Solutions


ADVANCED PROCESS CONTROL (APC)
Increase company profit through optimising processes!

BluESP’s Advanced Process Control (APC) has been on the forefront of Multivariable Model Predictive Control (MPC) projects since 2000 and a multitude of benefit-driven projects have been implemented across the world in both the Mining, Metals and Minerals sector as well as the Petrochemical sector.

TWith the Petrochemical sector traditionally being the early adopters of Advanced Process Control, BluESP used their knowledge and experience gained there to apply APC in the Mining sector, with great success.

In recent years implementing APC in the Mining sector, BluESP now have one of the largest install bases in the world for APC in mining. There are currently 80+ running applications contributing to massive returns and savings for mining customers. Typical benefits have a 3 to 6 month Return on Investment (ROI). No other company in this sector has delivered ROI’s of this order for APC or MPC projects.

Typical implementation include:

Primary Mills (Ball, AG, SAG)
  • Grind improvement (3-5%)
  • Electricity consumption (Up to 20% savings)
  • Improved stability
  • Include screen and/or cyclone and rougher feed tanks
Flash Dryers
  • Improved temperature control (27%)
  • Increased throughput (7%)
  • Decreased energy consumption (3%)
Evaporators
  • Reduced Energy consumption (Up to 10%)
  • Increased throughput (Between 3-15%)
  • Decreased variability in concentrate strength
Batch temperature control
  • Decreased batch times – throughput up by 10%
  • Improved temperature control – efficiency and recovery
Secondary mills
  • Improved stability and grind
  • Improved density control
IsaMill and UFG
  • Improved stability and grind
  • Power savings
Coal fired boilers & Steam header
  • Improved steam header pressure stability
  • Decreased coal consumption of 7%
Eimco Filters
  • Improved level control
  • Increased throughput
HCl recovery plants
  • Improved recovery and throughput, with
  • Decreased energy consumption
Flotation grade controllers
  • Increased recovery (1.5-2%)
SO2 removal plant
  • Decreased emissions
Autoclaves
  • Improved temperature control and increased leaching
Cooling water temperature
  • Improved temperature control

BluESP starts any APC project with a Profit Improvement Study & Functional Design Specification that determines the ROI and defines the business case for implementation. This business case makes it easy for the customer to motivate proceeding with the project. The post audit shows that we either have reached or exceeded the original estimate on which the project was justified.

The Petro Chemical experience base include the following processes:

  • Crude Disillation
  • Fluid Catalytic Cracking
  • Vacuum Distillation
  • Alkylation
  • TAME
  • Methane Reforming
  • Petrol and Diesel Blending
  • Fuel Gas Systems
  • Hydrotreating
  • Platformer
  • HF Alky
  • Distillate Hydrotreater
  • Naphtha Hydrogenation Unit
  • Cat Poly unit
  • Creosote Hydrocracker
  • Cat Poly Hydrotreater
  • Light Oil Fractionation