Chemicals & Materials

Continuous reactions and heat,
under precise control

Challenges on
chemical sites

Recurring problems where continuous reaction
and heat-based equipment run.

Several energy sources run at once

Electricity, LNG, steam and water all feed the process, yet each is aggregated separately and the whole picture never forms.

Small changes upset quality and production stability

Reactors, boilers, blowers and compressors run continuously, so a slight change in conditions carries straight through to the result.

Process variables need precise control

Air-fuel ratio, temperature, pressure and flow must all be held in range at once, and going by feel cannot keep them at the optimum.

Energy cost and carbon rules tighten together

Beyond simple monitoring, target-based energy management and process optimization are now expected.

How the problems are solved

What Refinery actually does
on a chemical site.

Unified electricity, LNG, steam and water monitoring

Problem
Multiple energy sources, each aggregated separately
Approach
Electricity, LNG, steam, water and consumption by asset are connected through an ontology into one structure, so the whole energy flow sits on one screen.
Outcome
Usage patterns made visible by energy source

Energy targets and overrun alerts

Problem
Over-consumption confirmed only after the fact
Approach
Targets are set by asset and process, and overrun is raised in real time.
Outcome
Over-consumption prevented and immediate response in place

Air-fuel-ratio-based blower VFD control for thermal fluid boilers

Problem
Thermal fluid boiler air-fuel ratio set by feel
Approach
The blower VFD is controlled against the thermal fluid boiler air-fuel ratio so the optimum is held.
Outcome
Better combustion efficiency and lower energy cost

Energy use analysis by asset

Problem
No way to tell which assets are eating up the energy
Approach
Energy is metered separately by asset and compared on equal terms.
Outcome
Energy-intensive assets identified

Air compressor state and operating parameter monitoring

Problem
Compressor anomalies that surface only after a stop
Approach
An AI agent reads compressor state and operating parameters together to catch early signs in patterns that differ from the norm, and proposes both the cause and the next action.
Outcome
Steadier equipment operation and more efficient maintenance

Unified greenhouse gas emissions management

Problem
Manual aggregation of emissions and regulatory reports
Approach
Emission metrics are aggregated automatically from field data into reports traceable to their source.
Outcome
Carbon compliance and energy performance management

How it fits together

How field data gains meaning and turns into a decision.

Site
  • Reactors
  • thermal fluid boilers
  • blowers
  • compressor sensors
Connect
  • SCADA
  • PLC
  • Plant EMS
  • Modbus
  • Serial
  • 4–20 mA
Refinery
  • Ontology
  • AI agent
  • rules and automation
Use
  • Energy dashboard
  • target alerts
  • emission reports

Where SCADA or a plant EMS already exists, a layer sits on top of it and integrates bidirectionally rather than replacing it. Where none exists, collection is built from the ground up.

Systems we connect to

The systems and protocols commonly used on chemical sites.

SCADAPLCPlant EMSERPModbusSerial (RS-485)4–20 mAOPC UA

Systems not listed here can still be connected over standard protocols and APIs. Get in touch and we will walk through it.

What you gain

Benefits across operations, engineering and management.

Target-based energy management

Targets are set and overrun is raised in real time.

Optimal air-fuel ratio control

Combustion data holds the ratio at its optimum.

Energy variance by asset

Energy is split asset by asset to pin the heavy consumers.

Early detection of energy anomalies

Patterns that differ from the norm are noticed first.

Carbon compliance

Emissions are aggregated automatically, with sources traceable.

The Refinery team will work with you to find
the answer that fits your chemical operation.

Request a demo