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Process engineering and data analytics have become increasingly important in regulated industries such as chemical and manufacturing processes. With strict regulations in place to ensure safety and environmental protection, process engineering and data analytics can help companies achieve compliance, optimise operations, and reduce costs.

Process engineering involves the design, development, and optimisation of processes and systems for the production of products. The goal is to maximise efficiency, minimise waste, ensure product quality and achieve SH&E regulations. Data analytics, on the other hand, involves the use of advanced software tools to analyse large datasets and extract insights that can inform decision-making.

As domain experts, process engineers are uniquely positioned to understand the dynamics behind big data through the evaluation of inputs, the ability to guide the process and assess outputs in the context of value and validity and leverage the insights provided through data analytics.

Process data analytics provides potential for a variety of outcomes from a dataset:

• Analysis – Analysis is a crucial component of continuous improvement initiatives in any industry. Root cause analysis, in particular, can accelerate the identification and resolution of underlying issues that may be hindering progress. By identifying the root cause of a problem, rather than simply addressing the symptoms, companies can implement targeted solutions that lead to long-lasting improvements.
• Monitoring – Early warnings through monitoring can help to identify potential issues before they become major problems, allowing companies to take corrective action before it is too late. With real-time monitoring, companies can make data-driven decisions, optimize their processes, and reduce unplanned and planned downtime.

• Prediction – Analysis of historical data and by using advanced modelling techniques, companies can gain insights into future trends and behaviours, enabling them to take proactive actions to improve yield, quality, robustness, stability, and reliability. With the help of predictive analytics, companies can make data-driven decisions and take proactive measures to improve their operations.

• Simulation – The ability to create virtual models of systems, processes, and products has become an indispensable tool for companies looking to make more accurate decisions faster and at a lower cost. This enables companies to identify potential issues before committing to costly physical prototypes or implementations, reducing the risk and accelerating the decision-making process. By leveraging these virtual models, companies can optimize their processes, improve product design, and ensure their operations are running as efficiently as possible.

• Optimisation – By analysing data and identifying optimal setpoints and settings, companies can ensure that their operations are running at peak performance levels. This can lead to significant cost savings, increased productivity, and improved product quality. Through continuous monitoring and adjustment of these setpoints and settings, companies can maintain optimal performance even as conditions change.
Process data analytics allows companies to gain a deeper understanding of their operations, identify inefficiencies and opportunities for improvement, and make data-driven decisions to optimise processes and reduce costs.

Overall, process data analytics presents a huge opportunity to transform the chemical processing industry, enabling companies to achieve compliance, optimise yield and robustness, and reduce costs. As regulations continue to evolve and become more stringent, it is crucial for companies to adopt these technologies in order to stay ahead of the curve. If you are a company operating in the chemical processing industry and are interested in implementing process engineering and data analytics to enhance your operations, consider reaching out to Industrial Technology Systems Ltd.

Our experts can provide tailored solutions to help you stay ahead of the competition and meet the challenges of the future. Don’t hesitate to get in touch today!