Chemicals · Materials

Continuous reactions and heat,
under precise control

Challenges on chemical sites

Recurring problems in continuous reaction operations.

Several utilities run at once

Electricity, LNG, steam and water all feed the process, yet each is tallied on its own and the whole picture never forms.

Small changes move quality and stability

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

Process variables need precise control

Air-fuel ratio, temperature, pressure and flow must be held together, and judgment 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.

Representative use cases

What Refinery
actually does

on a chemical site.

Unified electricity, LNG, steam and water monitoring

Problem
Utilities tallied separately, each on its own
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 inverter control

Problem
Thermal boiler air-fuel ratio set by feel
Approach
The blower inverter is controlled against the thermal 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 asset consumes the energy
Approach
Energy is metered separately by asset and compared on equal terms.
Outcome
Energy-intensive assets identified

Air compressor state and operating factors

Problem
Compressor faults that surface only after a stop
Approach
An AI agent reads compressor state and operating factors together to catch flows 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 accounting

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

How it fits together

How site data gains meaning and turns into a decision.

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

Where SCADA or FEMS already exists, Refinery sits on top of it and integrates both ways 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.

SCADAPLCFEMSERPModbusSerial · RS-4854-20mAOPC-⁠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

Flows that differ from the norm are noticed first.

Carbon compliance

Emissions are aggregated automatically, with sources traceable.

Let’s find the answer that fits
your chemical operation, together.

Request a demo