In today’s globally competitive marketplace, chemical plants and refineries are looking at new ways to increase plant efficiency, production rates, safety and reliability. In the process control arena, base-level PID tuning optimization, APC (Advanced Process Control) and MPC (Model Predictive Control) remain attractive and under-utilized options. This paper describes various new and novel ideas harnessing the power from primary PID control improvements and APC/MPC implementation. The techniques and methodologies described can increase a plant’s profit margin from 2 to 10%. Spectacular increases in plant profits as high as 15 to 20% (equivalent to 2 million Euros/year) have been achieved and demonstrated in some cases. A few real examples from actual industrial plants have been provided in this paper..
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