In the central control room of a sulfuric acid production facility, operators are faced with large screens displaying hundreds of data points and intricate flowcharts. How can they quickly grasp the "pulse" of the factory from this ocean of information? How can they avoid oversights during the complex startup process?

The value of an excellent DCS system goes far beyond stable operation. Transforming information into insights, this article will show you how we build the intelligent brain for the operation management of the sulfuric acid plant through three core screens: KPI monitoring, startup navigation, and sequence control.

01 KPI Monitoring Screen

If the entire sulfuric acid plant is compared to an aircraft, then the KPI monitoring screen is like the "instrument panel" in front of the pilot. Its core lies in extracting key information from the vast amount of data, allowing managers and operators to instantly understand the plant's operational efficiency and status.

Our design consolidates the critical information scattered across multiple flowcharts onto a single screen.

The economic indicators section visually presents real-time data such as the flow rate of finished acid and sulfur, and through process formulas, calculates core KPIs such as load and sulfur consumption in real time. For instance, the load is calculated based on the current liquid sulfur feed flow rate to the sulfur burner; sulfur consumption is calculated using the actual flow rate of finished acid, the concentration of the second absorption acid, and the liquid sulfur feed flow rate to the sulfur burner.

The health diagnosis section for conversion clearly lists interlayer temperature differences, outlet gas concentration, conversion rate, and layer resistance. By calculating and displaying these in real time, operators can intuitively determine whether the thermal balance is optimal, providing immediate data support for process optimization.

The key operating parameters section acts as a "vital signs monitor" for the entire plant. We categorize the most critical detection points by process parameters such as level, flow, temperature, pressure, and acid concentration, presenting them in a centralized manner.

02 Startup Navigation Screen

The startup process of a sulfuric acid plant is highly complex, with numerous steps and conditions. Any omission or failure to meet the conditions can lead to startup failure or even safety incidents.

Our startup navigation screen transforms this highly complex process into a visual and error-proof standardized procedure. For different processes, the entire startup process is decomposed. Each module lists all the startup conditions that must be met for the process. For example, in the "liquid sulfur" process, the conditions include: the opening degree of the liquid sulfur storage tank discharge valve is greater than 10%, the liquid level in the distillation underground tank is within the range of 1200-1500mm, and the sulfur pump is started, etc. Each condition is associated with real-time data from the site.

Beside each step, there are indicator lights. Green indicates that the conditions are met, while red indicates that they are not. When all the sub-conditions of a certain process are satisfied, a green "√" will be displayed at the end of the process. At the bottom of the screen, "Number of Items Ready for Completion" is continuously accumulated in real time, and the "Safety Confirmation Allow Driving" indicator light automatically turns on after all conditions are met. The operator can also start timing with one click to record the driving time.

Ensure that every operation is carried out within the safety boundaries; this significantly improves the driving efficiency. The operator no longer needs to repeatedly consult drawings and procedures; it lowers the operational threshold, and even inexperienced employees can understand the complex driving operations.

03 Sequential Control Screen

The driving navigation screen solves the problem of "whether the conditions are met", but for new employees or those unfamiliar with the device, they still need to know: "What exactly should be done next? What is the target value of the operation?"

The sequential control screen is an operation procedure specifically designed for this question. It is the "detailed manual" of the driving navigation. The operator can execute it by reading like a checklist, following the "steps". After each step is completed, the system will provide clear status feedback.

This is derived from and synchronized with the driving navigation screen data. The operator only needs to follow the guidance on the screen to quickly and accurately get started, and can monitor the operation by comparing it with the driving navigation interface.

04 Summary

Under the wave of digital transformation, the value of the DCS system has far exceeded the basic "monitoring and control". It is evolving into a comprehensive management platform that carries process knowledge, optimizes operational processes, and ensures production safety.

From a clear process diagram, to a stable loop, to a set of intelligent management views. We have always focused on the sulfuric acid industry, using professional technical capabilities to ensure the safe, stable, long-term, full, and optimal operation of each set of equipment.