Implementation Of Advanced Process Control Research Articles

Energy Reduction with Super-Resolution Convolutional Neural Network for Ultrasound Tomography

This study addresses the issue of energy optimization by investigating solutions for the reduction of energy consumption in the diagnostics and monitoring of technological processes. The implementation of advanced process control is identified as a key approach for achieving energy savings and improving product quality, process efficiency, and production flexibility. The goal of this research is to develop a cost-effective system with a minimal number of ultrasound sensors, thus reducing the energy consumption of the overall system. To accomplish this, a novel method for obtaining high-resolution reconstruction in transmission ultrasound tomography (t-UST) is proposed. The method involves utilizing a convolutional neural network to take low-resolution measurements as input and output high-resolution sinograms that are used for tomography image reconstruction. This approach allows for the construction of a super-resolution sinogram by utilizing information hidden in the low-resolution measurement. The model is trained on simulation data and validated on real measurement data. The results of this technique demonstrate significant improvement compared to state-of-the-art methods. The study also highlights that UST measurements contain more information than previously thought, and this hidden information can be extracted and utilized with the use of machine learning techniques to further improve image quality and object recognition.

Enhancement of biological nutrient removal process with advanced process control tools in full-scale wastewater treatment plant

One of the major challenges in existing WasteWater Treatment Plants (WWTPs) is to comply with the increasingly stringent nutrient discharge limits established by the competent authorities to enhance environmental protection, while keeping operation costs as low as possible. This paper describes the results obtained from upgrading a full-scale WWTP during seven years (2013–2020) applying five different Advanced Process Control (APC) strategies. Results show that implementation of APC and the development of ammonia-based aeration control, aeration/non-aeration cycles, improved internal/external recirculation and chemical dosage controls resulted in an improvement in nutrients removal rates (+25.48% and +9.25%, for nitrogen and phosphorus, respectively) and in a reduction (-21.79%) of the specific energy ratio. In addition, the promotion of an Enhanced Biological Phosphorous Removal (EBPR) process by APC resulted in an improvement in biological phosphorous removal (+43.90%), chemical savings (-20.00%) and nutrient recovery in the dewatered sludge. Molecular biology tools and laboratory batch tests confirmed the Polyphosphate Accumulating Organisms (PAOs) activity, specifically Tetrasphaera genera. Finally, an economic analysis was conducted, showing a rate of return for the incurred capital expenses with the implemented APC systems of about five years, being an affordable alternative to the upgrading existing WWTPs.

Advanced operation and monitoring the economic performance of ammonia production based on natural gas steam reforming by using programmed feedforward–Ratio–Cascade controllers

The paper addresses the implementation of advanced process control (APC) and monitoring the economic performance for ammonia production facility relying on natural gas steam reforming. The plant profit optimization was the main goal in the development of a custom APC structure by using a programmed feedforward–ratio–cascade control scheme. The ammonia plant model constructed by UniSim Design software gave a basis for the implementation of a closed-loop control. Ammonia production rate set point acts as the primary/master while holding the steam-to-natural gas and air-to-natural gas molar ratios as secondary/slave controllers. Moreover, the paper considers the main process disturbances on the controlled and manipulated variables. The APC controller with economic objective function ensured better disturbance rejection, more efficient operation of the whole ammonia plant, and increased profitability of up to 7%.

AIChE PD2M Advanced Process Control workshop‐moving APC forward in the pharmaceutical industry

AbstractThis whitepaper summarizes the outcome of the first Advanced Process Control (APC) workshop in the pharmaceutical industry, presented by AIChE PD2M, and held in Washington DC, Sep 30 to Oct 01, 2019. Approximately 50 attendees from regulatory agencies, industry and academia had an opportunity to share perspectives and best practices on the business, technical and regulatory aspects of APC for both small and large molecule drug manufacturing. The event consisted of keynote talks, case studies and panel discussions, filled with lively interactions that focused on: (a) Business drivers for APC in pharma; (b) Alignment on the definitions of key terminology; (c) Clarification of roles and relationships of APC with regards to popular initiatives such as Quality by Design (QbD), Process Analytical Technology (PAT), Real Time Release testing (RTRt), Continued Process Verification (CPV), continuous manufacturing and digital manufacturing; (d) APC manufacturing implementation considerations; (e) Quality system and regulatory considerations for APC implementation; (f) APC opportunities in modular manufacturing, process intensification, integrated continuous manufacturing. (g) standards, training, and collaboration.

Multicriteria Ammonia Plant Assessment for the Advanced Process Control Implementation

Rehabilitation of control systems or implementation of Advanced Process Control (APC) in any large scale industrial installation poses several challenges. First of all, the implementation process has to meet stringent safety regulations. Moreover, it has to minimize normal production violation. All human, technology and control system risks need to be identified and a mitigation plan has to be prepared. Once the implementation limitations are fulfilled the installation requires to be prepared. The plant needs to be comprehensively assessed. All APC project related aspects, like control system or process instrumentation must be reviewed. Furthermore existing installation performance has to be measured for further justification of project results. The paper presents authorial assessment methodology aiming at the installation preparation before APC implementation. It is obvious that any supervisory control helps only when the underlying process, infrastructure and regulatory base control operates properly. Any performance malfunctioning within plant equipment or base control logic misfit limits, even the most sophisticated APC. The paper presents developed and practically adopted comprehensive multicriteria assessment procedure, which prepares the large scale chemical installation for APC supervisory control upgrade. Proposed procedure is accompanied with identified implementation risks and their mitigation plan.

Uniformity Control of 3-D Stacked ICs: Optical Metrology and Statistical Analysis

This paper evaluates various optical metrology techniques for in-line control of the uniformity of 3-D stacked structures. Key process steps during 3-D integration flow were identified and characterized in order to quantify their specific intra-wafer dispersion signature. The cross correlation between the various intra-wafer process step signatures was then analyzed to verify the data set consistency. The analysis indicated that the measurement data are consistent over the process integration flow, and that a simple model quantitatively explains the intra-wafer signatures observed. The results highlight the importance of controlling those specific steps and provide a new alternative for advanced process control implementation.

Dynamic Simulation for Verification of Gains with the Implementation of Advanced Process Control for a Nickel Sulphide Ore Beneficiation Plant

A dynamic simulation tool was used to quantify the benefits from the implementation of an advanced control system for a low grade Nickel sulphide ore beneficiation plant. In order to obtain a consistency between the simulation and the process a database that represented the natural variability of the ore was used. The information consisted of laboratory analyzes every 2 hours for the concentrations of nickel in the feed, product and tailings from the plant. In addition, variability in the feed rate was included in order to simulate the performance of the circuit. Empirical and phenomenological mathematical models, of each unit operation of the processing circuit, were calibrated in the simulator. The representativeness of the tool was proven by the confrontation of the results obtained against the data from the laboratory. The variables of the models were changed during the dynamic simulation to reproduce the usual control done by the operators. To provide comparison data another scenario was simulated with advanced process control. This was possible due to the fact that the simulator has a data manager performed by an artificial intelligence that allows configuring process control strategies, such as an expert system. After the analysis of simulation results, it was possible to estimate the improvement obtained with the implementation of an expert system through evidence of increased Nickel metallurgical recovery. There was also reduction of the variability of product quality. The above mentioned results shows that techniques for advanced process control are among the most effective methods in cost and time to improve plant performance.

Importance of Quality Historical Data for Improved Plant Operation and Advanced Process Control Implementation

With over 20 years of providing historians for many and varied applications, Vista Control Systems has learned much about the uses of and, at times, extremely valuable, data. From leading to a deeper understanding of the process to finding the cause of very expensive plant upsets, good and complete historical data can be priceless. Process data can be used effectively for system identification followed by PID tuning optimization and implementation of powerful advanced process control schemes inside a DCS, PLC or a SCADA system. PiControl has developed some powerful tools in this area. This paper describes some tools we supply and outline some customer experiences to support these statements.

Neurocontrol of a multi-effect batch distillation pilot plant based on evolutionary reinforcement learning

The time cost of first-principles dynamic modelling and the complexity of nonlinear control strategies may limit successful implementation of advanced process control. The maximum return on fixed capital within the processing industries is thus compromised. This study introduces a neurocontrol methodology that uses partial system identification and symbiotic memetic neuro-evolution (SMNE) for the development of neurocontrollers. Partial system identification is achieved using singular spectrum analysis (SSA) to extract state variables from time series data. The SMNE algorithm uses a symbiotic evolutionary algorithm and particle swarm optimisation to learn optimal neurocontroller weights from the partially identified system within a reinforcement learning framework. A multi-effect batch distillation (MEBAD) pilot plant was constructed to demonstrate the real world application of the neurocontrol methodology, motivated by the nonsteady state operation and nonlinear process interaction between multiple distillation columns. Multi-loop proportional integral (PI) control was implemented as a reduced model, reflecting an approach involving no modelling or significant controller tuning. Rapid multiple input multiple out nonlinear controller development was achieved using SSA and the SMNE algorithm, demonstrating comparable time and cost to implementation in relation to the reduced model. The optimal neurocontroller reduced the batch time and therefore the energy consumption by 45% compared to conventional multi-loop SISO PI control.

Multivariable Control Application for the Flash Furnace at Codelco Norte

Abstract Today, the economics and technical features of the processes must be optimised subject to all the relevant environmental regulations while outputting products of the highest quality. In the mining industry, this new framework has generated interest for Advanced Process Control technology. Currently within the mining industry, several applications have been implemented. Codelco has some customised implementations of special applications which can be found in some of Codelco's Divisions. In the light of all the above, and because of the significant benefits that the technology can generate across the corporation, the Automation Projects Department (DPA) within its activities has decided to support and promote the implementation of advanced process control. This paper describes the development and implementation of an advanced control application on the Flash Furnace at Codelco Norte concentrate smelter complex. The results obtained with this advanced control application are very interesting, mainly for the control of magnetite in slag, and copper percentage in the matte. Results obtained show that the performance of process applying the technology provides superior results when compared with normal operator control for the variables that it controls.

A roadmap towards cost efficient 300 mm equipment

Micro- and nanoelectronics will see a further extension of Moore's Law with the prediction of a cost reduction of 25% to 30% per year. The introduction of 300 mm technology is one step towards cost reduction. A description of the time lines of the maturization of 300 mm technology reveals the necessity for equipment improvement, especially for the implementation of Advanced Process Control (APC). Examples for APC are given in the fields of fault detection by in situ analysis of plasma parameters and their electrical verification, of an advanced endpoint detection system capable of reliable endpoint detection for a large variety of cleaning reactions and for the reduction of clean durations for chamber wall cleaning in plasma deposition systems, and in the field of the integration of a particle sensor in high temperature furnaces. Another promising technology described in the article is the re-use of 300 mm equipment, especially of cluster tools, targeting at a long term use of equipment by using the highest degree of standardisation and modular processing module integration. Thus, additional nodes of the ITRS, the roadmap for semiconductor technology, can be manufactured without the full investment into new equipment.

Process and installation for preparation of oxidized bitumens

This paper will describe a program for the planning and implementation of advanced process control in an existing refinery. Such a program is a typical example of new concepts and methodologies utilized by companies seeking improved operating efficiency through increased yields of valuable products and decreased consumption of required energy.Advanced process control applications vary in complexity and hierarchy due to the variations of control objectives among the refinery units. For the refinery discussed here, advanced process control was applied to the following primary units:.- Two topping units, with downstream vacuum units.- Visbreaker.- Fluid catalytic cracking unit.- Storage and blending.These advanced control strategies were specifically designed for this refinery to address a complex pattern of changes in crude oil type and product demand mix. For example, the atmospheric and vacuum distillation units require strategies for the dynamics of crude changes every three days and up to 18 different product demand patterns.The implementation of advanced process control is part of an overall refinery control modernization project. The project entails replacement of the current main control room pneumatic control system with an up-to-date digital control system which specifically provides for implementing advanced control strategies.Implementation of the control system changeover will be an online operation and carried out on a unit-by-unit basis.

Integrating hazard analysis into the implementation of advanced process control

AbstractIn mid‐1997, an Advanced Process Control (APC) scheme was implemented at a resins manufacturing complex with the goal of minimizing flare fuel gas usage while maintaining sufficient energy (BTU/SCF flare gas) to be in environmental regulatory compliance. Prior to APC implementation, the flare system was manually controlled by plant operators with minor attention paid to the minimization of fuel gas usage. Since implementation, APC has saved the plant thousands of dollars in fuel gas costs and reduced unnecessary combusted fuel gas emissions.Hazard analysis techniques were used in the development of the control scheme. An overview of the APC used, the economic evaluation, and the hazard analysis techniques used in the project are presented here.

Advanced Process Control System Design for a Refinery: A Case Study

Abstract This paper will describe a program for the planning and implementation of advanced process control in an existing refinery. Such a program is a typical example of new concepts and methodologies utilized by companies seeking improved operating efficiency through increased yields of valuable products and decreased consumption of required energy. Advanced process control applications vary in complexity and hierarchy due to the variations of control objectives among the refinery units. For the refinery discussed here, advanced process control was applied to the following primary units:. - Two topping units, with downstream vacuum units. - Visbreaker. - Fluid catalytic cracking unit. - Storage and blending. These advanced control strategies were specifically designed for this refinery to address a complex pattern of changes in crude oil type and product demand mix. For example, the atmospheric and vacuum distillation units require strategies for the dynamics of crude changes every three days and up to 18 different product demand patterns. The implementation of advanced process control is part of an overall refinery control modernization project. The project entails replacement of the current main control room pneumatic control system with an up-to-date digital control system which specifically provides for implementing advanced control strategies. Implementation of the control system changeover will be an online operation and carried out on a unit-by-unit basis.