Real-time monitoring of an industrial batch process

This paper describes the development of a real-time monitoring system for a batch process operated by Aroma and Fine Chemicals Limited. The process shares many similarities with other batch processes in that cycle times can vary considerably, instrumentation is limited and inefficient laboratory assays are required to determine the end-point of each batch. The aim of the work conducted in this study was to develop a data driven system to accurately identify the end-point of the batch. This information can then be used to reduce the overall cycle time of the process. Novel approaches based upon multivariate statistical techniques are shown to provide a soft sensor that can estimate the product quality throughout the batch and provide a long-term estimate of the likely cycle time. This system has been implemented on-line and initial results indicate that it offers potential to significantly reduce operating costs.