Application of DCS in fermentation section of pharmaceutical enterprises

Application of DCS in fermentation section of pharmaceutical enterprises Most of the fermentation process in the industry is still in the traditional stage, manual operation and experience control, not only the operator's labor intensity is high, the work efficiency is low, the energy consumption is large, but also the production is lack of scientific, affected by human factors, prone to errors, and will cause serious economic losses This paper introduces the application of distributed control system (DCS) in the fermentation process of pharmaceutical enterprises Distributed control system (DCS) is a kind of distributed integrated control system which integrates computer technology, network technology, automatic control technology, redundancy and self diagnosis technology It has friendly interface, powerful function, high reliability, convenient operation, flexible configuration and strong applicability The fermentation process is a very complex process In the process of fermentation, it is necessary to maintain a certain culture temperature, provide appropriate oxygen, and timely supplement the nutrition needed for the growth of bacteria Therefore, it is required to effectively control the temperature and humidity of the air entering the tank, the temperature of the fermentation liquid and the content of dissolved oxygen, and supplement materials when necessary I system hardware configuration (I) system block diagram (II) system configuration (main equipment) 1 A set of distributed control system (DCS), including: DCS control station, DCS operation station and system control software 2 Input and output mechanism, including: temperature transmitter, pressure transmitter, flow transmitter, differential pressure transmitter, dissolved oxygen meter, pneumatic control valve, solenoid valve, speed controller, intelligent control frame, etc (III) brief introduction of main functions of the system 1 The input part is mainly composed of temperature transmitter, pressure transmitter, flow transmitter, differential pressure transmitter and dissolved oxygen meter, etc it completes the sampling and conversion of field signals, forms standard signals and sends them to the control station for analysis and processing 2 The control station is composed of power box and cage The cage is equipped with various types of input, output and main control cards to complete the signal processing and calculation sent to the input part, form the display information and send it to the operation station through scnet network At the same time, the operation processing is carried out according to the configured control scheme, and send the control data to the actuator The control station can also receive the operation instructions from the operation station and convert them into control data output to the actuator 3 The actuator is mainly composed of pneumatic control valve, electric valve, speed controller and intelligent control cabinet, which is used to receive the operation data sent by the control station, perform field operation and complete the automatic control process 4 The operation station is composed of industrial PC, display and scnet network card The real-time communication with the control station is realized through scnet network, and the system configuration, control configuration, control scheme and operation information are downloaded At the same time, the field data returned by the control station is received for real-time display and recorded to form historical data for query 2 Software configuration of the system (1) the system requires to run under Windows 95 / 98 (2) the distributed control software includes: configuration software, flow chart design software, real-time monitoring software and / User-defined language III technological process and control scheme: the bacteria in the fermentation process are cultured in small tank, medium tank and large tank according to this The fermentation process is exothermic reaction During the fermentation process, it is required to maintain a certain temperature, timely supplement nutrients and control dissolved oxygen The temperature and humidity of the air entering the tank are controlled by the cooling of the air cooler and the heating of the air heater The dissolved oxygen content of fermentation liquid is controlled by changing air intake and stirring speed of fermentation tank The temperature of large tank and medium tank is controlled by regulating the refrigerant water volume, while that of small tank is controlled by regulating the refrigerant water valve and steam valve IV evaluation of system operation and control effect Through the preliminary exploration and technical preparation, we invested more than 700000 yuan to reconstruct, install and commission kanamycin fermentation section of our company for one month by using jx-300dcs system of Zhejiang University central control After six months of trial operation, it shows that the system is reliable, flexible and easy to operate The automatic control system has achieved the expected effect and met the fermentation requirements Process requirements The whole system runs stably Good economic and social benefits have been achieved 5 Benefit analysis (1) energy saving: the fermentation workshop consumes a lot of energy and operates continuously for a long period, so energy saving is of great significance 1 Reduce the consumption of refrigerant water, reduce the actual power of refrigerant water production from the original 40kW to 34Kw, and save 52500kwh and 31500 yuan annually 2 Reduce the consumption of compressed air, reduce the actual power consumption of centrifugal air compressor from 612kw to 586kw, save 22770kwh of annual power consumption, and save 136620 yuan of annual cost 2 Improve the production level After this automatic control transformation, the fermentation production level has been improved to a certain extent through the optimization of process energy number The average fermentation unit is increased by 1.8%, and the annual economic benefit is 252720 yuan In total, the two items can generate 31500 + 136620 + 252720 = 420840 yuan of economic benefits every year According to the above analysis, the investment payback period is about 17 months, which shows that the project is of great investment value This transformation not only brings good economic benefits to the enterprise, but also improves the industrial automation level of our company After the completion of this transformation, our company has obtained the CIMS application engineering demonstration enterprise in Zhejiang Province At the same time, it reduces the human factors in the traditional production, makes the production more scientific, reduces the labor intensity of the operator, and improves the production efficiency At the same time, it also laid a good foundation for the further development of industrial automation of our company.