Advanced Process Control Market Size USD 3.63 Billion By 2030

Published Date : 04 Nov 2022

The global advanced process control system market size accounted for USD 1.78 billion in 2022 and is projected to hit USD 3.63 billion by 2030, growing at a CAGR of 9.31% during the forecast period from 2022 to 2030.

Advanced process control, also known as multivariable predictive control (MPC) or model predictive control, incorporates model-based software that is used to direct process operation. For these applications, the process model must precisely capture the process dynamics. Improved operational economics or production improvements are common motivators for implementing these applications.

Crucial factors accountable for market growth are:

  • Improved operation or production economics 
  • Rising demand for automation solutions across various industries 
  • Higher adoption rates of automation and the critical nature of industry operations 
  • Growing safety concerns in the process industries

Report Highlights

  • Due to the large installed base of advanced process control systems in developed regions such as North America and Europe, the service type dominates the market. 
  • Based on the end-use industries, oil & gas took the largest share in 2020. The term "advanced process control" (APC) refers to a wide range of sophisticated technologies and tools used to optimize oil and gas plant performance in a variety of applications. It is used to improve plant performance and stabilize operations by reducing fluctuations in key process variables.

Advanced Process Control Market Report Scope

Report Coverage Details
Market Size in 2022 USD 1.78 billion
Market Size by 2030 USD 3.63 billion
CAGR From 2022 To 2030  9.31%
Base Year 2021
Forecast Period 2022 to 2030
Segments Covered
  • By Product
  • By End-User
Regions Covered
  • North America 
  • Europe
  • Asia-Pacific 
  • Latin America 
  • Middle East and Africa 

Regional Snapshots

The Asia Pacific has the largest share of the advanced process control market. India and China dominate the Asia Pacific region's advanced process controls market. During the projection period, North America is expected to increase at a rapid pace. Because of the early adoption of automation throughout end-use sectors in nations such as the United States and Canada, this region has developed into a mature market for advanced process control technologies. In addition, the country has the highest installed nuclear power capacity and produces the most nuclear electricity in the world. Approximately 20% of the electricity produced in the United States is generated by 99 nuclear reactors scattered across 31 states. New nuclear reactors are likely to be built by 2021, according to estimates.

Market Dynamics

Driver: The rising demand for automation solutions across various industries

Rising demand for optimizing raw materials, resources, and production processes, and minimizing human labor are significant themes driving industrial automation adoption. In the industrial automation market, products, equipment, software, and systems are utilized to manage numerous processes and component mechanical devices to replace and expedite tasks formerly done by humans. They can provide improved operational flexibility while maintaining process quality. EDF Energy, situated in the United Kingdom, is utilizing RPA to automate human order entries that used to take 70 hours per month. The automation of eight procedures resulted in a six-fold return on investment. Furthermore, Exxon Mobil employs a contract planning bot that sends out notifications when contracts are up for renewal. Procurement now has more time to seek out new suppliers or rework old contracts. This means that contracts cannot expire without anyone being aware of them.

Restraint: High implementation cost

The high implementation cost will be a stumbling block in the advanced process control market. The APC plant's cost is determined by the control systems, interface and display, computing systems, software costing, and service charges. There is a high cost connected with the adoption and maintenance of the APC system due to a lack of unprofessional individuals. The economics of the APC continues to be a source of worry. Costs have not decreased. High maintenance, specialized support, and performance monitoring were all unanticipated and have increased ownership costs. Meanwhile, benefits have been less tangible than predicted and are frequently a matter of faith.


Many areas of the automobile value chain, from design to manufacture, distribution, and retail, are already infiltrated by technology. Connectivity, artificial intelligence, and an abundance of customer data, according to automotive experts, will drive investment well into the future. According to Frost & Sullivan's Future of Mobility research, IT spending would rise from $38 billion in 2015 to more than $168 billion in 2025. Tesla has long been a forerunner in the application of artificial intelligence and big data. They've been collecting data from drivers using onboard sensors since 2014, allowing them to release a wireless upgrade that improved the accuracy of their autopilot software. Significant expenditures in digitization by various industries such as autos, pharmaceuticals, and so on are driving the growth of the advanced process control market. 

Challenges: The issues in the advanced control processes will act as a challenge in the market  

The use of advanced control and optimization systems in oil and gas and petrochemical plants has become a commercial reality. These advanced systems offer numerous benefits to process units, including greater stability and safety, adherence to limitations, and increased profitability. It is a significant difficulty to install and maintain these complex systems with high performance. Instrumentation issues, poor tuning of the regulatory and advanced control, unreliable process dynamic models, unmeasured disturbances, and other factors all have an impact on its performance.

The difficulties in tuning controllers are mostly linked with the identification of models, the detection of process non-linearities, the interaction between control loops, and defining the required performance for each control loop. Some systems, such as offshore petroleum platforms, have disturbance patterns that fluctuate over time. The intensity of the slug flow can alter due to variations in the gas lift, for example.

Recent Developments

  • January 2019 – ControlSoft, Inc., a global provider of software products and advanced control technologies used for real-time process control in industrial markets, acquired eSimulation Inc., a pioneer in the field of cloud-based software solutions for midstream natural gas gathering and processing. 
  • Honeywell Process Solutions (HPS) revealed that their advanced process control (APC) system at the Bashneft oil refining complex (a subsidiary of Rosneft Oil Company) has proven to be highly efficient, paying for itself in the first year of operation.

Some of the Prominent Players

  • Schneider Electric
  • Siemens
  • Rudolph Technologies
  • Aspen Technology, Inc.
  • Emerson Electric Co.
  • ABB
  • Yokogawa Electric Corporation
  • Panasonic Corporation
  • Rockwell Automation, Inc.
  • Honeywell International Inc.
  • Control Soft

Market Segmentation

By Product

  • Hardware
    • Control Systems
    • Interface and Display
    • Computing Systems
    • Others
  • Service
    • Advanced Regulatory Control
    • Multivariable Model Predictive Control
    • Inferential Control
    • Sequential Control
    • Compressor Control
  • Software

By End-User

  • Oil and Gas
  • Chemicals
  • Pharmaceuticals
  • Energy & Power
  • Mining, Minerals, and Metals
  • Food & Beverages
  • Others

Regional Segmentation

  • North America 
  • Europe
  • Asia-Pacific 
  • Latin America 
  • Middle East and Africa 

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