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Polyester is a type of a polymer which contains the ester functional group. It most commonly refers to a type called polyethylene terephthalate (PET).  All-natural polyesters and a few synthetic ones are only biodegradable.  Polyesters are mostly used in the material for the clothing industry.  Synthetic polyester fibers have high water, wind, and environmental resistance, and they are less fire-resistant and can melt when ignited. Depending on the chemical structure, polyester can be a thermoplastic or thermoset.

Polyesters are used extensively used in apparel and home furnishings, from shirts and pants to jackets and hats, bed sheets, blankets, upholstered furniture, and computer mouse mats. Some industrial polyesters used in car tire reinforcements, fabrics for conveyor belts, safety belts, coated fabrics, and plastic reinforcements with high-energy absorption. Polyesters are also used to make bottles, films, tarpaulin, sails, canoes, liquid crystal displays, holograms, filters, dielectric film for capacitors, film insulation for wire, and insulating tapes. Polyesters are widely used as a finish on high-quality wood products such as guitars, pianos, and vehicle/yacht interiors.

Primary Process Control Improvements for Compressor and Polyester Fiber Units

Prior to any advanced process control (APC) project, even in polyester fiber plants, base-level PID tuning and optimization is a critical pre-requisite step. Unless base-level PID control loops are well tuned, advanced process control (APC) cannot work well, since advanced process control (APC) will be manipulating the setpoints of the base-level PID control loops. Therefore, the first necessary step in the overall process control improvement procedure for polyester fiber plants is PID tuning and optimization of primary or base-level PID controllers. The benefits of PID tuning and optimization in polyester fiber plants is the reduction of the oscillation amplitude or increase of the controller action by a factor of 2 or 3. This allows to enable smoother running of the polyester fiber plants with increased stability in all control loops avoiding unnecessary polyester fiber plants problems such as: damage and/or to fast wear and tear of the equipment, plant irregular shutdowns or off spec product properties and/or grades.

Many engineers are worried about causing shut-downs and operating problems when tuning PID controllers on equipment in the polyester fiber plants. Trial-and-error PID tuning methods can be ineffective and even catastrophic since these processes are super-fast and very unforgiving.PiControl Solutions LLC has extensive experience in PID tuning and optimization for PID controllers in the polyester fiber plants. We understand and know how to tackle with typical PID control loop problems and have customized PID tuning and optimization software tools to help optimize all polyester fiber plant controllers.

Our unique and novel closed-loop system identification technology makes it possible to tune and optimize base-level PID control loops quickly, efficiently and precisely. With our closed-loop technology we can perform system identification and PID tuning optimization of the following critical base-level PID controllers easily. Moreover, all process and data analysis and PID tuning and optimization work can be easily performed remotely by PiControl Solutions LLC process control engineers.

Advanced Process Control (APC) Improvements for Compressor and Polyester Fiber Units

PiControl Solutions LLC has extensive experience in advanced process control optimization for polyester fiber plants.  We understand the economics factors that drive the profit margin and have customized multivariable closed-loop system identification and advanced process control (APC) design and optimization tools to help optimize and improve the polyester fiber plants.

Because of the relatively small size of many polyester fiber plants, it is more cost-effective to implement DCS-based APC (advanced process control) rather than model predictive control (MPC) techniques. DCS-based APC (advanced process control) approach is fast, cost effective, all inside the existing DCS/PLC, avoiding the complications of OPC/other data communication links from computer to DCS.

We focus to analyze the process and provide the right economic advanced control solution for each polyester fiber plant. Our DCS-based APC (advanced process control) methodology has proven particularly successful in the polyester fiber plants. Our DCS-based APC (advanced process control) design will result in the following polyester fiber plant benefits:

  • Improved and stable performance of Feed preparation and Slurry mixing unit by keeping the desired Mol ratio between reactants (PTA/TPA and Ethylene Glycol)
  • Improved performance of Esterification units producing optimal reaction conditions and reaction conversion
  • Improved separation and reduced waste of Ethylene Glycol over separation columns without any column constraints violation
  • Improved performance of Pre-polymerization unit producing optimal reaction conditions and reaction conversion
  • Improved separation and reduced waste of Ethylene Glycol and carryover polymer product over spray separator columns without any column constraints violation
  • Improved performance of Finisher unit producing optimal reaction conditions and reaction conversion
  • Designed overall production rate maximization logic for increased complete polyester fiber unit production while staying inside of safety and shutdown process and equipment limits
  • Designed inferential control of product properties such as Intrusive Viscosity and Color for more stable and tighter unit operation
  • Designed signal validation and bumpless mode transfer logic for safe and stable unit operation
  • Designed advanced Furnace control which helps to increase the stability and efficiency of the furnace performance
  • Improved operation of a Dowtherm unit

After DCS work on advanced process control (APC) schemes is complete and all advanced process control (APC) parameters are calculated and optimized, PiControl Solutions LLC will over factory acceptance test (FAT) make sure that the advanced process control (APC) design is complete, correct and operable.  After completion of process control (APC) control project, PiControl Solutions LLC will conduct dedicated process control training for polyester fiber company.  PiControl Solutions has designed, optimized and started more than several well-proven polyester fiber control.

PiControl Solutions expects to see a minimum 2-4% improvement in the Polyester Fiber plant’s operating efficiency production and wasted Ethylene Glycol (E.G.) recovery increase and a 30% or more reduction in oscillation amplitudes due to optimized and advanced control. The oscillation reduction will enable smoother but faster running of the plant with increased stability in all control loops.

PiControl is an innovative process control software and services company that offers state of-the art, modern solutions at a lower cost, implemented in shorter time compared to competitors.

PiControl Solutions is the only process control and automation company in the world which can perform any advanced process control (APC) project completely remotely. Nowadays, every country uses high speed and reliable internet connection and with a help of medium to high resolution cheap web-cameras or even over widely used remote meeting and screen sharing applications it is possible to do complete design, tuning and optimization, FAT test and start-up of any advanced process control project. Over this low cost online/remote approach huge travel and accommodation costs can be saved and human health and safety can be kept on the high level.

For more information and details, please send us an email: [email protected] or call the Tel: (832) 495 6436.