Case Study
Streamline - Turning Pollution Into Gold
Leveraging IT/OT Convergence Technology to Create Sustainable Solutions
Hydrogen sulfide (H2S) is a flammable, colorless gas found in oil and gas refineries and other industries. It is toxic, affecting the central nervous system and respiration, and can also cause corrosion, threatening both safety and infrastructure.
Streamline Innovations developed a redox H2S and acid gas treatment system that removes H2S and converts it into agricultural-grade sulfur for use as fertilizer. To efficiently control this process, Streamline needed an automation platform to handle calculations and remote control, as traditional methods require constant manual monitoring.
Moxa’s IT-OT converged solution, using Inductive Automation’s Ignition SCADA software and Python scripts for machine learning, enabled Streamline to automate data collection, control, and process stabilization, overcoming the challenges of H2S treatment and improving operational efficiency.
Client
| Industry: | Oil & Gas |
| Headquarters: | San Antonio, Texas |
| Website: | streamlineinnovations.com |
| Founded in: | 2016 |
Operational Challenges
Hydrogen sulfide (H2S) concentrations and flow rates can fluctuate significantly in natural gas, requiring constant monitoring to ensure the safety and efficiency of treatment systems.
Traditionally, this task has been managed by experts on-site, who must frequently check and adjust H2S levels every few minutes. However, it is often impractical to have these specialists present at natural gas facilities due to their remote locations, staffing limitations, or logistical challenges.
Regular travel to these sites can be costly and time-consuming, making it difficult to maintain consistent, real-time oversight.
Streamline Innovations faced a significant challenge in replacing the "expert in the field" with a suitable technological solution.
Standard Programmable Logic Controllers (PLCs) were insufficient for this task, as they lacked the capability to perform the complex calculations required for accurate control of the redox process and to model dynamic variables, such as fluctuating H2S concentrations and flow rates. The existing PLCs couldn’t handle this level of complexity, and Streamline needed a more advanced solution to ensure precision in real-time monitoring and control.
To bridge this gap, Streamline considered using a customized OPC server to facilitate communication between devices and a cloud server. However, this solution raised concerns about security.
The OPC server lacked proper authentication and protection, leaving the system vulnerable to potential cyber threats. Without the necessary security measures in place, the system was at risk, not only in terms of data integrity but also in ensuring the overall safety and reliability of the treatment process.
Thus, Streamline Innovations needed a more robust, secure automation platform capable of handling advanced control, providing secure remote monitoring, and reducing the reliance on on-site expertise.
Solution
Moxa’s rugged computers are designed to thrive in harsh environments, with Class I, Div. 2 certification for oil-and-gas applications, making them ideal for preprocessing motor vibration data in such challenging conditions.
These computers handle vast quantities of sub-second data, ensuring continuous and reliable operation. In the event of external connectivity issues, Moxa’s systems can autonomously record data, guaranteeing maximum uptime for operational technology (OT) equipment.
In addition to their rugged design and reliable connectivity, Moxa’s computers run cloud-based SCADA software, enabling Streamline’s engineers to remotely access real-time monitoring and control from anywhere.
The system also integrates Python scripts connected to the U.S. National Weather Service, allowing Streamline to leverage machine learning to predict temperature and humidity levels—critical factors that influence sulfur production. This IT/OT convergence ensures a seamless, efficient, and data-driven approach to optimizing the redox process.
“We needed a system that was robust enough, can do the calculations, provide good uptime, and is reasonable priced— and that’s why we chose Moxa.”
Peter Photos, Chief Technology Officer at Streamline Innovations
Results
1.
Improved Operational Performance: By integrating machine learning and model-predictive control, Streamline Innovations is now able to address key performance indicators (KPIs) that were previously challenging to monitor and optimize, enhancing overall process efficiency and precision.
2.
Cost Savings: The implementation of this solution resulted in a 75% reduction in labor costs and significantly improved equipment uptime, minimizing the need for on-site personnel and optimizing operational resources.
3.
Data-Driven Innovation: The adoption of advanced data analytics has enabled Streamline to unveil a revolutionary H2S removal technology, enhancing their sulfur recovery process and positioning the company at the forefront of innovation in environmental sustainability.
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