Spray Dryer Optimization - Minimize Variance in Powder Output

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 by reducing waste, costs, and stabilising the output product to satisfy delivery first time. Plus, applying Advanced Process Control, which uses multivariate optimization, will enable predictable powder quality over changing conditions.

Minimize Output Powder Variation, Maximize Product Quality

  • Maximize product moisture content – maintaining product quality while reducing specific energy consumption.
  • Maximize use of drying capacity (e.g. respond to ambient air humidity, optimize distribution between the dryer and fluidised beds).
  • Improved energy efficiency.
  • Reduce process variability.
  • Coordinated optimization of multiple units.
  • Increase product yield or process throughput.
  • Minimize specific energy consumption.
  • Maintain product quality.
     
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Capture Process Data from Existing Automation Systems

  • Connect to 1000s of different control system.
  • OPC connectivity to all DCS/PLC systems. 
  • Integrated data capture and historization, trending.
  • Custom calculations.

Advanced Process Control, Enables New Levels of Stability Above Traditional Control

  • Understand process constraints and complex process interactions.
  • A mathematical model of the process input/output dependencies is used to predict the future process output trajectories.
  • Multivariate correlation between variables and actuators, causes and effects.
  • Predict the impact of known disturbances on the operation.
  • Make co-ordinated moves on multiple actuators.
  • Exploit all opportunities to push quality and/or throughput close to the constraint.
  • Multivariable model-predictive dynamic control (MPC).
  • Steady-state economic optimization by Linear Program (LP).
  • Inferential virtual sensor modeling by a neural network – to enable continuous product quality measurement by calculating the estimated value.
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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 Visualization of predicted vs actual, enable virtual sensors

  • Continuous improvement by comparing different modeling Scenarios.
  • Compare Actuals vs predicted Data.
  • Enable Virtual Sensors for increased quality awareness and control.
  • Intuitive User configuration experience.
  • Implement a project and get results in 10-12 weeks.
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Multi - Unit Coordination and Optimization

  • APC’s Linear Program (LP) Optimizer can span the individual local control functions.
  • Open connectivity to all local PLC control systems.
  • Individual unit models are consolidated into a single multi-unit model.
  • Allows the reconciliation of plant-wide constraints, locates the true global optimum operating point.
  • Maximize throughput.
  • Minimize energy consumption.
  • Downloads real-time operating targets to the control layer.
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