Case Study: Qenos achieves 5–10% throughput gain and seamless APC revamp with Aspen Technology’s Aspen DMC3

Next Generation of Advanced Process Control Delivers Benefits for Ethylene Manufacturer

Qenos, Australia’s leading ethylene and polyethylene manufacturer, needed to revamp its APC controllers to deliver a consistent supply of high‑quality ethylene despite a fluctuating ethane feed and no full‑time APC staff. To address throughput loss and high process variability, Qenos turned to Aspen Technology, deploying Aspen DMC3 with Adaptive Process Control.

Aspen Technology implemented Aspen DMC3, converting the cold end controller and running adaptive calibrations in closed loop with minimal disruption, completing the revamp in days. The solution boosted cold end throughput by 5–10%, cut overhead methane variability by 40% and tower dP by 20%, raised APC service factors to nearly 100%, and automated model updates—freeing engineers and improving operator acceptance.

Qenos

Richard Wawrzon

Process Engineering and Controls Team Leader