Minimize Variance in Powder Output with Spray Dryer Optimization

Spray drying presents a unique challenge in controlling output and cost, especially in milk and coffee production. Spray dryer optimization provides a new level of proven opportunity to bring the process under control while reducing waste, material and energy costs.

Minimize Output Powder Variation and Maximize Product Quality

  • Maximize product moisture content and maintain product quality while reducing specific energy consumption
  • Optimize use of drying capacities such as responding to ambient air humidity, optimize distribution between the dryer and fluidized beds
  • Coordinate the optimization of multiple units
  • Increase product yield or process throughput
 
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Capture Process Data from Existing Automation Systems

  • Connect to virtually any control system including DCS and PLC
  • Integrate data capture, historisation, and trending
  • Enable custom calculations
 

Advanced Process Control to Enable New Levels of Stability Above Traditional Control

  • Stabilize the output composition to reliably satisfy product specifications.
  • Understand process constraints and complex process interactions
  • Implement a mathematical model of process input/output dependencies to predict future process output trajectories
  • Multivariate correlation between variables and actuators, causes and effects
  • Predict the impact of known disturbances on the operation
  • Make coordinated moves on multiple actuators
  • Exploit all opportunities to push quality and/or throughput close to the constraint
  • Allow multivariable model-predictive dynamic control (MPC)
  • Facilitate steady-state economic optimization by a linear program (LP)
  • Establish inferential virtual sensor modeling via a neural network that enables continuous product quality measurement to calculate estimated values
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Proven Optimization Results for Spray Dryers

  • 10% increase in throughput from the initial “recipe” conditions
  • 8% reduction in specific energy consumption
  • Auto-compensation for ambient air humidity changes
  • Powder moisture in-specification at all times
 
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Enable Virtual Sensors and Visualization

  • Compare different modeling scenarios for continuous improvement
  • Compare actuals vs. predicted data
  • Enable virtual sensors for increased quality awareness and control
  • Access an intuitive user configuration experience
  • Implement a project and get results in 10-12 weeks
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Multi-Unit Coordination and Optimization

  • Span individual local control functions with APC’s Linear Programme (LP) Optimiser 
  • Open connectivity to all local DCS and PLC control systems
  • Consolidate individual unit models into a single multi-unit model
  • Enable the reconciliation of plant-wide constraints and locates the true global optimum operating point
  • Download real-time operating targets to the control layer
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