advanced process control for food & beverage · the schneider electric industrial software...
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The Schneider Electric industrial software business and AVEVA have merged to trade as AVEVA Group plc, a UK listed company.
The Schneider Electric and Life Is On trademarks are owned by Schneider Electric and are being licensed to AVEVA by Schneider Electric.
Advanced Process Control for Food & Beverage
Confidential Property of AVEVA Group plc.
Yasser Ahmed
Senior Technical Consultant
Agenda
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Advanced Process Control (APC)
F&B Process Optimisation
Dryer Control
Customer References
Q&A
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• What is it?
‒ A method of process control that uses mathematical models of process behaviour to predict and control
variation.
‒ Consistently drives the process to an optimum operating point (maximum throughput, minimum energy
consumption,….)
‒ Implemented in a supervisory manner relative to the existing basic control system (PLC, DCS)
• SimSciAPC is Schneider Electric’s software package for the implementation of APC
• Typical benefits for industrial F&B processing:
‒ 3-8% increase in throughput
‒ >5% reduction in specific energy consumption
‒ ZERO product quality violations
‒ ROI <2 months
Advanced Process Control
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• Optimising process operation under conventional control is difficult:
– Product quality measurements are infrequent
– Control actions interact with each other
– Time delays prevent accurate adjustment
– Disturbances are frequent
– Optimum conditions are unknown.
• Typically the process is operated to a recipe: a set of conditions that ensure in-specification
product at all times.
• The dryer is operated in-specification but at low efficiency:
– Low throughput
– Low product moisture
– High energy consumption
F&B Process Optimisation
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• SimSciAPC is Schneider’ software package for the implementation of Advanced Process
Control (APC):
– Multivariable model-predictive dynamic control.
– Steady-state economic optimisation by Linear Program (LP)
– Inferential “soft sensor” modelling by neural network
– OPC connectivity to all DCS/PLC systems
– Web interface for remote monitoring and intervention
– Integrated data capture and historisation, trending
– Custom calculations
• Multiple implementations in F&B processing:
– Multiple effect evaporation
– Spray drying
– Flash drying
– Coffee processing
Introducing SimSciAPC
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Stabilize, Then Push Constraints
Target or Constraint
Increased
benefit
Before
Stabilization
Stabilize
and Re-Position
Increase Production, Quality, etc.
MPC
Improve Control then Operate Closer to Limits
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Motivations for Optimization
MPC allows closer control to optimum point
Conventional
operating envelope
With MPCReduced operating
envelope
Constraint
Constraint
$$$ Most profitable
operating pointWith OptimizationCloser approach to
optimum
Improved control reduces operating variability
Optimization locates the best operating point
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Dryer Control
Effects of Dryer Control (alone)
Yield increase: Increase by 0.2%H2O
More powder from same liquid feed!
Powder at ~3% moisture
Skim milk
at 8%TS
Concentrate
at 49%TS
Tank Farm
Balance
Tank
Pre-heat &
Pasteurise
Concentrate
Tank
Multi-effect
Evaporator
Spray
Dryer
Fluidised
Bed(s)Steam
to CondenserHot Air
less waterless energy
Conventional Dryer Control
Operator ManipulatedVariables
Operator MonitoredVariables
DI
TIC
TIC
TIC
TIC
AI PowderMoisture
Milk Flow Rate& Tank Level
FB Inlet AirTemperature SP
Dryer OutletTemperature
SetpointDryer Inlet Air
Temperature SP
Dryer APC Controller Structure
Powder Moisture %
Atomiser current
Air heater steam vlv posn.
Exhaust fan speed
Outlet air temperature
Outlet air RH%Dryer Feedrate
Inlet Air Temperature
Inlet Air Fan Speed
Fluid Bed Inlet Air Temperature
Fluid Bed Inlet Air Flow
These are manipulated automatically by SimSciAPC
Controlled VariablesManipulated Variables
Dynamic
Model
Ambient Air Humidity
These are monitored and controlled by SimSciAPC
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Typical Operator Interface
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SIMSCI APC Configuration Interface
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Challenging the Constraints
Maximum unit throughput: determined by ambient conditions,
feed dry matter, etc.
Favourable swing in ambient temperature.
Operator-preferred operating point (infrequent changes,
significant margin).
APC operating point (frequent changes, reduced
margin)
“Lost opportunity”
captured by APC
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• Milk protein spray dryer
• SimSciAPC installed 2011
• Objectives:
‒ Maximise dryer capacity
‒ Control and maximise powder moisture content
‒ Respond to ambient air humidity changes.
• Manipulates:
‒ Concentrate feedrate to spray dryer
‒ Dryer Inlet air temperature
• Benefits:
‒ Increased product tonnage (approx 8%)
‒ Project payback < 3 months.
Case Study: Lactose protein dryer, Holland
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• Infant formula evaporator/dryer, 2.8 tph
• SimSciAPC installed 2001
• Objectives:
‒ Minimise process variability
‒ Co-ordinate evaporator and dryer operation
‒ Predict and maximise powder moisture content
• Manipulates:
‒ Evaporator steam pressure and feedrate
‒ Dryer inlet air flow and temperature
‒ Fluidised bed air flow and temperature
• Benefits:
‒ Concentrate total solids increased 1.4 to 3.0%
‒ Powder production rate increased 5-10%
‒ Energy efficiency increased > 5%
Case Study: Abbott Laboratories, Ireland
Company Country Licence Type Application Product Dairygold Food Products Ireland Application Multiple effect evaporator Whey
Loders Croklaan Holland Application Multiple effect evaporation Speciality fats
Kraft Jacobs Suchard UK Application Multiple effect evaporation Coffee
Kraft Jacobs Suchard UK Application Multiple effect evaporation Coffee
Nestle, Hayes UK Application Coffee Evaporation Coffee
Dairygold Food Products Ireland Application Multiple effect evaporator Whey
Kiwi Co-op Dairies New Zealand Study Multiple effect evaporation Dairy products
Avonmore Ireland Study Multiple effect evaporation Whey / Permeates
Express Dairies, Staplemead UK Application Evaporator Control Skim Milk
Nestle, Dennington Australia Application MVR-type Evaporator Dairy Products
Kerry Ingredients Ireland Application Evaporator Control Milk Products
Nutricia (Numico) Ireland Application Evaporator Control Infant Milk
Formula St. Ivel, Chard UK Study Evaporator Control Milk Products
Murray Goulburn, Koroit Australia Application Evaporator and Dryer Skim Milk
Kiwi Dairies New Zealand Application Powder 3 Evaporator & Dryer Skim Milk
Dairygold Food Products Ireland Application Multiple effect evaporator Whey
GoldenVale Bailieborough Ireland Study TVR evaporator Skim / Whole
Ingredia France Study MVR evaporator Milk Products
Abbott Labs Ireland Application Evaporator & Dryer IMF
Evaporator Control Projects
Plus many projects with Unilever from 1986 to date ...
Dryer Control Projects
Company Country Licence
Type
Application British Sugar, Newark UK Application Pulp dryers
British Sugar, Wissington UK Application Pulp dryers
British Sugar, Bury UK Application Pulp dryers
National Starch, Kansas City USA Application Drying Process
National Starch, Indianapolis USA Application Drying Process
British Sugar, Cantley UK Application Animal Feed Drying
National Starch, Indianapolis USA Application A Drying Process
Colgate Palmolive, Villawood Australia Application Detergent Spray Dryer
Kiwi Dairies New Zealand Application Powder 3 Evaporator and Dryer
National Starch, Indianapolis USA Site wide Various Processes
Murray Goulburn, Koroit Australia Application Evaporator and Dryer
Express Dairies UK Application Evaporator and Dryer
Abbott Labs Ireland Ongoing Evaporator and Dryer
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• Advanced Process Control (APC) offers significant benefits in the control and optimisation of
food and beverage processes:
– Increased throughput (3-8%)
– Reduced specific energy consumption (>5%)
• These results have been repeated across a number of types of dryer: spray, rotary, flash, etc
• Schneider has industry-leading experience in this area.
• Benefits are well-proven and can be guaranteed, following a benefit study.
Conclusions
Questions?
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