DENIOS meets CHT Group: trend-setting, modular chemical storage.

Chemical companies are confronted with complex legal requirements when it comes to storing large quantities of various hazardous substances. Depending on the characteristics and quantity, elaborate protective measures are necessary. In their Dusslingen plant near Tübingen, the CHT Group produces 50,000 tonnes of special chemicals annually for customers all over the world.? Over time the products have become increasingly customer-specific and the regulations more complex, so the storage must be designed flexible and efficient.?

To accomplish this task, Günther Sch?tzle, Manager Plant Engineering Production & Logistics at CHT Germany GmbH, relied on a modular concept with DENIOS. He decided against an industry-standard way with a large warehouse and open shelf racks. "They are way too inflexible, they cost too much and require huge customized regulatory compliance and therefore need a lot of time to plan and build." he concludes.?

After a one-year technical and commercial planning phase, CHT and DENIOS started the joint project, which includes the installation of 30 storage modules and in addition the digital remote monitoring of the plant data. Together with the industrial construction specialist Company4, five key points were defined: safety, flexibility, modularity, energy self-sufficiency, digitalisation.

Maximum space and flexibility of all storage modules.

Each storage module is separately equipped for fire protection and assessed according to TRGS 510. These are F 90/REI 90 fire protection warehouses and insulated warehouses with fire protection panels, which have been placed on a special concrete slab as a liquid-tight retention bassin to save space. The alternating installation of the two module types allows efficient use of space to store twice as many pallets in compliance with regulations.

Sch?tzle particularly emphasises the additional flexibility of the new hazardous materials warehouse: "Each storage module is a separate storage area according to hazardous materials legislation. We can change the storage classes per module at any time. " This is a highly flexible concept and gives us the necessary freedom to equip the warehouse with all the storage classes that the German Technical Rules for Hazardous Substances (Technische Regeln für Gefahrstoffe, TRGS 510) recognises."

A digital network and alarm in real time.?

For each storage unit, we have a general building authority approval from DIBt - as proof of suitability for water protection in accordance with German AwSV and for fire protection suitability. In addition, each system is equipped with the digital leakage warning system SpillGuard? connect, which transmits the data via narrowband IoT to a DENIOS cloud application, where it is made available for retrieval by the customer. CHT converts the cloud data into an MTP data format* and uses it in its own process control system for condition monitoring.

Reviewed, approved and implemented in record time.?

The overall system offers maximum safety, which not only impressed the TüV (Technical Inspection Agency Germany). The responsible approval authority for the construction project also assessed the safety concept as trend-setting for the chemical industry and approved the project within record time.?During the construction period, CHT was already supplied by DENIOS with the first storage modules for uninterrupted interim storage. The final delivery of the remaining systems and the final assembly took place smoothly and quickly beginning of November 2021. The 30 storage modules were assembled within three weeks.?

Subsequently, the spanning steel structure for the roofing was erected, the electrical supply for all storage systems and the data networking with the in-house process control system were ensured and the stationary extinguishing system was installed. A photovoltaic system on the roof ensures the energy self-sufficient operation of the entire facility.

Benefits with a showcase character

Thanks to the large number of separate storage modules, CHT can now react immediately to any storage requirement. Substance-related quantity thresholds are much easier to meet in the smaller storage units and adjustments due to fluctuating demand can be realised much quicker. "The benefits are absolutely convincing!" states Sch?tzle. From his point of view, the project is a showcase for the entire chemical industry and serves to secure the industrial locations in Europe.

Note: CHT synergised with this construction project with an IIoT/automation project involving the innovative integration of manufacturer-provided signal and control data into the customer's process control system. As one component, the signal data of the DENIOS SpillGuard? connect leakage warning system is merged with data streams of other plant components by using MTP data formats on OPC-UA-capable process data systems, independent of the manufacturer.?

*MTP = Module Type Package according to VDI 2658. A detailed project report follows separately.?