March 2009

Advanced control and real-time optimization (RTO) tools have become necessary technologies for today's process operating companies to compete and maintain profitable operations. It is widely accepted that the benefits of advanced process control (APC) technology include improved profitability through enhanced process stability, increased throughput and yield, decreased operating costs, improved product quality, and increased operating flexibility. Another benefit of advanced process control is that APC forms the foundation for on-line optimization, which typically adds an additional 20% of the advanced control benefits with project paybacks often in less than six months


Traditionally, companies involved in optimization projects adopted a 'top down' approach using detailed non-linear steady-state process models. These traditional, steady-state optimizers sent targets to multivariable controllers which drove the plant toward optimum operation. However, unless plant personnel were committed to understanding and maintaining such systems, most of these real-time optimization systems went out of service within the first year. Although there is a need for optimization based on detailed modelling in some cases, a large portion of the optimization problems in the process industries today can be addressed more directly with more leverage of plant data and less extensive, targeted modelling that focuses on key units that exhibit significant non-linearity.

Further information is available from Debbie Rae, Honeywell SA, on tel: +27 11 695 8000 or email hsa@honeywell.com.

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