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Optimization of Operations


Improvement & Optimization of Operations

Compuchem Consultants' technology, originally developed at Proctor & Gamble, is a unique innovative technology that is unparalleled.


Putting simply, it brings out the “best” that can be achieved with your existing plant configuration and set of equipment. It thus improves the operation without necessitating any additional investment for equipment or control system. The user defines what the objective function is and therefore, what constitutes “improvement”. Given a set of inputs and corresponding outputs (one can start with as little as just one set of relationship but more would certainly be better), the system formulates a mathematical relationship between the input and the output and more importantly, “learns” from the relationship using its proprietary technology and based on the user defined objective, provides an advice on how to adjust the input variables next so that the overall objective improves. Going through these iterative cycles of “Operate – Learn – Advise”, it sequentially improves the operation and reaches optimum or near optimum in a short time.


The technology is not based on physical and chemical principles of a process but rather on mathematical relationships and therefore, it is quite general in its application.


The system can also be integrated with a process control system such that the above referenced “cycles” and resulting improvements are all automated. The required interfaces to many popular control systems, such as, Honeywell’s TDC 3000, already exist and at many of its installations, the system is already integrated with the respective control systems.


The technology is based on highly complex mathematics but its use is rather simple and requires little training.


The initial data required is minimal and the technology is considered to be a step ahead of neural networks. Any operation that meets a certain criteria (and most operations do) can be subjected to improvement/optimization by this technology. Of course, there can be situations where an operation is already running at its theoretical “best” and in those situations, no further improvement would be possible. However, in our experience of many years and worldwide, only about 1% of the industrial operations  fall into that category and even for those, use of this technology serves an important purpose of confirming that the operation is running at its best and to ensure that it continues to run at its best.


Summary of Unique Features of the Technology

The most distinguishing differences between our technology and alternate solutions (from Automation, Control, and/or other Optimization suppliers) are:


1. Since the start of an optimization study or an on-line implementation it both optimizes the fastest and safest.  It also maximizes cumulative performance. 


2. It is the simplest optimization technology to implement and maintain – we only need to have general knowledge about production operations, not special process expertise.


3. It optimizes while engaging in regular operations: it does not require performing non-productive, disruptive or expensive experimental or validation runs.


4. It is Non-Intrusive – it does not require changes to legacy process equipment or control system.


5. It performs full, non-linear, multivariable, balanced optimization of all performance metrics, even of those affected but not controlled directly by the Process Control System.


6. Because it is non-intrusive, generic and full-featured, the software does not require customization, and thus training is straight-forward and total costs are highly competitive. 


7. For the same reasons, maintenance and reconfigurations for changes in the optimization scope can be fully in the hands of the user.  However we offer on-site support such as training, guidance and reviews, plus remote support.


8. It can be applied in three optimization modes: stand-alone advisory, integrated advisory (one and bi-directional interface), and closed-loop; and users can readily change from one mode to the other – users are always in full control.  It can even be turned off so users can continue with the old Process Control System but now with enhanced awareness and knowledge, as happens with Studies.


We propose our technology as your company’s standard method to optimize and/or manage production operations, at least for the bottleneck processes. 


Please allow us to provide you with further details and also, study your existing operations and formulate an optimization plan for appropriate operations  - batch or continuous, for your further consideration, with no obligation on your part.


Electric Power Clients

Electric Power Industry

Allegheny Power
Ameren Marketing
BHEL (India)
Delta Electric (Australia)
Chemopetrol (Czech Republic)
Colorado Springs Utilities
Detroit Energy
Hoosier Energy
KU (Kentucky Utilities)
Long Island Lighting
NEES Companies
Scottish Power
Union Electric
Wisconsin Public Service
Zou-xian (China)

Industrial and Commercial Clients

Industrial & Commercial

Akzo Nobel
Allied Signal
Baxter HealthCare
Cardinal Health
Colbond Nonwoven
Collins & Eickman (Textron, Evart, Rantoul)
General Electric
Golden Aluminum
Kimberly Clark
Johnson Controls
Navdeep Chemicals (India)
Oxy Vynils
Pierre Foods
Pohang Iron & Steel (Korea)
Procter & Gamble
Sara Lee
ThyssenKrupp Budd