Enhancing Plant Performance at Scale Using Digital Twin for a leading Integrated Petrochemical Manufacturer, Asia
Increased yield and production
Enhanced uptime of
equipment and plant assets
Reduced energy consumption
Revenue Augmentation
Business Challenge
To remain ahead in a highly competitive and efficiency-driven market, the leadership aimed to elevate digital maturity—moving beyond basic data collection to intelligent, real-time performance monitoring and optimization. The key challenge was to transform fragmented, under-leveraged data into dynamic intelligence that could drive real-time performance orchestration, increase yield, enhance energy efficiency, and increase asset reliability, while setting the stage for autonomous decision-making and future-ready operations.
Solutions Deployed
We deployed a digital twin solution powered by mcube, to transform plant monitoring from reactive to intelligent and insight-driven.
Key initiatives included:
Key initiatives included:
- Building a digital replica of the plant, integrated with a real-time data lake capturing sensor and process data.
- Enabling real-time monitoring of plant health, KPI’s, and equipment conditions.
- Implementing detailed visibility across all major systems—feedstock, cracking, polymerization, storage, and utilities.
- Empowering teams with visual dashboards, performance baselines, alerts, and root cause diagnostics.
Benefits
$8M in projected savings/revenue augmentation driven by:
- Increased production and improved yield
- Reduced energy consumption
- Enhanced uptime of equipment and plant assets
- Faster issue detection and response