Plant Optimiser is the closed-loop optimisation engine of the Process Plant AI platform. It fuses live SCADA and sensor data with a hybrid-physics digital twin to recommend optimum setpoints — for dosing, aeration and pumping — that are pushed straight to your DCS/PLC.
Plant Optimiser runs where treatment never stops — turning operational data into measurable savings.
Optimise chemical dosing and aeration for high-COD, variable-load industrial effluent while holding ZLD compliance.
City-scale energy-efficient aeration control and sludge management that holds effluent quality 24/7.
Stop overdosing. Coagulant, pH and nutrient dosing tuned continuously to influent quality and flow.
Intelligent blower load-balancing and peak-shaving cut energy use without sacrificing dissolved oxygen control.
Spot mechanical anomalies from vibration and thermal trends before they trigger unplanned downtime.
Benchmark and optimise across every plant, site and process train from a single control-room view.
A hybrid-physics engine that understands your plant's thermodynamics, fluid dynamics and chemistry — not just correlations.
A 1:1 virtual replica of your facility that simulates operational changes safely before they touch the real plant.
Streams live sensor, PLC and lab data into the model on a continuous cadence — edge-first, zero-latency.
The optimiser proposes exact target values — you approve, or let it apply directly to the DCS/PLC.
Load-balancing and dosing logic that trims consumption while protecting effluent quality — typically 15% energy, 20% chemical.
Anomaly models flag drifting equipment and process upsets early — so maintenance is planned, not reactive.
Hard limits keep every recommendation inside discharge consent — audit-ready evidence, automatically.
Plant Optimiser sits between your instruments and your controllers — sensing, simulating and acting in a continuous loop.
Flow, DO, pH, COD, BOD & lab feeds
Hybrid physics + AI model of the plant
Simulates & solves for best setpoints
Dosing, aeration & pump schedules
Setpoints applied to the plant
Live SCADA, sensor and Lab Digitiser records stream into the platform on a continuous cadence.
The hybrid-physics twin projects how the plant will behave under shifting load and conditions.
The engine solves for the lowest-cost setpoints that still meet every compliance limit.
Recommendations are approved and pushed to the DCS/PLC — the loop repeats with fresh data.
The Plant Optimiser console gives operators and engineers a single view of live performance, recommended actions and forecast risk.
| Parameter | Current | Recommended | Saving | |
|---|---|---|---|---|
| Blower airflow | 1,850 m³/h | → | 1,640 m³/h | 12% energy |
| Coagulant dose | 55 L/h | → | 44 L/h | 20% chem |
| Return sludge (RAS) | 68% | → | 61% | 9% pump |
| pH setpoint | 7.1 | → | 7.3 | stable |
| Feed pump VFD | 62 Hz | → | 57 Hz | 7% energy |
Typical results across deployed industrial and municipal plants running Plant Optimiser.
See Plant Optimiser run against your own process data in a guided pilot — and quantify the savings before you commit.
A module of Process Plant AI · Plant Optimiser v1.0 · Secure and Private