-Sulfuric acid is the largest-volume industrial chemical produced in the world. -Concentrated sulfuric acid (93-98 %) is used in the manufacture of fertilizers, explosives, dyes, metal and petroleum products. -The production of sulphuric acid is a delicate process that must be completed in a safe and efficient manner. -Automation needs to be carefully designed to control the different stages of the process as per stringent parameters, and to provide continuous monitoring for better management of the plant.

3. THE LEADING EDGE
Messung is a Leading Industrial Technology Expert in India, seeking to be a dynamic organisation driven
by pioneering zeal, a passion for new ideas and pursuit for excellence to bring progressive solutions that
deliver the competitive edge for customers. Continuing its legacy of innovations in Industrial
Automation, the Messung Group has diversified into various businesses.
Messung empowers businesses and industries with the foremost technologies and high performance
products backed by deep domain knowledge and reliable support.
We work closely with customers, understand their needs and challenges; identifying opportunities and
technologies to bring the most relevant solutions that contribute to their success. Even in business, our
social consciousness and sense of environmental responsibility remain firm and uncompromising.
Our competencies are as diverse as our portfolio - which today spans the fields of Automation &
Controls, Electrical Engineering and Workplace Technology. In these, and many more emerging fields,
we are constantly expanding and enhancing our market expertise to achieve - and deliver - the Leading
Edge in the Food & Beverage (F&B) industry.

4. SULPHURIC ACID PLANT AUTOMATION WITH
MESSUNG'S NX-ERA SERIES
(A CASE STUDY)
www.messungautomation.co.in

5. www.messungautomation.co.in
ABOUT SULPHURIC ACID
PRODUCTION
• Sulfuric acid is the largest-volume industrial chemical
produced in the world.
• Concentrated sulfuric acid (93-98 %) is used in the
manufacture of fertilizers, explosives, dyes, metal and
petroleum products.
• The production of sulphuric acid is a delicate process
that must be completed in a safe and efficient manner.
• Automation needs to be carefully designed to control
the different stages of the process as per stringent
parameters, and to provide continuous monitoring for
better management of the plant.

6. THE CUSTOMER
www.messungautomation.co.in
An agri-input Company focused on manufacturing, distribution and retailing of a wide
range of crop yield enhancing and protection products.
Product portfolio includes crop protection, crop nutrients, seeds, veterinary feed
supplements.
To secure supply of sulphuric acid, one of their key ingredients, they ventured into
manufacturing of sulphuric acid.
They produce sulphuric acid as well as other sulphuric acid-based chemicals like LABSA,
DMS and Oleum that have wider applications across industries like agrochemicals,
veterinary feed supplements, pharmaceuticals, synthetic detergents, etc.

7. www.messungautomation.co.in
KEY FEATURES OF THE SULPHURIC
ACID MANUFACTURING PLANT:
The raw material for sulphuric acid manufacture is clean SO2 gas.
It comes from
(i) burning molten by-product sulphur
(ii) roasting or smelting metal sulphide concentrates, and
(iii) decomposing contaminated organic chemical process
sulphuric acid catalyst.

8. KEY SOLUTION GOALS:
www.messungautomation.co.in
1. To produce Sulphuric Acid by controlling
the boiler pressure, steam flow and acid
level in the process tanks using
• NX-ERA NX3004 PLC
• NX-ERA JET I/O Modules
• 1500 Tags SCADA
2. To develop a logic to measure Pressures,
Temperatures, Levels, Flow and SO2
Analysers at various stages of process.
3. To control the pumps and monitor the RUN/TRIP status
4. Also, to control the Steam pressure and drum level of a
boiler PLC, SO2 concentration and Tank temperature
using PID controllers in PLC.
5. To measure flow and calculate the inlet and outlet
steam flow
6. To develop a logic to raise alarms, generate reports
and trends in SCADA.

9. www.messungautomation.co.in
THE SOLUTION:
Messung engineers studied the plant and its requirements, and came up with
a cost-efficient solution consisting of:
• 2 nos. of SCADA system
• MODBUS RTU communication for Thermocouple Sensors
• PID controllers 10 nos.

10. The Programmable Logic Controller utilised for this sulphuric acid plant was
the NX-ERA JET PLC.
It is a high-performance CPU for medium-to-small-size Machine and Process
applications.
Can be also combined with the main products of the series, such as CPUs,
backplane racks, communication and fieldbus modules.
Turns into a selection of input and output modules where requirements such as
hot swapping and advanced functionalities such as OTD (One Touch Diag) and
EPS (Easy Plug System) are no longer necessary.
The result is a group of compact and economical modules capable of providing
highly competitive solutions, with no loss of electrical characteristics such as
isolation, performance and accuracy.
www.messungautomation.co.in
POWERING THE SYSTEM: NX-ERA JET PLC

11. • Integrated power supply & I/O points
• Reliable and compact I/O modules
• Embedded I/Os - 14 DI/10 DO
• Encoder interface
• Stepper motor interface
• Multiprotocol support
• Expandable up to 184 I/O points
• For more flexibility and agility in the development of applications,
NX-ERA Jet counts on WEBSERVER
• Offers high speed counters and PTO for simple motion applications
www.messungautomation.co.in
NX-ERA JET PLC FEATURES

12. www.messungautomation.co.in
SCADA systems (2 nos):
Enables the customer to obtain information
leading to better process traceability, and
storage of performance data which is
essential to correct quality and process
issues. SCADA is programmed to raise
alarms, generate reports and trends.
PID Controllers (10 nos):
Automatically regulate process parameters
such as boiler pressure, steam flow and
acid level, etc., and keep the actual output
as close to the target/setpoint output as
possible.
BENEFITS FOR THE CUSTOMER
Programming and configuration
environment based on IEC 61131-3
standard:
The software has resources for all stages of
the life cycle of an automation and process
control project, ensuring efficiency
throughout the development,
commissioning and maintenance.

13. www.messungautomation.co.in
MODBUS RTU Communication for
Thermocouple Sensors:
• Standard Modbus-RTU protocol with high-
speed RS-485 communication
• Thermocouple linearization and sensor
break detection ensure reliable
measurements
• Self-calibration lowers maintenance costs by
reducing periodic manual calibration checks
• Software Watchdog timers provide a
configurable failsafe output state for use
when host I/O communication is lost
• Self-diagnostics monitor microcontroller
activity to detect operational failures (lock-
up) and execute a reset to restore
communication.
BENEFITS FOR THE CUSTOMER
System supplied at
affordable price

14. Production of sulphuric acid has increased since the
automation system was installed.
The client is able to produce high-quality sulphuric
acid with almost negligible impurities.
Also, the client is able to access the status of different
parts and processes of the plant on a single screen so
he can view and monitor the whole process easily.
The client can also view the history and trends of all
parameters so as to make improvements, pre-empt
problems, and ensure safe, smooth, reliable and
profitable operations consistently.
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THE OUTCOME:

15. ABOUT
www.messungautomation.co.in
If you're looking for best-in-class PLCs and automation system components to build a future-ready
system, who better than Messung, leading PLC manufacturer in India.
Messung Industrial Automation & Control division also offers PLC panels for remote control,
SCADA applications, Variable Frequency Drives (VFDs) and servo drives.
Messung’s programmable controllers, Remote I/Os, HMIs and SCADA solutions have
enabled industries, OEMs and automation system integrators achieve top-of-the-line performance
and efficiencies.
Messung’s Process Automation, Servo & Motion Control Automation, and General
Purpose Automation solutions have proven themselves across the gamut of industries with
their flexibility, efficiency and long service life.

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THANK YOU
Contact us
MESSUNG SYSTEMS PVT. LTD.
501, 502 & 503 Lunkad Sky Vista, Viman Nagar, Pune, India - 411 014.
T: +91 20 6649 2800 | E: sales@messung.com