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Customer references: NAPCON

Case Neste: NAPCON Informer Revolutionizes Production Tracking

Neste had, for some years, utilized their own system for production tracking, where production data was recorded manually into separate Microsoft Excel files. However, the Excel-supported system soon proved to be extremely arduous and time-consuming to the personnel maintaining it. It was also felt that the system was not cost-effective. Neste turned to NAPCON requesting them to provide new software, which would improve and stabilize their production tracking system.

"NAPCON Informer enables us to work more efficiently - after napconizing our production tracking system, we have recorded a 78% decrease in working hours to date. It is extremely important to have a production tracking system that is user friendly, trustworthy and flexible."

Markko Rajatora
Manager of Decision Support Systems and Processes at Neste

To meet Neste’s demands, the new production tracking system had to include a web-based, graphical user interface, certain data treatment functionalities, production tracking calculations, a stable database, and a reporting tool. NAPCON Informer met these requirements perfectly, providing Neste with an easy-to-use system, that is both accurate and stable. Most importantly, the new system enables personnel to perform the same production tracking tasks in a matter of hours, rather than a matter of days – decreasing resources required for production tracking by an incredible 78%.

To achieve these results, Neste Engineering Solutions delivered:

  • NAPCON Informer
  • NAPCON Analytics 

Key customer benefits

  • Provided an integrated, easy-to-use system that is both accurate and robust
  • People able to perform the same tasks than earlier in a matter of hours rather than days.

Case Forchem: 17% Productivity Increase

Forchem Oy owns and operates a world-scale tall oil distillation plant in Rauma, on the Western coast of Finland. The plant has an annual capacity of 200 000 tons and produces its main products Tall Oil Rosin (TOR) and Tall Oil Fatty Acid (TOFA) from a variety of crude tall oils, using a distillation technology developed by Neste Engineering Solutions, known as ArxPinus.

The tall oil distillation process is demanding due to the overlapping boiling ranges and thermal sensitivity of tall oil compounds. However, such biochemical processes often offer opportunities for substantial improvement in terms of production growth.

"During the NAPCON Performance Analysis and the subsequent NAPCON implementation, we became convinced of Neste Engineering Solutions’ expertise to carry out the production optimization with NAPCON Controller. We are very excited about the great results and the attractive payback of the investment in NAPCON."

Risto Näsi
CEO of Forchem

In the spring of 2015, Forchem began a NAPCON Performance Analysis project with Neste Engineering Solutions, aiming to quantify the possible benefits of Model Predictive Control (MPC) for their production process. NAPCON team reviewed Forchem’s production process in areas of instrumentation, online analyzers and process control. The two-month analysis demonstrated a feasible production increase of 9%, achievable by simple means and manual operations. In addition, the Performance Analysis indicated, that another 8% productivity increase could be gained through the implementation of MPC.

In September 2015, inspired by the positive results of the Performance Analysis, Forchem ordered an implementation of MPC from NAPCON. In March 2016, their TOFA production was controlled and maximized with NAPCON Controller, followed two months later by a similar napconization of their TOR production. In June 2016, NAPCON guarantee tests verified, that  the  production increase of 8% had materialized.

To achieve these results, Neste Engineering Solutions delivered:

  • Performance Analysis
  • NAPCON Controller (MPC software package)
  • Full implementation end engineering services
  • Client training

Key customer benefits

  • 17% sustainable production increase
  • 9% production increase by manual control
  • 8% additional production increase after implementing NAPCON Controller
  • Full turn-key implementation of MPC in 8 months, for two production lines

Project highlights 

  • 2 month delivery time for Performance Analysis
  • Full implementation in 8 months
  • 100% customer satisfaction, measured by Neste Engineering Solutions’ quality management system procedure