The guide to Advanced Process Control (APC)

Accomplish ultimate optimized plant performance with Advanced Process Control (APC)

In day to day operations, customers are experiencing the many challenges

  • The performance of the process depends on operator experience.
  • Customers need to produce a consistent product quality at a minimum cost with ever changing process conditions and a given set of process limits.
  • Environment regulations have a major impact on the profit. Operating with APC in the most optimal way helps to recover (a port of ) the lost profit.
  • Maximize production when high demand and good margins.
  • Produce a predefined amount with minimal specific energy consumption when low demand and low margins.
  • Find a trade-off between production and specific energy consumption when possible.
  • Operators get extra administrative responsibilities, preventing them focusing on the unit operations.

Advanced Process Control (APC) is the low cost tool that helps to overcome all above challenges.

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What is Advanced Process Control?

Advanced process control (APC) refers to a broad range of techniques and technologies that interact with process control systems. Advanced process controls are often deployed in addition to basic process controls (that are build around PID control).

Nowadays APC is almost a commodity in refineries and large petrochemical complexes, like ethylene crackers and polymer plants.

The chemical, fertilizer, power and fine chemical industry have discovered the power of APC in the last 10 years. Also in these industries APC is becoming more and more common.

The benefit of Advanced Process Control

The list below shows the most common benefits generated by APC systems on many different industrial processes:

  • Reduced process variations beyond what is possible with traditional PID control.
  • More hands off operation. Under normal operating conditions, operators would not need to touch the process at all.
  • Operate the plant always at the optimum. This can be at the maximum throughput, the lowest specific energy consumption, the point with the highest margins, or combinations of the above.
  • Respect under all conditions the process limits.
Advanced Process Control (APC) benefits

INCATools MPC Discovery: A Sophisticated New Software Package for Constrained Linear Model Identification

Learn in this white paper:

  • How to effectively identify models with INCA Discovery
  • How the user can impose process knowledge prior to the Identification step
  • The workflow to be used
  • The INCA environment.

INCATools MPC

the INCA MPC software creates value by continuously optimizing the key process parameters online, in closed loop, keeping the plant in the most economical operating point every minute, 24/7.

To be able to do that, the INCA MPC predicts the plant behavior, account for plant disturbances and takes all plant constraints into account. This will result in:

  • Reduced process oscillations resulting in less wear and tear of the equipment
  • Less alarms
  • Less operator interventions
  • More efficient plant operations (higher production, less specific energy consumption, better quality control,…)
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Do you want to learn how to achieve an optimal plant performance with APC?

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Talk to one of our experts and get advice on:

  • How APC helps you to boost your plant to the ultimate performance
  • How INCATools MPC can be integrated with your DCS.
  • How we can help you to define a risk free APC investment.