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市场调查报告书
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1850216

先进製程控制 (APC)：市场占有率分析、产业趋势、统计数据和成长预测（2025-2030 年）

Advanced Process Control - Market Share Analysis, Industry Trends & Statistics, Growth Forecasts (2025 - 2030)
出版日期: | 出版商: Mordor Intelligence | 英文 145 Pages | 商品交期: 2-3个工作天内

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简介目录

预计到 2025 年，先进製程控制 (APC) 市场将创造 31 亿美元的收入，到 2030 年将达到 51 亿美元，年复合成长率为 10.6%。

APC（先进製程控制）-市场-IMG1

随着能源密集型製造商寻求应对波动的公用事业价格、满足排放严格的排放法规，以及管理日益复杂、多变量的流程（这些流程已超出传统PID迴路的处理能力），预测控制技术的应用正在加速普及。云端连接和嵌入式人工智慧使预测控制模型能够在分散式设施中运行，从而缩短部署时间并提高投资回报率。供应商正在围绕能源成本优化、即时品质保证和内建监管报告等功能打包应用程序，从而缩短投资回收期。在能源密集产业中，1-2%的产量比率提升就能转化为每年数百万美元的成本节约。持续不断的併购活动凸显了这场战略竞赛，旨在将软体、分析和网路安全整合到一个统一的平台中，该平台可以从工厂车间扩展到企业云端环境。

全球先进製程控制 (APC) 市场趋势与洞察

即时能源成本优化的必要性

燃料和电力价格的波动正将製程控制从提高效率的工具转变为降低成本的必要手段。能源成本可能占非炼油运作成本的50%以上，因此工厂正在实施预测演算法，以便在满足规格要求的前提下，将负载转移到更便宜的收费系统时段。已公布的案例显示，能源消耗降低了10%至20%，优化后的运作延长了维护週期，并减少了非计画性停机时间。

APC与工业物联网和人工智慧分析的集成

低延迟工业网路如今连接了感测器、控制器和云端引擎，使机器学习模型能够预测异常情况并在偏差扩散之前製定纠正措施。美国食品药物管理局 (FDA) 于 2025 年 1 月发布的指南建议采用即时人工智慧驱动的监控，从而消除了受监管製造商采用该技术的关键障碍。

前期成本高且整合复杂

全面实施的成本可能在50万美元到500万美元之间，这对小型工厂来说难以负担。棕地工厂改造通常需要设备升级和DCS系统更换，这会将工期延长至18个月，并可能导致生产中断。

细分市场分析

到2024年，软体将占据高阶製程控制（APC）市场份额的54%，这标誌着系统正从以硬体为中心的模式转向云端对应平臺发生决定性转变。推动这一细分市场成长的因素包括对快速部署、无缝DCS整合以及能够降低资本密集度的远端分析的需求。随着订阅模式降低准入门槛并提供持续的演算法升级，预计到2030年，云端託管解决方案的复合年增长率将达到12.9%。虽然硬体对于边缘执行仍然至关重要，但它正变得越来越商品化，而涵盖模型维护和性能调优的服务合约将随着工厂持续改进文化的兴起而不断扩展。这种转变将使供应商能够在几週内而非几个月内发布新的最佳化模板，从而加速数位转型蓝图的实施。

软体驱动的高阶流程控制 (APC) 市场预计将从 2025 年的 17 亿美元成长到 2030 年的 30 亿美元，这反映了微服务架构和容器部署策略的广泛应用。边缘网关目前将过滤后的资料路由到云端 AI 引擎，为本地控制器提供即时建议，同时兼顾网路安全、延迟和监管限制。

模型预测控制（MPC）预计到2024年将占总收入的46%，巩固其作为协调受限多变量过程的领先工具的地位。线性MPC在原油蒸馏和乙烯裂解等动态关係相对稳定的大规模连续操作中占据主导地位。随着特种化学品和製药厂面临不稳定的反应和严格的品质窗口，非线性MPC正迅速发展，预计其复合年增长率将达到12.8%。

预计到2030年，非线性模型预测控制（MPC）高阶製程控制（APC）市场规模将达到11亿美元，反映出市场对能够处理复杂反应动力学和可变进料组成的演算法的需求日益增长。供应商透过整合自适应建模和自整定功能来实现差异化，这些功能无需人工干预即可解决漂移问题，从而使操作人员能够以更少的工程投入维持最佳性能。

区域分析

北美地区预计占2024年销售额的37%，这得益于其早期数位化、丰富的炼油产能和强大的人才生态系统。联邦政府的节能奖励和透明的碳市场进一步推动了控制设备的升级。亚太地区预计将以11.8%的复合年增长率实现最快增长，这主要得益于中国3000亿元人民币（约417亿美元）的工业自动化计划，该计划优先考虑国内技术自主。印度、日本和东南亚国协也纷纷效仿，致力于透过自动化解决劳动力短缺和生产力差距问题。

欧洲仍然是创新热点地区，因为严格的气候变迁政策和欧盟税收体系将资金筹措成本与可衡量的脱碳成果挂钩。工厂正在利用先进製程控制（APC）来减少范围1排放，同时保持竞争力。同时，中东、非洲和拉丁美洲正在采用云端原生APC来克服基础设施限制，其中采矿和液化天然气（LNG）计划占据了主要应用场景。

其他福利：

  • Excel格式的市场预测（ME）表
  • 3个月的分析师支持

目录

第一章 引言

  • 研究假设和市场定义
  • 调查范围

第二章调查方法

第三章执行摘要

第四章 市场情势

  • 市场概览
  • 市场驱动因素
    • 即时能源成本优化的必要性
    • APC与工业物联网和人工智慧分析的集成
    • 更严格的排放气体法规
    • 大型特种化学品和液化天然气计划的复杂性
    • 适用于模组化撬装设备的即插即用型云端APC
    • 促进自主采矿和金属作业
  • 市场限制
    • 前期成本高，整合复杂
    • APC的人力短缺和维持该模式
    • 远端/云端 APC 的网路安全风险
    • 小型多产品间歇式生产装置的投资报酬率低
  • 价值/供应链分析
  • 技术展望
  • 监管环境
  • 新型空气动力控制系统与现有系统现代化改造的比较分析
  • 五力分析
    • 供应商的议价能力
    • 买方的议价能力
    • 新进入者的威胁
    • 替代品的威胁
    • 竞争程度

第五章 市场规模与成长预测

  • 按组件
    • 硬体
    • 软体
    • 服务
  • 依产品类型
    • 高级监管控制（ARC）
    • 模型预测控制（MPC）
    • 非线性模型预测控制
    • 多变量预测控制
    • 推理和其他控制
  • 透过部署模式
    • 本地部署
    • 云端基础的
    • 杂交种
  • 依流程类型
    • 连续製程
    • 批量处理
  • 按最终用户行业划分
    • 石油和天然气
    • 化工/石油化工产品
    • 製药
    • 饮食
    • 能源与电力
    • 水泥
    • 金属加工
    • 纸浆和造纸
    • 其他的
  • 按地区
    • 北美洲
      • 美国
      • 加拿大
      • 墨西哥
    • 南美洲
      • 巴西
      • 阿根廷
      • 其他南美洲
    • 欧洲
      • 德国
      • 英国
      • 法国
      • 义大利
      • 俄罗斯
      • 其他欧洲地区
    • 亚洲
      • 中国
      • 日本
      • 印度
      • 韩国
      • 澳洲和纽西兰
      • 其他亚洲地区
    • 中东和非洲
      • 中东
      • 沙乌地阿拉伯
      • 阿拉伯聯合大公国
      • 土耳其
      • 其他中东地区
      • 非洲
      • 南非
      • 奈及利亚
      • 其他非洲地区

第六章 竞争情势

  • 市场集中度
  • 策略趋势
  • 市占率分析
  • 公司简介
    • ABB Ltd.
    • Aspen Technology Inc.
    • Emerson Electric Co.
    • General Electric Co.
    • Honeywell International Inc.
    • Rockwell Automation Inc.
    • Schneider Electric SE
    • Siemens AG
    • Yokogawa Electric Corp.
    • SUPCON Technology Co. Ltd
    • Hollysys Automation Technologies Ltd
    • Endress+Hauser Group
    • Valmet Oyj
    • KBC Advanced Technologies
    • Metso Outotec
    • FLSmidth & Co. A/S
    • AVEVA Group plc
    • Azbil Corporation
    • Endress+Hauser Group
    • Valmet Oyj
    • AVEVA Group plc
    • Gensym Corporation
    • ICONICS Inc.

第七章 市场机会与未来展望

简介目录
Product Code: 56666

The advanced process control market generated USD 3.1 billion in 2025 and is projected to reach USD 5.1 billion by 2030, advancing at a 10.6% CAGR.

Advanced Process Control - Market - IMG1

Adoption accelerates as energy-intensive manufacturers seek to counter volatile utility prices, satisfy tightening emission mandates, and manage increasingly complex multi-variable processes that outstrip the capabilities of conventional PID loops. Cloud connectivity and embedded artificial intelligence now allow predictive control models to operate across distributed facilities, cutting deployment time and improving return on investment. Vendors are packaging applications around energy-cost optimization, real-time quality assurance, and embedded regulatory reporting, which shortens payback periods in industries where 1-2% yield improvements translate into multi-million-dollar annual savings. A steady flow of merger and acquisition activity underscores a strategic race to integrate software, analytics, and cybersecurity into unified platforms that can scale from the plant floor to enterprise cloud environments.

Global Advanced Process Control Market Trends and Insights

Real-time energy-cost optimization needs

Volatile fuel and electricity prices have elevated process control from an efficiency lever to a bottom-line necessity. Energy can represent more than 50% of non-crude refinery operating costs, so plants deploy predictive algorithms that shift load to cheaper tariff windows while maintaining specification limits. Published case studies report 10-20% reductions in energy use, which compounds as optimized operations extend maintenance intervals and lower unplanned downtime.

Integration of APC with IIoT & AI analytics

Low-latency industrial networks now connect sensors, controllers, and cloud engines, allowing machine-learning models to predict disturbances and prescribe corrective action before deviations propagate. The FDA's January 2025 guidance endorses AI-enabled real-time monitoring, removing a key adoption barrier for regulated manufacturers .

High upfront cost & integration complexity

Full-scale installations can demand USD 500,000-5 million, a hurdle for smaller plants. Brownfield sites often require instrument upgrades and DCS replacement, stretching schedules to 18 months and exposing operators to production-interruption risk.

Other drivers and restraints analyzed in the detailed report include:

  1. Emission-driven regulatory stringency
  2. Mega specialty-chemical & LNG project complexity
  3. Scarcity of APC talent & model upkeep

For complete list of drivers and restraints, kindly check the Table Of Contents.

Segment Analysis

Software captured 54% of the advanced process control market share in 2024, underscoring a decisive migration from hardware-centric systems to cloud-ready platforms. This segment is propelled by demand for rapid rollout, seamless DCS integration, and remote analytics that reduce capital intensity. Cloud-hosted solutions are forecast to grow at 12.9% CAGR through 2030 as subscription models lower entry barriers and provide continuous algorithm upgrades. Hardware remains indispensable for edge execution but is increasingly commoditized, while service contracts covering model maintenance and performance tuning expand as plants embrace continuous-improvement cultures. The shift enables vendors to release new optimization templates in weeks rather than months, accelerating digital-transformation roadmaps.

The advanced process control market size attributed to software is projected to expand from USD 1.7 billion in 2025 to USD 3.0 billion in 2030, reflecting pervasive adoption of microservices architectures and containerized deployment strategies. Edge gateways now route filtered data to cloud AI engines that feed real-time recommendations to on-premises controllers, balancing cybersecurity, latency, and regulatory constraints.

Model Predictive Control held 46% revenue in 2024, affirming its reputation as the primary tool for coordinating constrained, multi-variable processes. Linear MPC dominates large-scale continuous operations such as crude distillation and ethylene cracking, where thermodynamic relationships remain relatively stable. Non-linear MPC is gaining momentum, posting a 12.8% CAGR outlook, as specialty-chemical and pharmaceutical plants face non-steady-state reactions and strict quality windows.

The advanced process control market size for non-linear MPC is set to reach USD 1.1 billion by 2030, reflecting rising demand for algorithms capable of handling complex kinetics and variable feed compositions. Vendors differentiate by embedding adaptive modeling and self-tuning capabilities that respond to drift without manual intervention, allowing operators to maintain optimal performance with less engineering effort.

The Advanced Process Control Market is Segmented by Product Type (Advanced Regulatory Control, Model Predictive Control and More), by Component (Hardware and More), by Deployment Mode (On-Premise and More), by Process Type (Continuous Processes and More), by End-User Industry (Oil and Gas, Chemicals and Petrochemicals, and More), and by Geography. The Market Forecasts are Provided in Terms of Value (USD).

Geography Analysis

North America commanded 37% of 2024 revenue, underpinned by early digitalization, abundant refinery capacity, and robust talent ecosystems. Federal energy-efficiency incentives and transparent carbon markets further encourage control upgrades. Asia-Pacific is the fastest-growing, with an 11.8% CAGR outlook, fuelled by China's 300 billion-yuan industrial-automation program (USD 41.7 billion) that prioritizes domestic technology self-reliance. India, Japan, and the ASEAN economies are following suit, targeting automation to manage labor constraints and productivity gaps.

Europe remains an innovation hotspot where stringent climate policy and the EU taxonomy link financing costs to measurable decarbonization. Plants exploit APC to cut Scope 1 emissions while safeguarding competitiveness. Meanwhile, the Middle East, Africa, and Latin America are rolling out cloud-native APC to leapfrog infrastructure limitations, with mining and LNG projects often serving as anchor use cases.

  1. ABB Ltd.
  2. Aspen Technology Inc.
  3. Emerson Electric Co.
  4. General Electric Co.
  5. Honeywell International Inc.
  6. Rockwell Automation Inc.
  7. Schneider Electric SE
  8. Siemens AG
  9. Yokogawa Electric Corp.
  10. SUPCON Technology Co. Ltd
  11. Hollysys Automation Technologies Ltd
  12. Endress+Hauser Group
  13. Valmet Oyj
  14. KBC Advanced Technologies
  15. Metso Outotec
  16. FLSmidth & Co. A/S
  17. AVEVA Group plc
  18. Azbil Corporation
  19. Endress+Hauser Group
  20. Valmet Oyj
  21. AVEVA Group plc
  22. Gensym Corporation
  23. ICONICS Inc.

Additional Benefits:

  • The market estimate (ME) sheet in Excel format
  • 3 months of analyst support

TABLE OF CONTENTS

1 INTRODUCTION

  • 1.1 Study Assumptions & Market Definition
  • 1.2 Scope of the Study

2 RESEARCH METHODOLOGY

3 EXECUTIVE SUMMARY

4 MARKET LANDSCAPE

  • 4.1 Market Overview
  • 4.2 Market Drivers
    • 4.2.1 Real-time energy-cost optimisation needs
    • 4.2.2 Integration of APC with IIoT & AI analytics
    • 4.2.3 Emission-driven regulatory stringency
    • 4.2.4 Mega specialty-chemical & LNG project complexity
    • 4.2.5 Plug-and-play cloud APC for modular skids
    • 4.2.6 Autonomous mining & metals operations push
  • 4.3 Market Restraints
    • 4.3.1 High upfront cost & integration complexity
    • 4.3.2 Scarcity of APC talent & model upkeep
    • 4.3.3 Cyber-security risks in remote/cloud APC
    • 4.3.4 Weak ROI for small, high-mix batch plants
  • 4.4 Value / Supply-Chain Analysis
  • 4.5 Technological Outlook
  • 4.6 Regulatory Landscape
  • 4.7 Analysis of New APC Systems vs Modernization
  • 4.8 Porters Five Forces
    • 4.8.1 Bargaining Power of Suppliers
    • 4.8.2 Bargaining Power of Buyers
    • 4.8.3 Threat of New Entrants
    • 4.8.4 Threat of Substitute Products
    • 4.8.5 Degree of Competition

5 MARKET SIZE & GROWTH FORECASTS (VALUE)

  • 5.1 By Component
    • 5.1.1 Hardware
    • 5.1.2 Software
    • 5.1.3 Services
  • 5.2 By Product Type
    • 5.2.1 Advanced Regulatory Control (ARC)
    • 5.2.2 Model Predictive Control (MPC)
    • 5.2.3 Non-linear MPC
    • 5.2.4 Multivariable Predictive Control
    • 5.2.5 Inferential & Other Controls
  • 5.3 By Deployment Mode
    • 5.3.1 On-Premises
    • 5.3.2 Cloud-based
    • 5.3.3 Hybrid
  • 5.4 By Process Type
    • 5.4.1 Continuous Processes
    • 5.4.2 Batch Processes
  • 5.5 By End-user Industry
    • 5.5.1 Oil & Gas
    • 5.5.2 Chemicals & Petrochemicals
    • 5.5.3 Pharmaceutical
    • 5.5.4 Food & Beverage
    • 5.5.5 Energy & Power
    • 5.5.6 Cement
    • 5.5.7 Metal Processing
    • 5.5.8 Pulp & Paper
    • 5.5.9 Others
  • 5.6 By Geography
    • 5.6.1 North America
      • 5.6.1.1 United States
      • 5.6.1.2 Canada
      • 5.6.1.3 Mexico
    • 5.6.2 South America
      • 5.6.2.1 Brazil
      • 5.6.2.2 Argentina
      • 5.6.2.3 Rest of South America
    • 5.6.3 Europe
      • 5.6.3.1 Germany
      • 5.6.3.2 United Kingdom
      • 5.6.3.3 France
      • 5.6.3.4 Italy
      • 5.6.3.5 Russia
      • 5.6.3.6 Rest of Europe
    • 5.6.4 Asia
      • 5.6.4.1 China
      • 5.6.4.2 Japan
      • 5.6.4.3 India
      • 5.6.4.4 South Korea
      • 5.6.4.5 Australia & New Zealand
      • 5.6.4.6 Rest of Asia
    • 5.6.5 Middle East and Africa
      • 5.6.5.1 Middle East
      • 5.6.5.1.1 Saudi Arabia
      • 5.6.5.1.2 United Arab Emirates
      • 5.6.5.1.3 Turkey
      • 5.6.5.1.4 Rest of Middle East
      • 5.6.5.2 Africa
      • 5.6.5.2.1 South Africa
      • 5.6.5.2.2 Nigeria
      • 5.6.5.2.3 Rest of Africa

6 COMPETITIVE LANDSCAPE

  • 6.1 Market Concentration
  • 6.2 Strategic Moves
  • 6.3 Market Share Analysis
  • 6.4 Company Profiles (includes Global level Overview, Market level overview, Core Segments, Financials as available, Strategic Information, Market Rank/Share for key companies, Products & Services, and Recent Developments)
    • 6.4.1 ABB Ltd.
    • 6.4.2 Aspen Technology Inc.
    • 6.4.3 Emerson Electric Co.
    • 6.4.4 General Electric Co.
    • 6.4.5 Honeywell International Inc.
    • 6.4.6 Rockwell Automation Inc.
    • 6.4.7 Schneider Electric SE
    • 6.4.8 Siemens AG
    • 6.4.9 Yokogawa Electric Corp.
    • 6.4.10 SUPCON Technology Co. Ltd
    • 6.4.11 Hollysys Automation Technologies Ltd
    • 6.4.12 Endress+Hauser Group
    • 6.4.13 Valmet Oyj
    • 6.4.14 KBC Advanced Technologies
    • 6.4.15 Metso Outotec
    • 6.4.16 FLSmidth & Co. A/S
    • 6.4.17 AVEVA Group plc
    • 6.4.18 Azbil Corporation
    • 6.4.19 Endress+Hauser Group
    • 6.4.20 Valmet Oyj
    • 6.4.21 AVEVA Group plc
    • 6.4.22 Gensym Corporation
    • 6.4.23 ICONICS Inc.

7 MARKET OPPORTUNITIES & FUTURE OUTLOOK

  • 7.1 White-space & Unmet-Need Assessment