Success Stories

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  • PID Tuning

Pulp & Paper: Characterizing Mechanical Issues

It’s one thing to know the likelihood that a valve has Stiction. It’s another thing to know just how much Stiction there is…


Oil & Gas: Continuous Process Modeling and Optimization

Sit back and relax – the underperforming PID was easily spotted and optimal tuning parameters were already calculated…


Basic Materials: Maximizing the Value of Plant Automation

The results are in – operating PIDs in automatic mode proved again to enhance production and save money…


Food & Beverage: Avoiding Premature Failure of Production Assets

As simple as that – retuning a single oscillatory control loop improved process performance, eliminated unnecessary wear and-tear, and nearly doubled the associated valve’s life…


Optimizing Control for More Profitable Operation

Professionals in the process control world understand that “less” can often mean more. That is especially true when referring to reduced cycling within a given production process. Reducing oscillations and otherwise tightening constraints around the control objective can present a significant challenge. It also presents an opportunity to dramatically improve a plant’s profitability.


Feed Your Way to Consistent Product Quality!

Typically Mill Feeders aren’t the first thing that come to mind when looking for performance improvements at a cement mill, especially at one with annual capacity of four million tons. But it was one area where engineers at Holcim’s Ste. Genevieve Mill looked when digging deep for productivity enhancements. The Feeders are located at the start of the mill’s production process – usually a good place to start.

Optimizing Pre-Heater Water Content

Are Oscillations Making Your Process All Wet?

It’s said that too much of a good thing is a bad thing. A leading oil and gas producer learned that too much variability in their gas pre-heater was negatively impacting the platform’s profitability. Unable to consistently control the process’ moisture content, this producer was forced to absorb the higher costs or be at risk of raising the moisture level to a point where downstream combustion processes failed.


Can Your Process Handle the Pressure?

Phenol is a vital raw material in the production of high-impact resins that are used in the construction, transportation and other industries. Located along the Ohio River, Haverhill Chemicals produces a broad range of chemicals in technologically advanced operations. The plant includes operations of both phenol and bis-phenol A production units.

Enhancing Heat Rate – One Loop At a Time

Modeling the Dynamics of Highly Oscillatory Processes

Optimizing heat rate is a critical success factor for most coal-fired power plants. Too little heat and the plant wastes the energy produced from bituminous coal and other costly production inputs. Too much heat and safety is put at risk – both the safety of production staff and of the plant’s production assets. Although optimizing a power plant’s injection water systems does not result in obvious financial gains, it plays an important role.