BASF turns hazardous waste into clean energy at chemical complex

Jan. 25, 2018 – Honeywell Process Solutions (HPS) announced that BASF has opened a control room equipped with Honeywell Experion technology at its waste incineration complex in Ludwigshafen, Germany.

The control room was officially inaugurated on November 28, 2017.

Honeywell re-designed the plant’s control room with BASF’s Industrie 4.0 initiative in mind. Virtualization technology delivers consolidated plant information to operators via eight large-screen Experion Orion Consoles, which also embed traditionally separate Microsoft Office desktop applications alongside the distributed control system one. Two Experion Collaboration Stations enable BASF to run production meetings with real-time data and online documents.

As part of Honeywell’s Experion Process Knowledge System, 29 C300 Controllers and 20,000 I/O modules facilitate plant-wide monitoring, improve safety and fire protection, and increase reliability, says HPS. In addition, a new MediluX lighting system in the control room helps improve visual conditions for operators day and night.

“This strategic project is a prime example of how Industrie 4.0 is transforming industrial operations,” Vimal Kapur, president of HPS said. “Previously, BASF operators had to gather and piece together data to form a high-level view. Now, critical information is digitally consolidated and streamed onto central displays, transforming efficiency, productivity and decision-making.”

The plant’s six incinerators process hazardous waste that cannot be reused or recycled and convert it into steam and electrical power. The clean, reusable energy is channeled back into BASF’s production processes, helping the company save resources and reduce emissions.

“Thanks to excellent cooperation with Honeywell, our 60-year-old plant now has one of the most modern control rooms in the world,” said Dr. Karin Flore, head of waste incineration, BASF.

The incineration plant serves more than 200 BASF production facilities within the company’s flagship, 10-square-kilometer production site as well as facilities outside the BASF complex.