Industrial Software that increases plant profitability

Advanced Process Control solutions

Introduction to Advanced Process Control (APC) solutions

 

 

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Advanced Process Control (APC) is a control solution that increases process performance. APC communicates with the plant’s distributed control system (DCS) or programmable logic controllers (PLC) as a level two optimization application via an OPC server that closes the loop between plant information and field actuators.

APC technologies such as fuzzy logic and model predictive control (MPC) and the inclusion of machine learning via inferentials and soft sensors allows for a robust solution to be tailored to almost any main unit on a plant.
 
Empower operations to automatically increase production and yield whilst reducing consumables with Industrial Software that is flexible in terms of integration with existing advanced process control systems as well as customizable to tackle any control problem.

Typical situations remedied with APC

  • Process is running “a safe distance” from optimum
  • Control must be optimized to adjust product quality and maximize benefits
  • Reduced site staff does not have bandwidth to identify opportunities and optimize process
  • Existing PID controllers cannot effectively manage interactions between different feedback loops
  • Controls do not include proper constraints
  • Tuning PID controllers does not improve productivity, energy usage, benefits

Savings opportunities from $300K to $5M+ annually

Key benefits of APC

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How APC can be useful?

APC, our advanced process control software significantly benefits the mining, cement, pulp, and metals industries. In mining concentrators, APC optimizes grinding by adjusting variables like grinding mill speed, conveyor belt load, and downstream by maximizing mass pull to concentrate grade limits. By minimizing energy consumption and maximizing throughput and recovery, it leads to higher productivity and improved opex savings. In cement production, APC enhances kiln operation, raw material blending, and clinker quality. This results in reduced energy usage, consistent product quality, and minimized emissions, contributing to sustainability goals. For the pulp and paper industry, APC improves pulp quality by improving control around the digesters, lime and bleaching units, increasing yield, and reducing consumables. In the metals sector, APC automates complex processes, particularly in pelletizing. Overall, APC acts as an autopilot, driving optimal performance across these sectors while minimizing human intervention.

Industry specific usage

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APC resource center

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