Title: Batch processes monitoring based on statistical and engineering process control integration: case of alkyd polymerisation reactor

Authors: Wafik Hachicha

Addresses: Unit of Mechanic, Modelling and Production (U2MP), Engineering School of Sfax, University of Sfax, B.P. 1173, Sfax 3038, Tunisia; Department of Industrial Management, Higher Institute of Industrial Management of Sfax (ISGI), University of Sfax, B.P. 954, Sfax 3018, Tunisia

Abstract: The aim of this research is to expand a framework that integrates two important concepts: statistical process control (SPC) and engineering process control (EPC). Most of the literature researches on integrated SPC/EPC systems are focused into continuous process mainly with algorithmic SPC. The integrated SPC/EPC systems in batch process control have not received the same degree of attention. This paper is a first of its kind in integrated SPC/EPC systems that applied in batch process. The proposed SPC/EPC integration is performed continually in active SPC for the batch making advance and in run-to-run (RTR) control action between batches. As a validation step, the proposed approach is applied to an industrial batch alkyd polymerisation reactor. Through this case study application, process engineers at the company are now able to use a valuable decision making tool when the production process is affected by certain disruptions, with obvious consequences on product quality, productivity and competitiveness.

Keywords: batch processing; process monitoring; statistical process control; SPC; engineering process control; EPC; integrated SPC-EPC; run-to-run; RTR control; data-driven quality improvement; alkyd polymerisation reactors.

DOI: 10.1504/IJAAC.2012.051886

International Journal of Automation and Control, 2012 Vol.6 No.3/4, pp.291 - 309

Received: 19 Dec 2011
Accepted: 08 Sep 2012

Published online: 07 Nov 2014 *

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