Accelerating the progress of
renewable fuels with Siemens
automation and instrumentation
National Corn-to-Ethanol Research Center
Pioneering partnership
Biofuels – renewable energy sources
derived from organic material such
as corn – are increasingly viewed
as a cleaner, cheaper, more efficient
alternative to traditional fossil fuels.
For nearly two decades, the National
Corn-to-Ethanol Research Center
(NCERC) at Southern Illinois University
Edwardsville has accelerated the growth
of the biorenewables industry through
the commercialization of advanced
biofuel products and technologies.
Featuring analytical and fermentation
laboratories, an intermediate-level
fermentation suite and a demonstrationscale pilot plant, the center is uniquely
positioned to provide clients with a full
range of commercialization services –
from project design and proof of
concept to validation and scale-up.
Biofuel and bio-based material
producers across the globe make use of
NCERC’s vast resources to evaluate new
ingredients, processes and equipment,
with the ultimate goals of improving
yields and reducing costs.
instrumentation solutions from
Siemens. For well over a decade,
Siemens has partnered with NCERC to
elevate renewable fuel production with
state-of-the-art technology for process
control, simulation and monitoring.
A flexible DCS to meet diverse needs
Originally designed as a small cornto-ethanol production facility, NCERC’s
24,000-square-foot pilot plant has
been modified and upgraded to handle
a much wider variety of biofuels,
biopolymers and specialty chemicals.
At the heart of its operations is the
SIMATIC PCS 7 distributed control
system, which automates, visualizes and
optimizes the core process equipment
for every client. With PCS 7, NCERC has
the flexibility to offer continuous or
batch runs for multiple feedstocks.
PCS 7 has been operating at NCERC
since 2007, when Siemens made a
formal donation of the DCS. The center
has since modernized to PCS 7 Version 9
to take advantage of intuitive operator
tools such as alarm management and
interlock visualization. Their installation
includes SIMATIC PLCs (S7-1200
To ensure the success of every project,
NCERC provides clients with access to a
world-renowned staff of experienced
engineers, operators and scientists –
and to facilities equipped with leadingedge process automation and
The SIMATIC PCS distributed control system automates, visualizes and optimizes the core
process equipment for every NCERC client.
usa.siemens.com/process
controllers and S7-1500 controllers with
PROFINET) as well as SIMATIC AS 410
controllers connected to SIMATIC ET200
distributed IO.
NCERC also utilizes SIMATIC BATCH addon software for batch automation, which
allows them to configure, plan, control
and log batch processes directly in PCS 7,
as well as the PCS 7 Process Historian
server solution for centralized archiving
and reporting of all batch data, process
values, tags and alarms in real time.
With their modular approach to PCS 7
configuration, NCERC is able to change
campaigns quickly and with minimal
effort – making it possible to support
a large number of clients with diverse
needs. “We depend on PCS 7 with BATCH
and Process Historian to gather all
process data and export it directly to our
clients,” says John Caupert, Executive
Director of NCERC. “PCS 7 enables us to
provide every client with the information
they need to make important decisions
about how to move forward with their
project – whether the campaign lasts
three days or nine months.”
Real-world experience with
simulation
As the only organization in the world
to offer both classroom training and
hands-on instruction specific to the
biorenewables industry, NCERC plays a
key role in filling the growing need
for qualified personnel to operate and
manage biofuel refineries. Each year
the center hosts dozens of motivated
college students, interns and
apprentices interested in learning
how to operate a process plant. The
centerpiece of this dynamic workforce
education program is the SIMIT
Simulation Platform for PCS 7.
SIMIT creates a virtual model of a plant’s
original PCS 7 control screens, making it
possible to train operators on a variety
of procedures and critical scenarios –
without disrupting production or
endangering worker safety. NCERC
uses SIMIT to develop fully functional
replicas of the DCS operating in their
pilot plant. The software is downloaded
to a SIMIT Virtual Controller, which
emulates a physical controller and
eliminates the need for additional
hardware. NCERC leverages two unique
features of the Virtual Controller to
enhance the effectiveness of training:
Virtual Time Management, which
allows users to speed up or slow down
simulations, and Snapshots, which
save current controller and simulation
states to be re-loaded for future
training sessions.
“SIMIT has proven very cost-effective in
training students and interns as well as
new part-time and full-time employees,”
says Caupert. “When we hire someone
with little to no experience, we use the
software as part of their onboarding
process to familiarize them with PCS 7 –
how to turn on a pump, how to trend,
how to detect whether something
is going wrong. SIMIT really helps
to optimize the NCERC workforce
by familiarizing them with the
important control system terminology
and technology.”
Additionally, as NCERC uses the
Advanced Process Library (APL) feature
of PCS 7, they benefit from tight
integration between PCS 7 and SIMIT.
APL includes pre-configured function
NCERC trains students and new hires using the SIMIT Simulation Platform, which creates a virtual model of a plant’s original PCS control screens.
blocks, faceplates and block icons with
corresponding templates in SIMIT that
accept the outputs from the control
system with no manual adaptions
necessary. The APL upgrade is paying
dividends for NCERC since they can
easily test potential changes to the
physical plant with SIMIT before putting
anything into production – resulting in
“right the first time” campaigns that
save time and money.
Intelligent, integrated
instrumentation
NCERC relies on Siemens as a trusted
technology supplier for more than just
process control and simulation. Today,
there are more than 3,300 data points
throughout NCERC’s pilot plant –
including a variety of intelligent
Siemens field instruments. Designed for
full integration into PCS 7, these devices
oversee the health of each product
stream and transmit all process data
seamlessly back to the control system.
As fermentation is the most common
method for producing biofuels, the
plant operates four 6,000-gallon,
jacketed fermenters with eductor
pumps for solids sweeping. The tanks,
eductors and other key points in the
fermentation process are monitored by
SITRANS FC Coriolis mass flow meters,
SITRANS P pressure transmitters and
SITRANS LR radar level indicators, with
SIPART valve positioners controlling
pneumatic valves.
SITRANS P pressure transmitter monitoring the pressure in an eductor.
Many of the Siemens instruments in use
have built-in PROFIBUS PA capabilities
across a digital network, allowing for
high-speed, two-wire communication
of not only measured process values,
but also cost-saving diagnostic and
preventative maintenance information.
The SIMATIC PDM (Process Device
Manager) application integrated into
PCS 7 collects this valuable data from
all PA- and HART-enabled field devices
in the plant to support NCERC operators
in minimizing plant downtime –
while additionally simplifying device
configuration, parameter assignment,
commissioning and calibration. This
centralized asset management tool
allows NCERC to continually interrogate
their instrumentation via the PCS 7 HMI
screen, ensuring consistently accurate
and high-quality production runs. PDM
also works with NCERC’s smart electrical
devices from Siemens, including the
SIPART valve positioner on a carbon dioxide scrubber.
SIMOCODE Pro motor management
system and SINAMICS variable
frequency drives.
To further drive innovation, the
center has incorporated Siemens gas
analytics products into the facility.
The NCERC team is not afraid to take
on a challenge – so when a client
asked about evaluating a biochemical
application, NCERC added a bank of
OXYMAT and ULTRAMAT gas analyzers
for measuring oxygen and CO2 levels
in the fermentation process. The client
production runs led to the results they
had hoped for as they moved to fullscale production.
NCERC appreciates the versatility and
sophistication of Siemens process
automation and instrumentation,
motors and drives, and analytics – but
also the technical expertise that comes
with it. According to Caupert, “The level
of support we receive both directly from
Siemens and from our local Siemens
distributor is consistently high. They are
very responsive to our needs and their
deep knowledge means that everything
will be up and running quickly, which
is particularly reassuring when an
installation is complicated or our staff
is too busy. We like to think of Siemens
support as the ‘ace in our pocket.’”
Fueling the future of an industry
To date, NCERC has assisted in the
commercialization of more than 70
biofuel products and technologies
generating nearly $6 billion in revenue,
and is responsible for the direct
creation of 5,000 jobs. The continued
technology partnership between NCERC
and Siemens ensures an ever-brighter
future for the biorenewables industry.
SITRANS FC Coriolis flow meter installed on a
fermenter tank.
NCERC added a bank of OXYMAT and ULTRAMAT gas analyzers for measuring oxygen levels in the
fermentation process.
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Norcross, GA
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© 2020 Siemens Industry, Inc.
All photos courtesy of the National
Corn-to-Ethanol Research Center.
NCERC’s installation includes SIMATIC PLCs.
Level monitoring on the fermenters is carried
out by SITRANS LR radar level indicators.
The technical data presented in this document is based on an actual case or
on as-designed parameters, and therefore should not be relied upon for any
specific application and does not constitute a performance guarantee for any
projects. Actual results are dependent on variable conditions. Accordingly,
Siemens does not make representations, warranties, or assurances as to the
accuracy, currency or completeness of the content contained herein. If
requested, we will provide specific technical data or specifications with
respect to any customer’s particular applications. Our company is constantly
involved in engineering and development. For that reason, we reserve the
right to modify, at any time, the technology and product specifications
contained herein.
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