Process optimization
From Wikipedia, the free encyclopedia
Process optimization is the practice of making changes or adjustments to a process, to get results.
Optimization is the use of specific techniques to determine the most cost effective and efficient solution to a problem or design for a process. This technique is one of the major quantitative tools in industrial decision making.
[edit] Description
In chemical engineering terms, a process is typically a set of equipment arranged, controlled, and operated in a particular way, to produce a product. The product must meet certain specifications, such as a certain production rate, product quality, and cost. Typically, specifications are supplied as a range of values, such as "Must be between 84% and 87% octane", or "must cost less than $250 per ton."
When we talk about optimizing a process, we are usually trying to maximize one or more of the process specifications, while keeping all others within their range.
[edit] Types
Fundamentally, there are 3 things that can be adjusted to ensure optimal performance. These are:
- Equipment
- Operating procedures
- Controls
Optimizing equipment The first step is to make sure that the existing equipment is being used to its fullest advantage. You must look at operating data to determine the equipment bottlenecks.
Optimizing procedures Operating procedures may vary widely from person-to-person or from shift-to-shift. Automation of the plant can help significantly. But automation will be of no help if the operators take control and run the plant in manual.
Optimizing controls In a typical process plant, such as a chemical plant, or oil refinery, there are hundreds or even thousands of control loops. Each control loop is responsible for controlling one part of the process, such as maintaining a temperature, level, or flow.
If the control loop is not properly designed and tuned, the process will run below its optimum. The process will be more expensive to operate, and equipment will wear out prematurely.
To make each control loop run optimally, you should check for sensor problems, valve problems, and tuning problems. It has been well-documented that over 35% of control loops typically have problems.
Optimizing the whole plant You can optimize equipment, procedures, and controls. But it can be overwhelming. There are so many things to look at, and so little time in a day. Modern software tools can gather data from a distributed control system or programmable logic controller, and prioritize the corrections that you need to make.
The process of continuously monitoring and optimizing the entire plant is sometimes called performance supervision.
