Challenges in the petrochemical industry include outdated control systems, reliance on manual operations, and high energy consumption. SUPCON's solutions encompass upgrades to adsorption column control systems (ACCS), integrated extruder management, and other OMC-based solutions for comprehensive process control. Key parameter optimization achieves product purity of ≥99.75% and yield of ≥97%, while reducing upgrade costs by 30-40%. A successful case study: modernization of an isomerization (PX) unit at the Liaohe refinery to meet Information Security Level 2.0 standards.
Oil & Gas
The industry faces challenges such as dependence on imported equipment, difficulties in managing LNG terminals, and pipeline monitoring issues. Solutions include localized control devices, ultrasonic gas flow measurement systems, and autonomous LNG terminal management systems. A fiber-optic monitoring system detects intrusions with ≤25 m accuracy and a low false-alarm rate (0.14 per day per km). The Shandong Pipeline project successfully protected 1,131 km of pipelines from unauthorized interference.
Battery and VIE
Lithium battery material production struggles with manual quality control and data tracking. Solutions involve online particle size analysis, digitalized quality management, and autonomous cathode material production systems. Implementation at companies like SVOLT and Hubei Ronbay enabled automated quality control and reduced operator errors by 99%.
Chlor-Alkali
High corrosion activity in the environment and risks during electrolyzer maintenance demand automation. Solutions comprise explosion-proof inspection robots, TPT-model-based membrane status prediction, and online hydrogen ion concentration analysis. Deployment at Inner Mongolia Xingfa improved measurement accuracy to 95% and reduced energy consumption by 5%.
Fine Chemicals
Unstable PTFE polymerization processes and PAV production coordination challenges are addressed through APC optimization and AI-based systems. Autonomous electronic chemical systems at Hubei Xingfu factory reduced personnel by 10 while improving temperature control accuracy to ±0.5°C.
Pharmaceuticals
Difficulties with wiring in hazardous explosive zones and stringent sterility requirements in bioreactors are resolved using APL technology, which reduces cabling infrastructure by 95%. The QRCS system automates the preparation of GMP reports, saving 90% of the time. Visual AI on extraction units replaces manual control.
Pulp & Paper
Challenges of fragmented control systems and weighing errors are resolved through DCS/MCS/QCS integration. Implementation at Fengsheng Paper automated paper grade changes and increased production efficiency to 95%. Conveyor monitoring systems reduced repair costs by 30%.
Power Industry
Risks in isolated power grids and inefficient fuel management are addressed by automatic switching systems and coal warehouse digitalization. The Narisun project (400 MW solar generation) implemented electrolyzer control systems producing 80,000 tons of oxygen annually.
Nuclear Power
High risks during fuel loading necessitate automation. SUPCON's solutions for Hualong reactors incorporate FPGA protection and 3D accelerators, increasing loading speed by 30% and reducing personnel by 80%.
Construction Materials
High energy consumption in glass fiber and gypsum board production is reduced by 15-20% through temperature regime optimization. Measures increased annual qualified product output rate to 99%.
Coal Chemistry
Control delays in gas generators and frequent hydraulic support failures are resolved by autonomous systems, reducing accident rates by 50%.
Metallurgy
Strict environmental regulations and high compressed air costs are addressed through gas purification systems and compressor optimization, saving up to 20% of energy.
Food Processing
Subjective alcohol quality assessment and slow sugar crystallization control have been automated, increasing premium product yield by 10% and accelerating analysis by 80%.
Custom Solutions
Unmanned laboratory systems boost productivity by 50%, while carbon management ensures compliance with the EU Battery Regulation and reduces tax liabilities.
