Project NameAutomation & Control System for 10 TPD Ethyl Acetate Plant
Case Study: Chemical / Process - Ethyl Acetate
Turnkey Automation for 10 TPD Ethyl Acetate Plant - Siemens S7-1500 Redundant PLC
Full lifecycle automation - Siemens S7-1500 redundant CPU, in-house panel manufacturing, and SCADA deployment - for a 10 TPD ethyl acetate esterification plant delivered for Egyptian Sugar & Integrated Industries.
Project Overview
Project Information
Hive Automation delivered a fully integrated, turnkey automation and control solution for a 10 TPD Ethyl Acetate Plant for Egyptian Sugar & Integrated Industries Company.
The project scope spanned the complete automation lifecycle - from control system engineering and in-house panel manufacturing to PLC and SCADA development, rigorous Factory Acceptance Testing, and site commissioning in Egypt.
The automation system was built on a Siemens S7-1500 redundant CPU (CPU-1513R) platform with ET200SP I/O stations - providing process reliability through CPU redundancy for continuous production without single-point-of-failure risk.
All control panels were designed and fabricated in-house at our Ahmedabad facility to full industry quality and safety standards before shipment.
Project Details
Project Delivery Snapshot
Completion DateOctober 2022
Scope of WorkControl System Engineering | Panel Manufacturing | PLC, HMI & SCADA Programming | Testing | Site Commissioning
LocationEgypt (engineered and manufactured in OEM Place)
System Architecture
Technical Architecture
Siemens S7-1500 redundant CPU (CPU-1513R) with ET200SP distributed I/O stations for reliable continuous process control and fault-tolerant operation.
SCADA system for real-time process monitoring and control, including alarm management, data logging, and trend reporting across the esterification plant.
In-house manufactured control panels with all electrical panels designed, fabricated, and FAT-tested in Ahmedabad before export to Egypt.
Delivery Scope
Scope of Work & Key Deliverables
- Control system engineering - P&ID review, I/O schedule, control philosophy, and FDS documentation
- In-house control panel manufacturing - fabrication of main control panel and MCC
- PLC programming - Siemens S7-1500 (TIA Portal) process logic, PID loops, and safety interlocks
- SCADA system implementation - process mimics, alarm management, data logging, and trend reporting
- In-house Factory Acceptance Testing (FAT) of full system before export
- On-site commissioning at Egyptian Sugar & Integrated Industries facility
Project Impact
Challenge & Outcome
Challenge
Engineering and manufacturing the complete control system in Ahmedabad for a chemical plant being built in Egypt required precise project documentation, export-ready panel manufacturing standards, and a thorough FAT protocol that could substitute for limited on-site development access.
Outcome / Result
The 10 TPD Ethyl Acetate Plant was commissioned for Egyptian Sugar & Integrated Industries in October 2022. The redundant Siemens S7-1500 architecture with in-house manufactured panels enabled full turnkey delivery across 276 I/O points.
Process Coverage
Processes Automated
- Reactor feed flow control for ethanol and acetic acid feed rates using PID-regulated process control loops.
- Reactor temperature and pressure control with condensate return management for stable esterification performance.
- Distillation column control including column pressure, reflux ratio, and product purity control loops.
- Recovery section automation for solvent recovery and product purification sequences.
- Tank farm and utilities management covering feed storage levels, pump sequences, and utility coordination.
- Safety interlocks for high-temperature, high-pressure, and loss-of-flow emergency shutdown conditions.
I/O Summary
I/O Capacity & Configuration
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Frequently Asked Questions
Chemical / Process - Ethyl Acetate Automation Questions, Answered
Yes. The Ethyl Acetate project for Egyptian Sugar & Integrated Industries was fully engineered and manufactured in Ahmedabad, then commissioned on-site in Egypt - a model we use for multiple international chemical plant projects.
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