Fertilizers
Improving Fertilizer Operations with Sigmafine
Sigmafine is a comprehensive, model-based solution with advanced calculations that, supports fertilizer operations and its supply chain, including plants with limited instrumentation.
A conditioned data-set facilitates improved management of inventories, giving insight on semi-finished and finished product material qualities avoiding out-of-spec products and minimizing reprocessing costs.
The highly competitive fertilizer industry often suppresses the product’s value, thus, it is critical that plants consistently achieve high asset utilization with maximized efficiency. To do so, top-tier fertilizer producers are demanding that their process data becomes more consistent, accurate, and accessible from start to finish; to do this they are turning to Sigmafine.
Production Accounting
Validated and reconciled data is combined with material information to provide production and consumption reports, inventory stocks, site balance by material, and plant/process unit yields.
Yield Accounting
Sigmafine supports accountants by identifying inconsistencies, bad values, and gross errors which can be traced back to individual process units.
Composition Tracking
Up-to-date estimates of materials stocked in inventories or fed to process units. Estimates can be calculated daily or even hourly, empowering operations teams to fix production deviations quickly.
Quality Tracking
Allow users to balance processes where a mass balance is not enough to determine the amounts of concentrated and purified components.
Performance Monitoring
Early detection of process deviations and measurement errors allowing users to more accurately estimate, monitor, and control site losses.
Inter-Company Material Exchanges
Modeling all inter-company material transfers and inventory measurements to provide the ERP system a consistent, daily balance of all productions and consumptions.
Near Real-Time Energy Management
Accurately monitoring energy-intensive equipment is critical to improving usage and decreasing emissions.
Compliance Reporting
A single source of truth, allowing users to automatically transfer data to business systems and databases.
Supported Applications
- Production and yield accounting
- Composition and quality tracking of Nitrogen, Potassium & Sulphur content
- Movement management
- Energy management and emissions monitoring
- Performance Monitoring of s efficiencies, process duty, energy consumption,
heat losses, emission losses, and more.
Integrating Sigmafine with SAP
Sigmafine comes with an integration framework component, allowing data to interface with external systems, including SAP. The most common SAP modules integrated with Sigmafine are:
- PPPI: Post reconciled figures of productions, consumptions, and losses compared with planned/business figures
- SD: Download inbound raw material receipts and outbound final product shipments from SAP
- WM/MM: Align physical or logical SAP inventories with Sigmafine inventories
The Benefits of Improved Data Quality
Improved data quality in the fertilizers industry is primarily associated with:
- Validating and automating production accounting
- Validating auditable estimates of raw materials, intermediates, and product inventories
- Validating KPIs for improved process control and system optimization
The Business Impact of Implementing Sigmafine
Customers who have implemented Sigmafine have achieved:
- Daily production accounting automation
- Equipment & site-wide performance monitoring
- Yield accounting
- Loss monitoring
- Results distribution throughout the organization
- Improved production planning and logistics
On top of delivering these benefits that drive operational excellence, it’s been estimated that Sigmafine has a payback period of less than 6 months – a critical value proposition for customers who are tightening resources to stay competitive.
Resources
ICL Rotem tests Sigmafine advanced analytics
Sigmafine extended capabilities were recently evaluated in the context of a proof of concept project to perform the daily mass & component balance; monitor the data quality of the meters, estimate material type and chemical properties of unmeasured inventories and flows. Hear about some of the findings in this presentation.
Quality Tracking for Fertilizer Process Plants
This webinar will discuss how Pimsoft’s Sigmafine Quality Tracking Analysis can deliver significant improvements in estimating and monitoring material qualities, from raw materials to finished products.
Material Tracking for NPK Facilities
Learn how Sigmafine tracks and traces raw materials throughout fertilizer production to monitor raw material costs within inventories and products.
Fertilizers
Improving Fertilizer Operations with Sigmafine
Sigmafine is a comprehensive, model-based solution with advanced calculations that, supports fertilizer operations and its supply chain, including plants with limited instrumentation.
Veletia Moodie
Industry Principal for Fertilizers
Pimsoft, S.p.A.
Milan