In the competitive world of soy processing, saving money and improving operations are top priorities. A leading soy processing plant teamed up with Interstates to use advanced technology to better control its Disolventizer Toaster (DT).
OPTIMIZING SOY PROCESSING THROUGH ROCKWELL PAVILION8 MPC CASE STUDY
Ionp et hr ae t ci oonms pa er et i tt oi vpepwr ioorrlidt i eo sf . sAolye apdr oi ncge ss os iynpgr, os caevsi ns ign mg polna enyt taena dmiemd purpowv iint hg ITnotaesrtsetra t(eDsTt)o. uT shee acdl iveannt c ne de etde ec dh nt oo l or eg dy ut coebsettet ae mr c uo ns at rgoel wi t sh iDl ei seonl vheanntci zi ne gr twe imt hp ea rsaot ul urtei ocno nc tarl ol el df oMr oi md epl r Po vr ee dd i cptri vo ed uCcot nqt ruoall i(t My . PWCe) . aI pn pj ruosat c9h emdotnhtehms , under half the time it was estimated, the client surpassed their ROI.
What is Model Predictive Control? M in P d C ust i r s ia l l ike pr t o h c e es “ s b e r s a , in o ” n o ly f m it od h er a n s suus pe se rmi oart hme uml taittiacsakl i mn go dc ea lpsa tboi l pi t ri ee sd. i cI tt tohne fcuut ur rreenbt e haanvdi o rpoafs at s dy satteam. Wb ahs ei l de tt rhaedci tui rorneanl t csot na tt er ool f say sstienmg lse fvoacrui as bol en, Ms i mP Cu l t al onoekosu s layt a nmduml t iapkl ee s rveaarli-atbi ml ees adjustments.
The Client’s Key Results:
$
Decreased DT high temperature set point by 6.8%
Reduced steam consumption by one pound per bushel
Saved $162,000 annually in steam utilization
Had an ROI in 9 months
712.722.1662 | www.interstates.com |
CHALLENGES
1 2 3 High steam consumption: Steam waste leads to operational inefficiency and increased costs. Temperature Variability: Inconsistent temperature controls which could result in product quality issues. Set Point Issues: A higher-than-necessary temperature set point for end-product quality led to higher energy usage and costs. The client’s DT exhibited less-than-optimal performance, with particular challenges in:
PROJECT PROCESS Tn eheed as .nWa l yi tthi c as nt eMaPmC us os el udt i Mo nP, Cb ottoh mmeaenti ptuhlea tceldi eannt ’ds cc oo nmt pr ol el x vi anrdi au bs tl er isa l apl lroowc e spsreos a. cMt i Pv eC amv oa indasg emma ec nh it n eosf hc haavni ngge ;t oi n swt ea ai tdu, ni tt icl otnhsetraen talrye mparkoebsl etmi nsy,t op rmo aackteivea cuosrerdetchtieofnosl.loInwtinhgisvparroiajebclte,so: ur soy processing client Manipulated Variables: Elements that MPC can adjust or control. In this project, that included flow control valve and extractors speed. Control Variables: The outcomes or results that sphr eo susl ud r eb, ea nodpgt ei ma ri bz eo dx . a mD opme rea gtee wmepreer ua tsue rde a, s ecxohnatur os tl variables for this client. Ttohteaacnkalelytthicisspteraomjectot.ok a multi-disciplinary approach | Project Kickoff: Met with the client to kick off the project, draft design specifications, and analyze psuroccceessss lvoaorkiasblilkees tfoorthaemcle. ar understanding of what | Technology Deployment: Reviewed control system h ch e e a c lt k h s , , da s t o a ftw c a o r ll e ecti i o n n sta a ll n a d tio p n r , oce a s n s d ing co r n ea n d e i c n ti e o s n s checkout. | MPC Enablement: Enabled custom logic for sa on fdt wc ao rnet ,rcohl evcakrei da bs lyesst, e amn idn tpergorcaet si os ne dp ec ra ml c ua lnai tpi ou nl ast et do support MPC application.
| Step Testing: Designed and documented step test eaxsspeesrsimedesnttesp, steetsturpesstuelptst. est plans, and executed and | Commissioning: Assessed steady state periods for ec oa mc hpcl eo tnetdr odl ovcaurmi aebnl et a, st ieot nuapnKd PoIpaenr ad t coor nt rt ar oi nl icnogn, shoelled, final consulting, and held final project closeout.
Graph 1: Historian trend of the DT temperature. The purple trend shows the variability of the temperature when MPC was disabled.
Graph 2: The blue graph is the histogram when the MPC was disable, representing the wide distribution of DT temperatures. The purple
712.722.1662 | www.interstates.com |
RESULTS & RETURN ON INVESTMENT Taking an MPC approach improved steam efficiency and DT temperature stability, resulting in cost savings and better quality. Once the project was complete, the client reduced steam consumption by one pound per bushel and saw a significant reduction in temperature variability. This enhanced the quality and consistency of their project. This meant:
The DT high-temperature set point
$162,000 annually in steam utilization costs.
6.8% from 161°F to 150°F for additional savings .
CONCLUSION & FUTURE OUTLOOK tTehceh ncol ileongty i isn doetlhi gehr t ae rde aws i tohf tt hh ee i rs uocpceersast i oo fn tthoi sf uprrt oh jeerc ts tar ne nd gitsh enno wt h ec iorncsoi dmepr ient gi t i tvhee a pd ov as snitbaigl iet yi no ft hues imn ga r tkheits. By partnering with Interstates, they could take advantage of their industrial, professional services expertise aonpdereaxtipoenraiel nefcfeiciinenicmy,palenmd eennthianngcRedocpkrwodelulcPt aqvuialiloitny8aMt tPhCe.irTshitise.resulted in significant cost savings, improved Gt hi ve ey nh tahde apnr oR jOe Ic to’ sf jcuosstt 9, I mn t oe nr st thast!eTs hees tci lmi eant te dc aannaRl sOoI eoxf p1e9c tma odndti ht iso. nHaol ws aevvi enrg, swf irtohmt hteh e$ 1i m6 2p, r0o0v0e da nt ne mu apl esraavtiunrges , control and optimized set point.
712.722.1662 | www.interstates.com |
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