Understanding the Fundamentals of Advanced Process Control

As a matter of fact, Advanced Process Control (APC) is increasingly powerful and effective, but suppliers and end users will attest to the fact that its implementation and maintenance is not a walk in the park and needs to be simplified.

What is Advanced Process control?

APC is basically as control and optimization technology which brings measurable and sustainable enhancements in production yield and goes a long way in saving energy as an added value. Today, APC has proven to be a standard solution for organizations that want to realize stable control processes.

APC typically consist of Soft Sensors or Model Predictive Control (MPC) which uses estimated product properties and multivariate analysis in real-time to enhance exceptional stability.

When this happens, the information gathered is used to create a stable ground for process control without necessarily requiring user interaction.

Benefits of APC

When APC was first introduced over three decades ago, its main aim was to help petrochemicals and refineries stabilize their chemical processes. Today, this narrative has changed. It now presents a number of benefits to different organizations which include;

Increase in production

Research shows that APC projects can increase production by 3-5%. This is because it reduces the variability in the process and operates closer to the limits; thus bottlenecking the entire process or part of it; thus allowing for increased production rates.

Energy savings

APC is widely known thanks to its ability to save energy. There are proven reports that a proper implementation of Advanced Process Control van saves 3-15% of energy depending on the current operations and processes in your organization.

APC systems are specially designed to efficiently manage utility systems by creating a perfect match between steam production and the needs of a process. This reduces pressure let-downs and eliminates vented steam on site. Some companies have reported a whopping 90% reduction of vented steam thanks to the proper use of APC.  Additionally, APC can be used for energy production optimization as soon as steam header pressures are stabilized.

Quality improvements

Using APC can reduce quality variability in product quality. This eliminates the need to sell some products – such as specialty chemicals and polymers in varying prices based on the quality of the batch produced.

Yield improvements

By using APC, some companies have reported a yield improvement of up to 2%. Usually, this is achieved through the optimization of the separation portion and/or the reactor section of the process.

The most successful companies today have deviated from traditional methods to a more sophisticated technology through the integration of Advanced Process Control. Find more information about it, and if for any reason you fail to access some sites for any reason, use VPN Windows 8 for unrestricted access. APC has saved businesses across the world, and it will save yours as long as you implement it correctly.