Advanced Process Control
Optimize your plant’s efficiency, product quality, and yield with APC
Advanced control reduces variations and maintains your plant at the optimal operating point.
Optimize product yield and quality
Advanced Process Control systems maintain your operation at the optimal operating point by adjusting the key setpoints in real time to improve product yield, and maximize throughput. Increase your plant’s efficiency, reliability, and productivity for varying feedstock quality and operating conditions.
Reduce variations in product quality
Automatically calculate product quality minute by minute and adjust key process parameters to maintain the optimal quality at all times.
Increase profitability by optimizing yields
An APC application customized to your operation can run parameters closer to the limits for maximum production rate, without affecting quality.
Reduce risk of human error
APC increases automation and reduces risk by reducing the chance for operator error, resulting in fewer unplanned shutdowns.
Meet ever-tightening environmental constraints
Reduce emissions of CO2, SO2, NOx, nitrous oxide, methane, and other pollutants by minimizing fuel consumption and controlling methane slip.
Reduction of CO2 emissions by implementing MPC in an ammonia plant
Optimize steam network power generation
Multivariable controller configuration was implemented on cogeneration boilers, steam turbines and auxiliary boilers, to minimize fuel consumption and optimize both steam production & power generation.
Steam network optimisation at Raffineria di Milazzo achieves significant savings
Reduce variability in VGO cloud point
An inferential expression for the cloud point was developed and used in an Advanced Process Control application to maximize VGO product while keeping its cloud point within specification.
Vacuum Gasoil Cloud Point Model Predictive Controller
Maximize the yield of more valuable distillates
Implementation of APC on a hydrocracker unit delivered both tangible benefits, in terms of a significant increase in the yield of more valuable products, and intangible, in terms of stability.
Implementing Advanced Process Control on Hydrocracker Unit
Increase in throughput
Typical pay-back time for an APC implementation
CO2 emission reduction.
PID Control & Tuning
Optimal base layer control starts with a good control design. Then tune all the PID loops such that every single loop in your plant is in auto mode and keeps all your process parameters at the desired setpoint 24/7.
Models based on historical data convert measurements such as temperature, pressure and flow rate to predict variations in production qualities. Softsensor output are used in control to optimize production.
Generate benefits on top of an advanced process control application, by capturing the non-linearities of the process and determining the most optimal operating point, in closed loop.
Benchmark your alarm situation and then develop an alarm management philosophy document tailored from best-practice templates with buy-in from process engineers, operators, and controls staff.