Integrated process and control system model for product quality control - A soft-sensor based application

In the near future of chemical industry, communication between design, manufacturing, marketing and management should be centered on modeling and simulation, which could integrate the whole product and process development chains, process units and subdivisions of the company. Solutions to this topic often set aside one or more component from product, process and control models, hence as a novel know-how, an information system methodology was developed. Its structure integrates models of these components with process data warehouse where integration means information, location, application and time integrity. It supports complex engineering tasks related to analysis of system performance, process optimization, operator training systems (OTS), decision support systems (DSS), reverse engineering or software sensors (soft-sensors). The case study in this article presents the application of the proposed methodology for product quality soft-sensor application by on-line melt index prediction of an operating polymerization technology.