Advanced process control (APC) is a process control and optimization technology that takes into account the multivariable interactive nature of process units to reduce variability and drive the process to an optimum. So, the goal of well-designed advanced process control (APC) strategy in the chemical industry is very simple: to maximize margins while meeting customer expectations by moving the process to a more optimal point. This results in consistently operating the unit close to the maximum possible profit day in and day out, safely and reliably. The following criteria can quantify the benefits associated with an advanced process control (APC) process:
Production increase: Advanced process control (APC) projects have proven to increase capacity minimum by 2% to 4%.
Energy savings: Energy savings from advanced process control (APC) project have been reported to be in the range of 2% to 10% depending on the process and current operations.
Quality improvements: It’s important to reduce variability in the final product quality. Many companies report a reduction in standard deviation of product qualities of up to 50% using advanced process control (APC).
Yield improvement: Many organizations experience a yield improvement of 2% through advanced process control (APC) deployments, typically achieved by optimizing the reactor temperature, ratio of feed to the catalyst, the separation portion such as impurities od desired products.
Grade transition time optimization: Through the advanced process control (APC) system, it is possible to “bust the production wheel” and produce grades when they are in demand while minimizing the time when the low-value transition products are produced. It’s common to achieve 20% to 50% reduction in grade transition time using the appropriate advanced process control (APC) system.
Recycle ratios optimization: The good advanced process control (APC) system strategy allows for optimizing the feed-to-recycle ratio to maximize throughput and/or maintain quality at specifications and/or to satisfy equipment constraints.
Emissions reduction: The implementation of advanced process control (APC) system can help control environmental constraints. By using this process, the emission equipment (such as furnaces and boilers) is possible to operate closer to the emissions NOx, SOx, COx and other limits without violating them.
Exploiting ambient temperature effects: advanced process control (APC) system has proven to exploit the benefits associated with ambient conditions which has got impact to many unit and equipment performances.
Disturbance effect reduction: Without advanced process control (APC), disturbances arising from upstream or downstream will affect process units and reduce margins.Authors: Tushar Singh & Kate Kulik, Aspen Technology Inc.
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