Automation technology is driving energy efficiency trends in the process industry. A feature of this is continuous process control, which holds the operating points as close to the optimum as possible. Thereby, processes can be kept at their individual limit.

An increase in energy efficiency due to process control can be achieved by continuous energy monitoring and implementation of energy-optimised process control measures.

The following tips can help companies planning to optimise process control systems:

• Determine status quo: This includes raw and processed data about the specific energy demand within a process, including information about how energy is supplied, transformed, and stored, as well as the technology used
• Rough and detailed analysis: This two-step analysis identifies plant components with potential for optimising, including the identification of relevant energy consumers and preparation of an energy flow diagram
• Valuation of collected information and selection measures: Adequate measures are deduced from collected information; identification of optimum operating points can boost energy efficiency
• Implementation and performance review: As soon as a measure is established it should be regularly monitored

Some effective measures to improve process control systems include:

• Optimising applied basic control
• Using advanced process control systems
• Using soft sensors
• Using of plant asset management
• Using of process diagnosis

Optimisation of basic controls results in a significant increase of energy efficiency. Specific measures include modification of applied controlled variables, manipulated variables and/or set points, and modification of applied closed-loop control.