Chemical Process Industry

The chemical process landscape is rapidly evolving. Many refineries rely on Advanced Process Control (APC) to optimize their distillation columns, but run into one big issue – missing or incomplete data. Expensive simulators and traditional modeling approaches haven’t solved this challenge effectively.

Common Refinery Challenges

Unstable Product Quality: Inconsistent product composition makes it difficult to maintain reliable control or find the root cause of variations.
Slow Response to Changing Conditions: Feedstock variations or catalyst deactivation create disturbances which APCs can’t always properly handle.
Limited Economic Optimization: While APC achieve certain economic benefit, it rarely has the insights needed to maximize profitability to the fullest extent.
Dependency on Faulty Analyzers: When key analyzers go offline or deliver poor-quality data, APC systems lose visibility into critical variables – disrupting control and reducing performance.

How Mechanistic AI Helps

Mechanistic AI estimates unknown variables -like product composition or catalyst health – and delivers these insights directly to your DCS/PLC via OPC UA. This added layer of clarity helps APC respond faster to fluctuations and opens the door to real economic optimization.

Unlike costly simulators or purely data-driven models, our solution efficiently combines process knowledge with machine learning to deliver actionable, transparent results.

Mechanistic AI can help refineries to achieve

Increased Profit Margins

Better real-time decisions reduce utility costs and improve product yields.

Faster Deployment

Typical project timelines show a working model in as little as six months.

Increased Profit Margins

Better real-time decisions reduce utility costs and improve product yields.

Faster Deployment

Typical project timelines show a working model in as little as six months.

Higher Production

Accurate variable estimates and predictions help push throughput without compromising quality.

Quicker ROI

Many clients see a return on investment only in few months, thanks to more efficient operations and lower costs.

Higher Production

Accurate variable estimates and predictions help push throughput without compromising quality.

Quicker ROI

Many clients see a return on investment only in few months, thanks to more efficient operations and lower costs.

Facing similar challenges?

High operational costs, unpredictable plant behavior, or frequent APC adjustments – Mechanistic AI can bridge those gaps and unlock your plant’s full potential.

Get in touch