Building a More Profitable Power Plant Through Advanced Process Control

In recent years, grid operation has entered a new paradigm—one that is more decentralized and less predictable. This shift is driven by the high penetration of variable renewable energy sources, combined with increasingly variable demand due to greater electrification in heating and transportation.

Not long ago, conventional power plants—such as combined cycle, hydro (STEPS), and nuclear—operated primarily as baseload generators with predictable output adjustments. Peaker plants, pumped-storage hydro, and demand response strategies managed real-time balancing.

Today, the rise of renewables has transformed grid operations, adding uncertainty and increasing dependence on dispatchable conventional power plants. The resulting more frequent startups, shutdowns, and rapid ramping significantly stress those plants and their equipment. This can lead to turbine deformation, thermal cycling of boilers and heat exchangers, and damaging thermal shocks in piping and valves. Combined-cycle facilities are particularly impacted and may face higher operation and maintenance costs, safety trips, reduced efficiency, and increased emissions.

Why modernization can’t wait

Short-term variability can often be managed with flexible assets. However, larger system-level challenges, such as the steep late-day ramping associated with the duck curve, require fast and flexible responses from conventional generation. Further, market structures are changing, and Transmission System Operators (TSOs) are rewarding flexibility. Together, this creates a compelling case for utilities to invest in both short-term assets and long-term modernization strategies.

Power plant modernization can range from upgrading control systems and software to replacing mechanical and electrical assets or complete units. In many conventional plants, such as hydroelectric or combined-cycle facilities, control and safety systems weren’t designed for today’s dynamic operating conditions.

To stay competitive, plant operators need smarter, data-driven systems that:

• Optimize performance in real time
• Reduce costs and emissions
• Adapt to shifting market conditions
• Avoid significant overhauls

Why traditional control systems fall short

For decades, power plants relied on traditional control systems built around simple Proportional-Integral-Derivative (PID) loops to manage key variable setpoint outputs and maintain recommended operating thresholds. These systems were designed for a time when power plants ran at a steady baseload and grid demands were more predictable.

However, because PID loops only have single-variable control, they struggle to handle the complex, multivariable interactions needed to optimize performance in real time. This is especially true under the dynamic conditions created by renewable energy integration, resulting in plant operators often taking a conservative approach to running equipment.

While this reduces perceived risk, it limits performance and leads to several key issues:

• Slow response times—Without predictive capabilities, plants can’t adapt quickly enough to sudden surges or drops in renewable generation.
• Manual adjustments—Operators frequently tune ‘by hand’ as conditions shift, such as fuel mix, load demand, or ambient temperature, which leads to inefficiencies and operator fatigue.
• Inefficient fuel use—Ramping is necessary, but without coordination, it causes instability in variables like temperature and pressure, accelerating wear, and driving up fuel consumption.
• Higher emissions—Fluctuations outside optimal operating conditions increase carbon and NOx emissions.
• Grid penalties—Power plants unable to meet fast-response requirements lose out on valuable flexibility rewards in modern energy markets.

Advanced process control

Advanced Process Control (APC) transforms this dynamic. While APC has been used for decades in industries such as refining, oil and gas, and chemicals, recent advances have made it increasingly relevant for power generation. Today’s APC solutions are becoming more flexible, easier to integrate, and better suited to real-time grid demands. This make them ideal for modernizing conventional plants.

Instead of relying on conservative setpoints and manual intervention, APC sits on top of existing Distributed Control Systems (DCS). Its predictive models identify the true optimal operating region and drive the process toward it. It respects the constraints that operators and engineers define while optimizing for safety, efficiency, and flexibility. APC doesn’t replace the plant’s core control system—it enhances it.

Think of APC as an intelligent assistant that continuously monitors plant conditions and makes predictive, real-time adjustments. Instead of operators making manual corrections, APC analyzes how factors like fuel and air demand, air distribution, or load ramps interact with critical plant variables like pressure, temperatures, or emissions. Then, it optimizes them simultaneously for maximum efficiency, safety, and flexibility.

From reactive to predictive with APC

Unlike traditional systems, APC proactively adjusts operations and helps maintain optimal performance in volatile grid conditions by:

• Fine-tuning multiple variables at once—Instead of adjusting one parameter at a time, APC solutions consider the complex multivariable relationships in the plant and drive the operation to the optimum point.
• Multipurpose handling—APC solutions surpass human capabilities to balance efficiency, flexibility, and emissions simultaneously.
• Anticipating changes instead of reacting to them—Predictive models analyze real-time conditions and proactively adjust plant operations before inefficiencies arise.

This helps achieve:

• Improved efficiency and reduced fuel consumption—Plants use less fuel and extend equipment lifespan, stabilizing operations and reducing unnecessary fluctuations.
• Integration without major infrastructure changes—Advanced optimization solutions are layered onto existing Distributed Control Systems (DCS), requiring no shutdowns or large-scale retrofits.
• Faster return on investment (ROI)—Small efficiency gains—even 1-2%—can translate into hundreds of thousands of dollars in annual savings, with ROI typically achieved within a year.*

Modern advanced process control systems are designed to work with any existing DCS. They operate independently and remain transparent to the operator. Once configured, the system is intuitive, easy to monitor, and requires minimal manual intervention, making it a trusted tool rather than a black box.

Real-world impact of APC: Measurable gains

These benefits are already being realized in power plants around the world. For example, a 400MW coal power plant in the U.S. implemented EcoStruxure™ APC  predictive process optimization. It achieved:*

• A 0.7% efficiency improvement
• 15,000 fewer tons of CO₂ emissions annually
• 24% reduction in nitrogen oxide emissions
• Nearly $700,000 in annual savings

Further, a biomass power plant in Spain saw similar gains. Their fuel savings reached $150,000 annually, emissions dropped by 10%, and operators reported significantly fewer manual interventions—reducing stress on the workforce and the plant itself.*

The path forward: A competitive edge for the future

We’ve seen firsthand how advanced process control can transform power plant operations. Today, our EcoStruxure APC solution is operational in over 300 installations worldwide, helping operators reduce energy usage, minimize emissions, and improve profitability.

As the energy transition accelerates, renewables will continue to grow, and grid demands will become more dynamic as power generation decentralizes further. This is an ideal opportunity for power plant operators to embrace real-time optimization and predictive control to improve efficiency and sustainability and gain a competitive edge in an increasingly complex market.

Find out more about Schneider Electric’s EcoStruxure APC.  Contact your local sales team to learn more.

*Schneider Electric internal customer data

Tags: Advanced Process Control, modernization, power and process