Introduction

Every company strives to minimize expenses as they maximize revenue. The basic method of achieving this will always be plant optimization.  Close attention to measurements, controls, and efficiencies are necessary for optimization, which enhances the plant’s yield, as well as improving site safety.  Plant optimization can be defined as when a plant’s processes are tuned to maximize yields. This can be attained when one understands aspects such as facility’s energy conservation, equipment efficiency, labor use, and then implement procedures that maximize them.  Further optimization of plant’s yield necessitates the minimization of production waste.  

Perform general and precise measurements

In order to have control over a process, you must have the ability to measure it accurately.  By obtaining and analyzing general measurements including pressure, temperature and flow rate; in addition to specific measurements such as quality and  By analyzing this data, you can formulate a picture of material flow within the facility, and from that picture, determine the efficiency at which product is flowing through your facility.

Implement controls for all the processes

Presuming the adequate installation and operation of instrumentation, the next step is to implement controls over all the processes. The aim of this step is to reduce error and process variation. For unit operations with changing process conditions, such as distillation columns and evaporators, automated controls are essential.

Improve Energy Efficiency

Energy inefficiency can affect plant optimization drastically. To reduce energy inefficiency expenses, make better use of the available utilities and perform energy efficiency audits. Energy efficiency audits should consider if the waste heat can be used elsewhere, or if waste streams contain traces of finished products that can be retained.  Energy is also lost when facilities recycle the processes due to poor quality. The audits should also consider whether general or specific measurements are within their ranges. Higher energy efficiency can be obtained by utilizing newer technologies, which, plants can be considered on a ROI (or other metrics) basis.   

Plant optimization is key to achieving operational excellence.  Plant optimization maximizes revenues, minimizes expenses and improves profitability.  Utilizing skilled personnel who are not involved in the daily running of the plant, will help ensure maximum efficiency is attained, as they can view the process from a unique perspective.