Change comes to the Chemical Industry

The Chemicals industry is expansive and distinguishable by the widespread application of batch production processes. Chemical manufacturing can present challenges for traditional PID-based control as the various stages of batch production typically involve different and often opposing control objectives. Indeed the goal of a rapid ramp during start-up is generally at odds with subsequent phases.

With careful consideration the PID controller has proven a highly effective and reliable tool for automating Chemical manufacturing. When equipped with appropriate technologies for monitoring, analyzing and optimizing PID-based regulatory control systems, Chemical producers can both reduce the cycle time and improve the consistency of their day-to-day operations.

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Our Experience

Leading Chemicals manufacturers utilize our technologies to improve their semi-continuous and batch operations.  While most process engineers are experts in their field they benefit from technologies that provide timely insights and that simplify advanced analysis of their process’ performance.  With our deep domain knowledge of PID-based regulatory control and portfolio of innovative technologies, we’ve become a trusted partner to many leading Chemicals companies.  Following are specific areas where Control Station can contribute to improve plant performance.


Chemical manufacturers are known for using process data to gain a better understanding of challenging process dynamics.  With its ability to proactively identify and isolate mechanical, interaction and tuning issues, PlantESP equips production staff with valuable details along with the advance warning they need to maintain optimal production levels.

While many industry practitioners are skilled at manual controller tuning, innovations in PID tuning software can now make everyone an expert.  LOOP-PRO is industrial-grade technology that’s capable of handling your plants highly variable process conditions.  It makes the tuning process faster and more consistent which are keys to success in chemical manufacturing.

Regular tuning of PID controllers has been proven to improve plant performance, but for many in the chemical industry control loop tuning is a hit-or-miss proposition especially during start-up.  We’re experts in PID control and can share a simple, repeatable method for optimizing loop performance during each phase of production.

Process Considerations

The dynamics of temperature present unique control challenges due largely to the associated Dead-Time. The tendency of temperature to drift combined with the delay that’s involved with returning it to Set Point often results in oscillations. Without effective control, that behavior can undermine production.

Whether a given chemical reaction is exothermic or endothermic the challenge of reaching the objective temperature quickly while keeping Overshoot in check can be significant. An effective PID-based control strategy can transition control of this production phase from manual to fully automatic.

 If the first order of business is to complete a given chemical reaction, then reducing the associated cycle time is a close second for many chemical manufacturers. Tight control of the production cycle limits the use of inputs. It also enables more batches to be produced using the same infrastructure.

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