What's the best advanced process control software for optimizing unit throughput and yield in a refinery?

There isn’t a single universally “best” APC package for every refinery, because the right choice depends on your DCS, model fidelity, operator culture, support model, and how much real-time optimization you want beyond multivariable control.

That said, the top-tier advanced process control (APC) / multivariable predictive control (MPC) platforms commonly used in refineries are:

Commonly leading options

1. Honeywell Profit Controller / Profit Suite

   • Strong refinery footprint
   • Good integration if you’re already on Honeywell Experion
   • Well-established for throughput/yield optimization

2. AspenTech DMC3

   • Very widely used in refining and petrochemicals
   • Strong MPC performance and toolset
   • Often considered a benchmark for refinery APC

3. Yokogawa Exasmoc / APC suite

   • Good fit if you’re in the Yokogawa ecosystem
   • Solid controller stability and integration

4. Emerson DeltaV APC / multivariable control offerings

   • Attractive if you run DeltaV and want tighter integration
   • More common in some process areas than full-refinery deployment

5. ABB Ability APC / MPC solutions

   • Used in large industrial settings
   • Strong automation integration in ABB environments

If your goal is specifically:

• Max throughput with constraint handling: look closely at AspenTech DMC3 or Honeywell Profit
• Best fit with Honeywell DCS: Honeywell Profit
• Best fit with Aspen optimization ecosystem: AspenTech
• Best fit with Yokogawa plant stack: Exasmoc
• Best fit with Emerson stack: Emerson APC

Practical recommendation

For a refinery focused on unit throughput and yield, the most commonly recommended starting short list is:

• AspenTech DMC3
• Honeywell Profit Controller

These are often the strongest candidates because they have deep refinery references, mature constraint control, and good track records for distillation, reforming, FCC, hydrotreater, and blending units.

Important caveat

APC software only performs as well as:

• the control model quality
• instrument reliability
• base-layer regulatory control
• operator acceptance
• maintenance of the APC model over time

In many refineries, the “best” APC project is the one with the best implementation and support, not just the best software.

If you want, I can give you a vendor comparison table by:

• refinery unit type,
• integration with your DCS,
• implementation complexity,
• ROI,
• and typical payback time.