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The chemical industry is characterized by large plants with a wide variety of different systems, as well as highly complex processes that are both energy- and resource-intensive. The industry supplies raw materials to numerous sectors and manufacturers of a wide range of chemical products, and as such faces intense competitive and pricing pressure despite its growth. At the same time, requirements for efficiency, sustainability, and flexibility are becoming more stringent.
End-to-end digitization of processes provides transparency regarding operational status, energy consumption, and material flows. On this basis, efficiency gains can be targeted and costs reduced along the entire value chain. Equally, modular plant design based on the Module Type Package (MTP) enables flexible production as well as faster integration and expansion of process modules.
Which advantages does Beckhoff offer the chemical and petrochemical industries?
- scalable control platform for new and existing plants of any size
- modular automation based on MTP for flexible production concepts
- high plant availability through redundancy strategies and predictive maintenance
- end-to-end connectivity from the field level to the cloud for centralized diagnostics
- transparent collection of energy data for intelligent optimization
Our technologies for your chemical plant
The control system for process automation
Beckhoff calls on a comprehensive modular range of components and deep-rooted, cross-sector expertise to create open automation systems using PC-based control technology. All control functions, such as PLC, visualization, cloud connection, explosion protection, safety technology, and measurement technology, are integrated on a universal platform. For large chemical plants, we offer comprehensive solutions for communication from zone 0/20 all the way to the cloud – whether you need to automate new plants or retrofit existing systems.
PC-based control for the chemical and petrochemical industries:
- universal platform for the automation of all processes and plants
- integration of all control functions into a single system
- high level of interoperability due to open interfaces in hardware and software
- control and cable redundancy for increased plant availability
- PC-based control technology is established worldwide across all industries
Ideal for the chemical industry: The open EtherCAT fieldbus
As a universal and open high-speed fieldbus, EtherCAT is suitable for all areas of application – from PLC and drive technology to sensors and measurement and safety technology. With EtherCAT, you only need one communication technology for your entire plant and can also benefit from the safety and optimum performance of the comprehensive EtherCAT architecture. The EtherCAT-based control is also open with regard to integrating third-party EtherCAT devices and other fieldbus systems. EtherCAT is clearly separated from IP networks and can be used – without any modifications – in a cyber-secure and standard-compliant manner, e.g., in accordance with the CRA requirements for security level 2.
Advantages of EtherCAT for the chemical and petrochemical industries:
- fast troubleshooting through diagnostic functions
- cable redundancy for high plant availability
- implementation of flexible topologies
- Extended Distance technology for communication between distributed plants
- lean system cabling through remote I/O
TwinCAT: The control platform for the chemical and petrochemical industries
With TwinCAT automation software, Beckhoff offers a central platform for controlling chemical plants. In addition to classic process control in the PLC program, algorithms written in C++, MATLAB®, and Simulink® can also be executed in real time. The scope of application of PC-based control for process automation is extended with the comprehensive integration of specific process technology protocols and interfaces. By supporting common standards such as NAMUR, HART, and FDT/DTM, TwinCAT covers the application areas of industry-specific applications.
TwinCAT highlights for the chemical industry:
- control-integrated Industry 4.0 and IoT applications
- modular plant automation with TwinCAT MTP
- TwinCAT Controller Redundancy for increased plant availability
- comprehensive data evaluation with analytics functions
- support for common standards such as NAMUR, HART, and FDT/DTM
Our product highlights for your chemical plant
Connecting Ethernet-APL field devices to the modular I/O system
The rise of digitalization, especially in the plant diagnostics and monitoring sectors, is currently one of the major topics in the chemical and petrochemical industry. Processing plants are generally very widespread and have particular requirements that are met by the specially developed standard Ethernet-APL, which offers a transmission rate of 10 Mbit/s and a cable length of up to 1,000 meters.
Beckhoff integrates the Ethernet-APL technology into the modular terminal portfolio. The compact ELX6233 can be mounted in the control cabinet in combination with other EtherCAT Terminals. Two Ethernet-APL field devices can be connected via each ELX6233 Terminal. As with all EtherCAT Terminals in the ELX series, the ELX6233 enables direct connection of intrinsically safe field devices from zone 0.
TwinCAT for modular plant engineering
With modular automation, chemical plants can be flexibly implemented and adapted with little effort. Modularity is standardized by the Module Type Package (MTP). MTP describes individual modules based on various aspects, including their interfaces and the executable services. The information about the module is stored in an MTP file, which is imported into a higher-level control. This enables efficient commissioning and linking of modules from different manufacturers. The integration of the MTP concept into TwinCAT simplifies the guideline-compliant automation of a plant module through automatically generated source code and libraries for PLC programming.
The advantages of TwinCAT MTP:
- automatic generation and export of the MTP
- high degree of customization for optimum adaptation to existing processes
- guideline-compliant IEC 61131 function block library
- seamless integration into TwinCAT Engineering
© Beckhoff
Flexible implementation of NOA concepts
NAMUR Open Architecture (NOA) is designed to make chemical plant operating data easily and securely available for plant and equipment monitoring and potential optimization without affecting existing automation systems.
Beckhoff has developed an NOA edge device for reading out the additional data for higher-level M & O (monitoring and optimization). The edge device, which consists of a compact embedded PC, EtherCAT Terminals with HART functionality, and the relevant TwinCAT project, can be placed directly in the plant.
Depending on the application, the installation of additional sensors for condition monitoring is also useful in the field level. For example, the IP67-protected EtherCAT Box modules are used here, which can be installed directly in the field and therefore do not require any space in the control cabinet.
Integrated controller redundancy increases plant availability
With plant availability playing such a crucial role in the chemical industry, measures to increase this include using redundant architectures to safeguard against failures of individual control components. For redundant control operation, TwinCAT Controller Redundancy is available.
This system-integrated software solution allows two standard industrial PCs to be operated as redundant controllers that both run the same PLC program. An additional high-performance network connection between the two controls provides the necessary data synchronization, and the fact that standard Ethernet is used means no dedicated hardware components are required. This ensures that only one of the two industrial PCs addresses the fieldbus components at any given time and that the control programs are executed on both computers with the same database. If one control fails, the second control seamlessly takes over, preventing plant downtime and data loss.
Functional safety for the chemical industry
We meet the increasingly stringent requirements for process control technology by consistently integrating safety technology into the automation system. Compact and with a modular structure, TwinSAFE fits seamlessly into the control platform. Communication via the integrated safety protocol (Safety over EtherCAT) and the modularity of the safety-related controller offer total flexibility when selecting the topology.
The safety I/Os form the interface to the safety-relevant sensor technology and actuators. Due to their integrated logic, complete safety control can be integrated into the EtherCAT system with a single space-saving component. The ELX Terminals with integrated safety enable implementation of TwinSAFE safety features up to and including zone 0. This means the extensive Beckhoff I/O portfolio offers a suitable module for every application in the chemical or petrochemical industry.
Control concept for the chemical and petrochemical industries
FAQs on chemicals and petrochemicals
The required measured values can be recorded by installing remote terminal units (RTUs) in power plants, distribution points, and systems. Their core task is to feed all physical measured variables into digital communication networks. To do this, the data often has to be transmitted over long distances. With the automation range from Beckhoff, RTUs can be configured to record all relevant measured variables. CX-series Embedded PCs, TwinCAT automation software, and EtherCAT Terminals for signal acquisition are used. The wide I/O spectrum allows the complete integration of all electrical and process signals from the field.
Beckhoff control technology can be easily integrated into an existing DCS via standardized interfaces such as OPC UA, Modbus TCP, or PROFINET. TwinCAT runs on industrial PCs and provides process data and control functions via these protocols, while field devices are integrated via EtherCAT I/Os. Edge controllers can preprocess data, exchange alarm and recipe data, and perform local control tasks without replacing the DCS. Beckhoff Automation supplies IPCs, TwinCAT, EtherCAT I/Os, and the necessary couplers to ensure fast and reliable integration
In the chemical and petrochemical industries, the demands for adaptability, product variety, and regulatory changes are constantly increasing. With modular automation via the Module Type Package (MTP), plants can be flexibly implemented and adapted with little effort. Rigid automation systems that have been operating unchanged for years are becoming a thing of the past. MTP enables:
- short time-to-market due to minimized plant engineering
- short time-to-repair due to uniform module interfaces
- individual production of small batches due to reusability of modules
- numbering-up instead of time-consuming scaling-up
- uniform look and feel of the visualization system
At the field level, sensors and actuators are connected deterministically via a fieldbus, such as EtherCAT, and the high-frequency measurement data is securely transmitted to a cloud system via OPC UA or MQTT. At the edge, an industrial PC collects, filters, and contextualizes the raw data before it is securely transmitted to the cloud, where it is analyzed and visualized as time series.
Our solution: PC-based control with EtherCAT I/O combined with TwinCAT IoT, TwinCAT Analytics, and OPC UA/MQTT support for time-synchronous data acquisition, edge preprocessing, and seamless cloud integration.
Condition monitoring detects wear and anomalies early on, thereby preventing unplanned downtime – for example, due to blockages in reactors and columns or in agitator bearings. This allows maintenance to be planned based on condition (e.g., replacing bearings when vibration increases or cleaning when pressure drop rises) and extends equipment uptime. To this end, Beckhoff provides EtherCAT I/Os for sensor connectivity, control platforms with TwinCAT Analytics for local analysis, and OPC UA/TwinCAT IoT for cloud integration. These components provide alarm functionality, trend display, and automatic triggers to enhance availability in the chemical industry.
More information
Information media
You can find our brochures, videos and webinars on the process industry here.
Digitalization for the process industry
Implement future-proof automation of process plants with Ethernet-APL, NOA, and MTP.
Module Type Package (MTP)
TwinCAT MTP integrates the Module Type Package concept into the engineering environment and enables efficient development of modular plants.