The state of the art in chemical process control in Japan: Good practice and questionnaire survey

In this age of globalization, the realization of production innovation and highly stable operation is the chief objective of the process industry in Japan. Obviously, modern advanced control plays an important role to achieve this target, but the key to success is the maximum utilization of PID control and conventional advanced control. This paper surveys how the three central pillars of process control – PID control, conventional advanced control, and linear/nonlinear model predictive control – have been used and how they have contributed toward increasing productivity. In addition to introducing eminently practical methods, emerging methods, and their applications, the authors point out challenging problems. In Japan, industry and academia are working in close cooperation to share their important problems and develop new technologies for solving them. Several methods introduced in this paper are results of such industry–academia collaboration among engineers and researchers in various companies and universities. Furthermore, soft-sensor or virtual sensor design is treated with emphasis on its maintenance, because soft-sensors must cope with changes in process characteristics for their continuous utilization. Maintenance is a key issue not only for soft-sensors but also for controllers. Finally, we will expand our scope and briefly introduce recent activities in tracking simulation and alarm management. A part of the results of our recent questionnaire survey of process control are also introduced; the results are extremely helpful in clarifying the state of the art in chemical process control in Japan.