Introduction
In the dynamic world of specialty chemical production, maintaining precise control over distillation processes is critical to product quality, efficiency, and safety. Parijat Controlware, Inc. (PCI) Distillation Column Control System offers advanced control solutions tailored for specialty chemicals, ensuring optimal separation, consistent purity, and reliable operations.
By integrating intelligent automation and AI-driven enhancements, the system provides predictive performance, adaptive tuning, and real-time decision-making support—helping plants achieve operational excellence across varied product batches and conditions.
Target Industries and Applications-
- Pharmaceutical Manufacturing: High-purity separation of intermediates and active ingredients.
- Fine & Specialty Chemicals: Precise control for custom chemical formulations.
- Petrochemicals & Refineries: Batch and continuous distillation optimization.
- Flavor & Fragrance Production: Accurate composition control for quality consistency.
- Biotech & Biofuels: Complex compound separation under variable feedstock conditions.
Core Components-
- Sensors and Field Instruments: Accurate real-time measurement of temperature, pressure, flow, and composition.
- Control Hardware: Robust controllers from PCI or PLC (you pick the make/model)
- Advanced Control Software: Real-time data acquisition, monitoring, alarm handling, trending, and control algorithms.
- AI Module: Machine learning engine for performance optimization, predictive control, and fault detection.
Control Capabilities-
- Temperature and Pressure Control: Real-time adjustment to maintain ideal column profiles.
- Flow Balancing: Optimized control of feed, reboiler, and condenser flows.
- Composition Monitoring: Integration with online analyzers (e.g., NIR, GC) to ensure product quality.
- Alarm & Safety Interlocks: Built-in logic for process safety and event handling.
AI-Driven Features-
- Predictive Control: Forecasts process behavior and adjusts proactively to minimize variability.
- Anomaly Detection: Identifies equipment or process deviations in real-time, enabling early intervention.
- Optimization Algorithms: Recommends setpoint tuning, energy-saving strategies, and production rate maximization.
- Digital Twin (DT) Integration: Simulates scenarios for training, failure testing, and predictive maintenance planning.
Options-
- PLC: Specify make/models
- Redundancy:
- AI & or DT
- Remote access
- Mobile Apps
- Smart Watch or Glass
- Emissions, compliance
- Warehouse, inventory management
- ERP systems
- Leakage detection
Some of the above features may require Hardware options, custom development or working with client’s SME