ABB’s distributed control system provides an integrated control architecture to help PKN ORLEN S.A.maximize asset performance, manage power consumption, ensure product quality and optimize process efficiency.

PKN ORLEN, one of central Europe’s leading energy and petrochemical producers, aims to reduce CO2 emissions by 30 percent per ton of product at its Olefin III facility in Plock, Poland. At the same time, the plant will increase production capacity by about 60 percent. Growing capacity while curtailing emissions requires advanced digital technologies to monitor, analyze and optimize every phase of production.

PKN ORLEN is ramping up production to meet the growing demand for olefins, a base compound made up of hydrogen and carbon. Olefins produce a variety of everyday cleaning, hygiene and medical products, including the synthetic fibers used in protective clothing and masks (PPE). The global market for olefins is expected to grow at an annual rate of 4.5 percent, reaching a value of USD 329.3 billion by 2028.

ABB is working with Hyundai Engineering and Técnicas Reunidas to help ORLEN implement digital solutions for the efficiency, safety and security of the Olefin III complex. The ABB AbilityTM System 800xA distributed control system (DCS) provides the control architecture across the entire facility to maximize asset performance, manage power consumption, ensure product quality and optimize process efficiency in real time.

Alongside the System 800xA DCS, ABB will also deliver several systems designed to ensure the complex operates at optimum safety levels, including a burner management system, an emergency shutdown system and a high-integrity pressure protection system. These will be complemented by an industrial cyber security solution focused on mitigating cyber threats towards the complex.

Harnessing the continuous stream of data from the System 800xA DCS, the company, in line with their objective to achieve a 30 percent reduction in CO2 emissions per ton of product, will be able to make more accurate, informed decisions to drive efficient use of energy. This includes maintaining tight controls over raw material consumption, plant energy levels and waste by products.

The project is scheduled for completion in 2024 with operations due to start in 2025. ABB will apply its unique project methodology Adaptive Execution™ to support this timeline. Adaptive Execution harnesses virtual engineering and digitalization to deliver a streamlined, standardized and agile experience for all stakeholders. Through this methodology, ABB can lower delivery time by up to 30 percent, start-up hours by up to 40 percent and overall automation related capital costs by as much as 40 percent.

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