Introduction
Advanced Process Control (APC) technology has been widely adopted in the refining industry but remains underutilized in many other sectors. Understanding how to optimize APC systems can help businesses maximize their return on investment (ROI) and achieve higher operational efficiency.
In highly commoditized industries such as refining, competition is fierce, and companies often sell each other’s products. For example, a BP gas station might sell gasoline refined by a neighboring competitor’s plant. In such a market, maximizing every available tool to increase profitability is crucial, and for decades, APC has been a go-to solution for refining companies. Many other industries can also leverage APC to enhance their operational efficiency and profitability.
What is Advanced Process Control (APC)?
APC is a multivariable control algorithm often associated with Model Predictive Control (MPC). These systems use matrix mathematics and linear algebra to establish statistical relationships between variables while identifying causal relationships across multiple inputs. APC serves as an additional control layer, positioned above traditional Proportional-Integral-Derivative (PID) control algorithms commonly used in Distributed Control Systems (DCS) and Programmable Logic Controllers (PLC).
The Role of APC in the Refining Industry
The refining industry is rapidly evolving due to increasing scrutiny from government and community stakeholders regarding environmental concerns, transportation permits, and energy efficiency. Additionally, the rise of electric vehicles (EVs) has led institutional investors to question their long-term stakes in traditional oil companies. Despite ongoing debates over the practicality and timeline of transitioning to renewable energy sources, it is clear that the industry must adapt to remain competitive.
Refineries initially introduced APC systems in the 1970s, and by the 1990s, they had achieved widespread adoption across the industry. These systems have proven invaluable in optimizing operations and improving economic performance. However, despite being available for nearly four decades, APC adoption outside the refining sector remains relatively low.
How APC Works
APC systems provide a comprehensive approach to process optimization by monitoring numerous process variables and dynamically adjusting them to improve overall performance. The system analyzes process dynamics and determines which variables to manipulate to achieve more cost-effective operations. The primary goal of APC is to bring the process closer to its operational limits without compromising safety or compliance, leading to significant cost savings and efficiency improvements.
APC implementations typically involve integrating standalone software that communicates with the existing DCS/PLC system. In recent years, some DCS platforms have started incorporating built-in APC/MPC functionalities, although they often lack the flexibility and scalability of standalone solutions.
Characteristics of Industries Suitable for APC Implementation
If APC offers such significant benefits, why has its adoption been limited outside the refining industry? The answer lies in the unique characteristics of refineries that make them ideal candidates for APC deployment. Some of these characteristics include:
Economies of Scale: Large-scale operations benefit the most from incremental improvements, as small efficiency gains can translate into substantial financial returns.
Complex and Interdependent Processes: Industries with intricate production workflows and numerous interrelated variables can see significant value from APC’s optimization capabilities.
Continuous Operations: Facilities that operate 24/7 with minimal downtime are well-suited for APC, as they can leverage real-time process adjustments to maintain optimal performance.
Regulatory and Compliance Demands: Industries facing stringent environmental and safety regulations can use APC to ensure compliance while optimizing costs.
APC Benefits for Process Facilities
Despite potential barriers to implementation, APC remains a valuable tool for reducing operational costs and enhancing efficiency. Key benefits include:
Cost Reduction: APC helps minimize energy consumption, reduce raw material waste, and lower operational expenses.
Improved Product Quality: By maintaining tighter process control, APC can enhance product consistency and quality.
Increased Throughput: Optimizing process conditions allows facilities to achieve higher production rates without additional capital investments.
Enhanced Safety and Compliance: APC helps maintain safe operating conditions and regulatory compliance by continuously monitoring critical parameters.
Reduced Operator Workload: Automation of complex control tasks allows plant personnel to focus on higher-level strategic activities.
Overcoming Implementation Challenges
Successful APC deployment requires careful planning and execution. Many organizations face challenges such as high initial costs, integration complexities, and a lack of in-house expertise. To address these challenges, process manufacturing companies should consider partnering with external specialists who can streamline deployment and accelerate the realization of benefits. Third-party vendors can provide expertise in system integration and offer flexible financing models, such as performance-based agreements, which minimize upfront costs and share operational savings.
Conclusion
As industries face increasing pressure to optimize operations and reduce costs, adopting APC presents a valuable opportunity to enhance efficiency and profitability. Drawing inspiration from the refining sector’s successful implementation of APC, other industries should consider leveraging this proven technology to stay competitive in a rapidly evolving market.
The time to embrace APC is now, and businesses that take proactive steps will be better positioned to navigate future challenges and capitalize on new opportunities.