Models
Twins built forcritical processequipment.
Each model combines live plant data, first-principles physics and machine learning — tailored to how that piece of equipment really behaves.
Heat transfer
Heat Exchanger
Our heat exchanger twin compares how the exchanger is actually performing against how it should perform at today's flows and temperatures. Rigorous thermal rating keeps the physics honest, while machine learning learns the exchanger's own fouling behaviour — so you know exactly how much duty you are losing and when cleaning will pay for itself.
What it tracks
- Inlet & outlet temperatures
- Heat duty & overall U-value
- Fouling resistance
- Shell & tube-side pressure drop
- Approach temperature
- Energy lost to fouling
What you get
- Plan cleanings on condition, not on the calendar
- Reclaim lost heat and cut furnace fuel
- Catch tube leaks and bypassing early
Reaction engineering
Methanol Reactor
The methanol reactor twin models syngas conversion through the catalyst bed using reaction kinetics and heat balances, calibrated continuously against plant data. It tracks the temperature profile and catalyst activity over time, helping operators push methanol yield safely, avoid hot spots and plan catalyst change-outs with confidence.
What it tracks
- Syngas composition (H₂, CO, CO₂)
- Bed temperature profile & hot spots
- Conversion per pass
- Catalyst activity & deactivation
- Methanol yield & selectivity
- Pressure & recycle ratio
What you get
- Higher methanol yield from the same feed
- Safer operation with hot-spot early warning
- Predict catalyst end-of-life months ahead
Rotating equipment
Water Pump
The pump twin places the live operating point on the pump's own performance curve and tracks how far it drifts from best efficiency. Combining pump hydraulics with machine learning on vibration and power data, it flags cavitation risk, wear and energy waste early — turning surprise failures into planned maintenance.
What it tracks
- Flow, head & operating point
- Efficiency vs. best efficiency point
- NPSH margin & cavitation risk
- Power & energy consumption
- Vibration & bearing temperature
- Remaining useful life
What you get
- Cut pumping energy by running closer to BEP
- Avoid unplanned trips and seal failures
- Maintain based on real wear, not run-hours