Soft Sensing
Maximize quality and output with robust online process models
Using available process data virtual analyzers calculate unmeasured parameters for closed loop controls.
Helping operation managers maintain realtime optimization
Virtual models based on historical data convert measured parameters such as temperature, pressure, and flow rate to rapidly predict variations in production qualities. Output from these models can be used in closed loop control systems to optimize production.
Directly see what happens in the plant
Soft sensors provide real-time feedback on your processes without investing in expensive online analyzers or waiting hours or days for manual laboratory test results
Improve asset performance
Process parameters calculated by soft sensors allow operators to maximize output by moving the average operating point much closer to operational limits. Higher impurity levels, within the operating limits, have a positive impact on the energy consumption.
Realtime monitoring of process health
Softsensors are used to compute, in real time, fouling in reactors and heat exchangers. This equipment health monitor reduces the risk for outages significantly. Running with equipment with less fouling will save millions per year on energy.
Realize significant cost savings
With the use of soft sensors based on good models and real time data, robust virtual sensors can be built in a cost-effective way to improve process controls.
Revamp of Inferential Models for Distillation Column
Minimize energy consumption
A soft sensor to predict sulfur dew point at each stage of a Claus reactor was developed based on known factors and then fed into an APC system to minimize energy use and maximize conversion.
Sulfur Dew Point Inferentials
Optimize product concentrations
Even for very slow process dynamics, a soft sensor/virtual analyzer can be developed to improve control of a property, and then used to optimize production output in conjunction with an APC system.
Controlling Properties with Very Slow Dynamics Using Virtual Analyzers and Step Response Models
Soft sensing end-to-end value
50%
.. and more reduction of product quality variations
10%
energy (steam) reduction in distillation columns when soft sensors used in combination with APC perform accurate quality control.
10%
reduction of emissions (CO2, NOx, Cl,..) due to optimal combustion control (furnaces/boilers/…) powered by soft sensors
> 1M US$
energy savings when fouling of reactors and heat exchangers is detected at an early stage.
Other services
Advanced Process Control
APC systems maintain your operation at the optimal operating point. APC improves product yield, maximizes throughput, increases your plant’s efficiency under varying feedstock quality and operating conditions.
Process Modeling
Turnkey models provide in-depth intelligence for improved analysis, troubleshooting, and operation
Emissions Monitoring
Meet environmental goals by tracking and reporting emissions & targets.
Machine Learning & Data Science
Data-driven models identify hidden patterns that can lead to increased quality and predictability.
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