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Minimal Organization: VELTRONA CHEMIE, Chemiekonzern (Verbundstandort) – das Gelände im Modell von schräg oben

シミュレーション · Minimal Organization · Industry

Chemical group with integrated site

A chemical site as a walkable model: see how a polyethylene order runs through the integrated site and which plants stall when the cracker trips.

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VELTRONA CHEMIE and all its values are invented. With your data the model can show what hardly anyone sees as a whole today – such as real flows between plants in tonnes per hour or the fill levels of your tank farms.

How does order fulfilment work at an integrated chemical site, and what happens when one plant goes down? The model of VELTRONA CHEMIE, a fictional chemical group, shows it. Plants are linked by pipe racks: if the steam cracker trips, ethylene runs short and polyethylene runs at only 40 percent for four days.

The main process: a film manufacturer orders pellets, sales confirms the date, production planning schedules the batch, the plant polymerises, analytics tests, logistics fills silo wagons and bags and ships by rail and truck, and the quality certificate goes to the customer. Target in the model: dispatched within 48 hours.

You see 15 buildings, from the cracker, tank farms and site power plant to the plant fire brigade and the gate. The integrated site is reduced to one chain of cracker, polyethylene and tank farm; real sites have hundreds of units. The page speaks to site management, the control room, logistics, procurement, safety and neighbourhood relations.

A customer orders polyethylene

  1. 01

    Customer orders: A packaging film maker orders 20 tonnes of pellets.

  2. 02

    Accept order, commit date: Sales checks quantity and date.

  3. 03

    Production planning: Production planning schedules the batch.

  4. 04

    Polymerise and pelletise: Ethylene from the cracker is polymerised and pelletised.

  5. 05

    Batch quality test: Analytics measures melt index and density.

  6. 06

    Filling into silo wagons and bags: The pellets go into silo wagons and bags.

  7. 07

    Dispatch by rail and truck: Twice a day trains and trucks depart.

  8. 08

    Quality certificate: The quality certificate goes to the customer.

  9. 09

    Delivered.

How a chemical group can use the model

  • Internal communication

    15 buildings, 21 departments and the pipe racks between them in one picture. ‘Who works with whom’ shows which plants hang on the cracker – a basis for talks between operations.

    対象Site management, business units, communications

  • Onboarding

    New staff learn their way around the site: ‘Who sits where – and reports to whom’ puts plants, control room, fire brigade and research on one map.

    対象New staff, contractor firms, maintenance

  • Training

    Apprentices trigger ‘Cracker down’ or ‘Process control system fault’ and watch the outage spread through the site, and which plants keep running at partial load.

    対象Chemical operator apprentices, students, control room staff

  • Explaining to customers and neighbours

    Customers see how their order runs from contract to quality certificate. Neighbours and school groups see the site with fire brigade, treatment plant and gate without setting foot on it.

    対象Sales, neighbourhood dialogue, visitor groups

  • Strategic overview

    Larger intermediate tanks, more polyethylene lines and predictive maintenance side by side, plus low river water and a gas price shock as disruptions. Buffers and investments can be weighed against each other.

    対象Board, engineering, procurement

What is shown – why – for whom

表示内容 なぜ 対象
Diagram ‘Who works with whom’: the cracker and the plants behind it なぜshows the cascade within the integrated site 対象Site management, crisis team
Diagram ‘What the work depends on’: power plant, control room, tank farm, treatment plant なぜshows the infrastructure beneath every plant 対象Infrastructure, authorities
Diagram ‘What each control does’: intermediate tanks, lines, maintenance なぜranks buffers and investments 対象Board, engineering
Diagram ‘Who sits where – and reports to whom’ なぜshows the site with fire brigade and research 対象Neighbours, training
Diagram ‘The path across the site’: pipe racks and gate なぜshows how materials and people move 対象Logistics, safety
Disruption ‘Low water on the river’ なぜshows the dependence on shipping 対象Procurement, logistics
Resources view over the plants when the cracker trips なぜshows partial load across the whole site 対象Control room, production

Departments in the model

  • Board

    Leads business units and site.

  • Basic chemicals business unit

    Base chemicals from the cracker.

  • Steam cracker operations

    Cracks naphtha into ethylene and propylene – the start of all chains.

  • Plastics business unit

    Profit responsibility for polyethylene.

  • Polyethylene operations

    Polymerises and pelletises around the clock.

  • Specialties business unit

    Small volumes, many recipes.

  • Sales

    Takes orders, commits dates.

  • Site control centre

    Keeps the network balance: which plant supplies what to which.

  • Energy and steam network

    Power plant, steam, electricity – including plant waste heat.

  • Maintenance and plant construction

    Repairs, rebuilds, works under permit.

  • Logistics (tank farm, rail, port)

    Fills and ships.

  • Engineering

    Plans new plants and modifications.

  • Analytics and quality control

    Tests every batch, writes certificates.

  • Plant fire brigade

    On site around the clock.

  • Plant security

    Checks every access.

  • Process safety and major-hazard officers

    Statutory officers – report independently.

  • Environment and wastewater

    Emissions, wastewater, permits.

  • Product safety and REACH

    Registrations and safety data sheets.

  • Research

    Catalysts and polymers.

  • Application technology

    Translates molecules into customer value.

  • IT and process control

    Control systems, planning, lab.

All processes in the model

A customer orders polyethylene

  1. 01Customer orders: A packaging film maker orders 20 tonnes of pellets.
  2. 02Accept order, commit date: Sales checks quantity and date.
  3. 03Production planning: Production planning schedules the batch.
  4. 04Polymerise and pelletise: Ethylene from the cracker is polymerised and pelletised.
  5. 05Batch quality test: Analytics measures melt index and density.
  6. 06Filling into silo wagons and bags: The pellets go into silo wagons and bags.
  7. 07Dispatch by rail and truck: Twice a day trains and trucks depart.
  8. 08Quality certificate: The quality certificate goes to the customer.
  9. 09Delivered.

The steam cracker trips

  1. 01Plant shuts down safely: A compressor fails, the cracker shuts down safely. The flare burns.
  2. 02Informing neighbours and balancing the network run in parallel.
  3. 03Inform neighbours and authority: The major-hazard officers inform town and authority.
  4. 04Network balance: who has buffers?: The control centre checks: which plants have tanks with stock?
  5. 05Situation clear.
  6. 06Partial load, purchase or shut down: Partial load, purchase by ship or shut down the downstream plants.
  7. 07Purchase by ship or pipeline: Ethylene comes by ship from outside.
  8. 08Repair: Maintenance replaces the compressor bearing.
  9. 09Restart, ramp up the chain: The cracker restarts, the chain ramps up step by step.
  10. 10Root cause analysis: Root cause analysis: what was the cause, how do we prevent it?
  11. 11Report to the authority: The report goes to the district government.
  12. 12Back in operation.

A plant is expanded

  1. 01Concept and investment request: Engineering plans a second polyethylene line.
  2. 02Safety study and permit application run in parallel.
  3. 03Safety study (HAZOP): A team goes through every line: what if something goes wrong here?
  4. 04Application under pollution control law: Environmental protection files the application.
  5. 05Filed.
  6. 06Permitting procedure: The district government reviews, with public participation.
  7. 07Construction in the running plant: Construction happens in the running plant.
  8. 08Acceptance by experts: Experts accept the plant.
  9. 09Accepted.

A customer needs a new plastic

  1. 01Customer describes the requirement: An auto supplier needs a lighter, stiffer material.
  2. 02Application technology tests grades: Application technology tests existing grades and recipes.
  3. 03Samples from the pilot plant: The pilot plant makes samples.
  4. 04Customer tests the sample: The customer tests for months in its own plant.
  5. 05REACH and safety data sheet: Product safety checks the registration and writes the safety data sheet.
  6. 06Recipe into the plant: The recipe enters production planning.
  7. 07Launched.

What you can change

Controls

  • Plastics demand: Economy and customers' stock cycles.
  • Polyethylene lines: How many batches run at once.
  • Larger intermediate tanks: More stock: more plants keep running at partial load during a trip (model assumption).
  • Predictive maintenance: Vibration sensors on compressors: fewer trips (model assumption).

Disruptions

  • Cracker down (cascade): For four days ethylene is missing: polyethylene runs at 40 percent.
  • Low water on the river: For a month ships run part-loaded: purchases and filling take longer.
  • Gas price shock: For two months plants are throttled.
  • Process control system fault: For two hours the control centre cannot redirect.

What the model gives a chemical site

  • 01

    The cascade made visible

    A trip at the start of the chain reaches all the way to dispatch. The model shows which plant runs at partial load and for how long – live, for as long as the disruption lasts.

  • 02

    Weighing buffers

    The ‘Larger intermediate tanks’ control shows how extra stock plays out during a trip. The effect is a model assumption; with your data the model calculates with your tanks.

  • 03

    The whole site

    Cracker, three plants, two tank farms, power plant, control room, research, fire brigade and treatment plant as walkable buildings – more than a site map can show.

  • 04

    Diagrams calculated live

    Fourteen diagrams in four groups come from the same simulation: collaboration, dependencies, paths, bottlenecks and org chart.

  • 05

    From control room to auditorium

    The model runs in the browser and on large projections, on an open day or in a crisis team exercise.

Basis and limits

Fictional chemical group · model based on researched industry structures · no forecast for real companies

1 case = 1 customer order, 1 trip, 1 plant change or 1 product idea · 1 figure ≈ 40 employees

All volumes, durations, rates and capacities are model assumptions, not values of a real chemical group.

The network is reduced to one chain: cracker, polyethylene, tank farm. Real sites have hundreds of plants.

Documented: coupling of plants in the network, major-hazard officers, seven-month permit deadline, REACH registration from one tonne.

Public sources the model is based on:

  • Störfall-Verordnung (12. BImSchV)
  • Bundes-Immissionsschutzgesetz (u. a. §§ 4, 10, 53 ff.)
  • REACH, ECHA
  • BImSchG § 10 (Fristen)

Your site as a model

We rebuild the integrated structure of your site with the plants and flows that matter for your questions. Get in touch for a first conversation; we provide the password to the simulation on request.

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VELTRONA CHEMIE and all its values are invented. With your data the model can show what hardly anyone sees as a whole today – such as real flows between plants in tonnes per hour or the fill levels of your tank farms.