White spirit, a widely used industrial solvent, is produced through the distillation of petroleum fractions. The efficiency and quality of white spirit heavily depend on precise process control in distillation plants. Advanced process control (APC) systems are now being implemented to optimize distillation, reduce energy consumption, and ensure consistent product quality. This blog explores key APC techniques used in white spirit distillation plants.

Challenges in White Spirit Distillation

Distilling white spirit requires separating hydrocarbon fractions within a specific boiling range (150–200°C). Variability in feedstock composition, energy inefficiencies, and product quality fluctuations are common challenges. Traditional PID (Proportional-Integral-Derivative) control systems often struggle with these dynamic conditions, leading to suboptimal performance.

Advanced Control Strategies

  1. Model Predictive Control (MPC)

MPC uses real-time data and predictive models to optimize distillation column operations. It anticipates disturbances (e.g., feed composition changes) and adjusts parameters like reflux ratio and reboiler heat to maintain optimal separation. MPC improves yield and reduces energy waste.

  1. Neural Network-Based Control

Artificial neural networks (ANNs) learn from historical process data to predict optimal operating conditions. ANNs can detect subtle patterns in distillation behavior, allowing for adaptive control that enhances efficiency and minimizes off-spec product batches.

  1. Real-Time Optimization (RTO)

RTO systems continuously adjust setpoints based on real-time analytics. By integrating data from multiple sensors, RTO ensures the distillation column operates at peak efficiency, balancing throughput and energy consumption.

Benefits of APC in White Spirit Distillation

Improved Product Consistency – Tighter control over boiling range and purity.

Energy Savings – Reduced reboiler steam consumption by up to 15%.

Reduced Downtime – Predictive maintenance minimizes unexpected shutdowns.

Conclusion

Advanced process control is revolutionizing white spirit distillation by enhancing precision, efficiency, and sustainability. As APC technologies evolve, plants can achieve higher profitability while meeting stringent environmental regulations.