1. Significant Benefits can be achieved by APC.
It has been reported that significant benefits have achieved after the introduction of APC in the process industry.
2. Expected Benefit
By introducing APC, users can expect the following benefits.
Tangible benefits
- Increase production through
- Feed Maximization
- Reduce chemical loss
- Reduce utility costs for energy (Steam, fuel etc.) over 3%
- Production of uniform quality products
- Decrease in off-spec. production
Intangible benefits
- Safe & stable operation (Safety / Stability)
- Improved operation efficiency (Effectiveness)
- Better understanding of the process
ROI(Return of Investment) of APC is typically within 1 year.
3. By using the APC control technique to stabilize the controlled variables of the process and operate the process closer to the process operation limit, benefits such as increased production and reduced energy costs (steam, etc.) can be generated.
4. APC can predict the future of process.
APC calculates the optimal input from the present time to make the future move in the desired direction and applies it to the process.
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The importance of predicting the future. :
How great would it be if we could predict the future? If we could predict the future, we could make the best choices we can in the present.
APC can predict the future. :
APC can predict the future by using process models. APC can predict the future of a process up to 2-3 hours into the future. In other words, it can predict how the process will operate and what values it will have at the present point in time.
5. APC Operation Concept :
APC uses advanced control technology to stabilize the quality variables of the process and generate benefits such as increased production and energy saving (steam, etc.) by operating the quality variables close to the constraints of the process.
6. Predictive Control
In order for the future predicted output values to follow the target, Calculate future input values and apply them to the process.
With cycling operation as below, APC ensure that the process is always operated in an optimal condition.
7. Multi-Variable Control
PID Control :
Stable operation is difficult because PID controls only one controlled variable without considering the complex correlation between multiple inputs and multiple outputs.
APC Control :
Stable operation is ensured by considering & controlling the complex correlation between multiple inputs and multiple outputs.
8. Success Story
Benefit : The loss of vented raw materials was reduced by 36% by APC control. (4.7% => 3.0%)
Before APC :
The ‘off-spec’ ratio is high and not stable.
After APC :
The ‘off-spec’ ratio has been greatly reduced and quality has been stabilized. Lab value was well predicted and stably controlled by applying a soft sensor(Inferential). (한글)
