in Genencor Belgium will result in an CO2 reduction in their application of 2 MTon (worldwide)

– Comparison : the Thornton windmill park will reduce CO2 emission by 1,6 MTon


Genencor High Level Production ProcessGenencor High Level Production Process

Fermentation

Recovery Formulated Product

Product Storage

Where the enzyme is

made.

Where the enzyme is purified.

Where the enzyme is

stabilized/standarized


Genencor Brugge…BatchBatch PROCESSPROCESS


Data aquisition up to 1996 : manual/ internally developped softwareData aquisition up to 1996 : manual/ internally developped software

PRO– Batch oriented– Integrated with Lab data– Variable charts, definable by the

operator– Profiles– Based upon Hour After Inoculation

CONTRA– Manual input (90%) possible

operator errors– Limited number of parameters

(128/batch)– Based upon hours, no detailed data– No time reference. (totals over

batches)– No interfacing with other programs

(Excel..)– No data compressing -> slow– A lot of paper


What do we want, check with the usersWhat do we want, check with the users

Process engineer (they define where we can find money)– Batch oriented– Comparison between batches (GOLDEN batch principle) over

the plant limits.– Fast & easy access to process data

• scale up• continuous improvement, • transfer between plants, lower the number of batches needed

for a transfer (10 #)• …

– Be able to make any special calculation Production engineers (they make the money)

– Production data concerning occupation / batch information– Warehouse management– Raw material management– Event registration


What do we want, check with the usersWhat do we want, check with the users

Capital engineers (they spend a lot of money)– Real time trendings– Possibility to evaluate equipment

Utility officer / maintenance people (they really try to save the money)– Fast overview of his utility equipment status– Real time data from equipment– KPI / efficiencies of the systems to detect

efficiency improvement


And then came: OSI PIAnd then came: OSI PI

After a market evaluation of different products we came to OSI PI

Not a lot of automation effort. Easily explained to the different end users

– Use of process books– Use of excel interface– Use of batch functionality

Batch oriënted Easy to use, maintain Great interface to automation systems (delta V, ABB, Metso,

Honeywell,…) so site independent. Easy interface to LAB system (Unilab) Rather low maintenance / maintenance costs


OSI PI use Functional SetupOSI PI use Functional Setup

MES

ERP

Control layer

SAP

PILong Data Archiving

Batch system

UNI LABLIMS

APOPLANNING

DCS : Delta V

????

MESsystem


OSI PI use in GENENCOROSI PI use in GENENCOR

+/- 50 000 tags world wide (small nevertheless efficient)

Plant servers: choise for system availability

All sites are having PI Batch working for fermentation.

The LIMS-to-PI interface is expanded to all other sites.

We are testing the SAP xMII tool; this tool is using a bidirectional interface to a PI server in the test environment.

How do we proceed for future (MES, Interfacing to SAP, Rlink, ….)


Process EngineersProcess Engineers

Flexible Batch process

seed

withdrawal

droptankSterilizer

feedsystem

fermentor


Process engineersProcess engineers

Golden batch : analysis of f.e. cellulose feed

Gathering data from 2 batches and the running one– Get the batch reports– Find out which fermentors were used– What was the sterilizer used for

cellulose– Find the TAG of the flowmeter– Find out the timing, when did the

process start– The extract the data and analyse

XEL: pure cellulose feed rate

0

50

100

150

200

250

0 20 40 60 80 100 120 140 160 180

EFT(h)

kg 1

00%

cel

lulo

se/h

F-XEL0163/XEL/HGcell dryPer U




Process engineersProcess engineers

Golden batch : analysis of time / temperature of sterilisation

Now with PI– Fill in the batch numbers– Choose the parameters you

want to see– Push the button

temp\\brugpp01\101.83-002/02temp\\brugpp01\101.83-002/02

Batch Trend

hours2 6 10 14 18 26 30 34 38 42

34

54

74

94

114

14

140

Batch Gantt

hours2 6 10 14 18 26 30 34 38 42

F-PRS5760104

F-PRS5760105

F-PRS5754083

F-PRS5754082

F-PRS5743542

temp\\brugpp01\101.83-002/02temp\\brugpp01\101.83-002/02

Batch Trend

hours-4 -2 0 2 4 6 8 10 12 16 18 20 22 24 26 28 30 32 34

34

54

74

94

114

14

140

Batch Gantt

hours-4 -2 0 2 4 6 8 10 12 16 18 20 22 24 26 28 30 32 34

F-PRS5760104

F-PRS5760105

OP_E... OP_EK_VRB_G... OP_EK_GISTEN:1-1

F-PRS5754083

F-PRS5754082


Production engineersProduction engineers

Detailed planning / analysis

101.54-003/02x

101.54-008/01c

101.54-010/01s

101.54-011/05x

101.54-012/01s

101.54-013/01c

101.54-017/01s

101.54-018/02x

101.54-000/05ton

101.54-009/01s

Plot-0

13/10/2008 15:59:33 13/10/2008 16:50:4651,22 minutes

2000

4000

6000

8000

10000

0

12000

-4,5

5,5

-5,00E+00

5,00E+00

-100

100

-4

6

-3

7

-3,5

6,5

0

1

0

1000

-0,5

9,5

dicht

2041

0,005

open

uit

dicht

3,7

dicht

uit

4790


Capital engineers EngineersCapital engineers Engineers

Detailed evaluation: pump curves, VFD controlled systems

totaal debiet ruw grachtwater motor P586 GrW motor P586 GrW101.83-001/02 m3/h

056.83-019/x

rpm

056.83-019/20x

kWh

100 200 300 400 500 600 700 8000

2000

2200

2400

2600

2800

1800

3000

0

75

0,2

0

280


Capital engineersCapital engineers

Chillers : energy optimization

COP f(tijd)

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

0 50 100 150 200 250 300 350 400

dagnr.

CO

P (

kWc/

kWe)

2005

2006

2007

measured

0

20

40

60

80

100

120

140

160

180

200

010

020

030

040

050

060

070

080

090

010

0011

0012

0013

0014

0015

0016

0017

0018

0019

0020

0021

0022

0023

00

Bin

Fre

qu

ency

0,00%

20,00%

40,00%

60,00%

80,00%

100,00%

120,00%

FrequencyCumulative %


Maintenance TechniciansMaintenance Technicians

101.22-210/sp

101.22-210/x

101.22-210/y

101.22-210/02x

101.22-210/05x

101.22-210/07x

V602

2000

4000

6000

8000

10000

0

13000

0

13000

0

100

0

13000

0

5

0

100

30,0

3,598

0

20,0

0

0101.23-610/sp

101.23-610/x

101.23-610/y

101.23-610/02x

101.23-610/05x

101.23-610/07x

V603

2000

4000

6000

8000

10000

0

13000

0

13000

0

100

0

13000

0

5

40

70

42,4

3,592

0

20,0

0

0101.24-710/sp

101.24-710/x

101.24-710/y

101.24-710/02x

101.24-710/05x

101.24-710/07x

V604

2000

4000

6000

8000

10000

0

13000

0

13000

0

100

0

13000

0

5

0

100

43,6

3,595

3793

28,3

4480

4500

101.25-810/sp

101.25-810/x

101.25-810/y

101.25-810/02x

101.25-810/05x

101.25-810/07x

V605

2000

4000

6000

8000

10000

0

13000

0

13000

0

100

0

13000

0

5

0

100

42,8

3,574

0

20,0

0

0101.26-910/sp

101.26-910/x

101.26-910/y

101.26-910/02x

101.26-910/05x

101.26-910/07x

V606

2000

4000

6000

8000

10000

0

13000

0

13000

0

100

0

13000

0

5

0

100

41,3

3,597

5025

32,0

5996

6000

compressoren

15/10/2008 23:05:39 16/10/2008 0:08:05

2000

4000

6000

8000

10000

12000

0

15000

0

15000

0

500

0

500

0

500

0

10

0

10

0

1

0

2000

0

2000

101.04-010/sp

101.04-010/x

101.04-010/y

101.04-010/02x

101.04-010/04x

101.04-010/06x

V611

100

200

300

400

500

0

600

0

600

0

100

0

600

0

6

0

100

34,6

3,565

349,1

30,8

534,7

540,0

101.04-510/sp

101.04-510/x

101.04-510/y

101.04-510/02x

101.04-510/04x

101.04-510/06x

V612

100

200

300

400

500

0

600

0

600

0

100

0

600

0

6

0

100

34,2

3,571

0,0

100,0

0,0

0,0


Utility officerUtility officer

Bronwaterputten

put4bis put12 put5bis put5 put7bis put6 put9ter

5,07

65

bar

m3/h

Zandfilters

Micro-filterUV installatie

P350

44,04m³/h

0,00

44,73

16,9019,42

5,99 11,32 17,96

%

P349

P363

P364

P365

P366Anti-scalant

brine flows

geleidbaarheid

uitvoerdebiet-pH

RO Straat 1 F364

RO straat 2 F364

RO straat 3 F365

P351

m3/h

V519

P518

P517

m³/h

P532

P529

P533

P534

P535

UF-LP

TLHS'

BMG+OP

GP+KTW

LFS

P513

P514Ontgasser V530

E521

P524P525P526

AMF3 AMF1Stork2

E507/509 F370/71

P562 P561

V561

Sperwater

9,50 bar

3,90 m3/h

Revap

0,00m3/h 0 4148l/h l/h

0,96m3/h

m3/h

m3/h0,00

53,70

0,00 m3/h

GP

76

V517

%

V520

70%

21%

69 %

V516

9,13

0

1

0

1

0

1

0

1

0

1

V367 Loogdosering

KVW pompen

1

2

3

0

25

0

25

0

25

0

7,5

brine flows

0

5000

0

200

2

12

0

50

geleidbaarheid

uitvoerdebiet-pH49 µS/cm

P363

P364

P365

RO Straat 1

RO straat 2

RO straat 3


ConclusionsConclusions

Very useful especially with our batch systems

Fast and quick responses Multiple interfaces make connectivity very easy

PI used as a client tool and not a programming/IT task Very user friendly and consistent in upgrades to existing configurations

Resulting in– Fast data gathering, fast introducing / transferring new products– Very good tool for analyzing the process resulting in less events, finding

root causes and final fixes.– Preventive maintenance increases significantly up-time and reduces

corrective actions (costs)– Optimizing processes based on good reliable data

Still a lot of opportunities to explore


Conclusions some numbers from Bruges plant…Conclusions some numbers from Bruges plant…

Plant to plant transfert of products: number of trials to result in the same output : reduced from 10 -> 3# gain : 500k€ /transfer resulting in > 2 M€/yr only for Bruges plant

Reducing corrective maintenance by preventive actions. Capacity gain in fermentation due to an increase in availability of the equipment from 92% to 96%.

Justification data for optimizing the energy use: projects in 2008 resulted already in a yearly saving of >200 k€/yr on the electricity bill.

OSI PI has delivered an essential part into these successes


Documents

© 2008 OSIsoft, Inc. | Company Confidential Genencor and PI Johan Saerens