How to optimize a greenfield chemical plant: three tips

Case study | July 24, 2024

Greenfield plants navigate unchartered waters and face new challenges as the chemical sector is undergoing deep transformation on its journey to reduce emissions, adopt low-carbon technologies, and maintain competitiveness and profitability.

In a fiercely competitive market, today’s chemicals producers face mounting pressures from customers, governments, and society to meet stricter environmental and safety regulations, while maintaining competitiveness and revenue growth.

Here are three tips on optimizing a greenfield chemical plant.

1. Invest in the planning phase

New chemical plants face a myriad of challenges already in the planning phase.

Most of these challenges can be solved by deploying smart technologies and data driven applications. But you need to plan for this from the outset because integrating smart technologies comes with its challenges. Even in a mid-scale chemical plant, as many as 10,000 field devices may be needed to measure and report on processes, creating a complex and extensive digital ecosystem.

2. Think water efficiency and better process control

A greenfield chemical plant can benefit vastly from improving water efficiency through better process control. The chemical industry consumes high quantities of water for cooling purposes or to convert water into steam, hydrogen or oxygen. With global demand for freshwater expected to exceed supply with 40% by 2030, operators face regulatory pressures to better control how greenfield chemical plants manage water and minimize wastewater, particularly in water-stressed areas.

3. Embrace digitalization and sustainability

The chemical industry, a key enabler of modern life, has a role in everything from food and pharmaceuticals to electronics, construction and petrochemicals. It can also be an enabler of a low-emissions society by creating more sustainable chemical products that assist decarbonization in other industries.

Smart measurement technologies enable plants to meet government regulations, improve energy efficiency and open the door to new chemical initiatives, including a shift away from fossil fuels.

With smart instrumentation solutions you are also transitioning to a more efficient, digitally enabled plant.