Stay Ahead of Change

Explore our research, insights, and examples of real client imapct, designed to help you embrace the key forces of change and get to value faster.
Patents

Burner shield to reduce soot buildup

DC Bookbinder, BL Harper, MB Mummudi-Boopathy, P Tandon US Patent 9,540,27

Patents

Limit based threshold estimation for prognostics and health management

S Ramaswamy, MM Boopathy US Patent 10,126,209

Patents

Behind casing wash and cement

R Watts, S Haavardstein, L Hovda, JC Stevens, D Mueller, B Borland, US Patent 11,136,86

Patents

Behind casing wash and cement

L Hovda, D Mueller, JC Stevens, A Phadke, P Gonuguntla US Patent 11,686,175

Patents

Behind casing wash and cement

R Watts, S Haavardstein, L Hovda, JC Stevens, D Mueller, B Borland, US Patent App. 18/116,744

Patents

Behind casing wash and cement

L Hovda, D Mueller, JC Stevens, A Phadke, P Gonuguntla US Patent App. 18/316,030

Patents

Behind casing cementing tool

L Hovda, JC Stevens, D Mueller, A Phadke, P Gonuguntla US Patent 11,879,305

Case Studies

Order fill projection

Predicting the end-of-cycle (EOC) for a heat exchanger due to fouling is a persistent challenge for refineries. By proactively forecasting when a heat exchanger requires cleaning, refineries can implement risk-based maintenance planning, optimizing processing rates, and reducing operating and maintenance costs. Historically, engineers had to manually combine data entries in spreadsheets, spending ...

Case Studies

Debutaniser Column Monitoring

Predicting the end-of-cycle (EOC) for a heat exchanger due to fouling is a persistent challenge for refineries. By proactively forecasting when a heat exchanger requires cleaning, refineries can implement risk-based maintenance planning, optimizing processing rates, and reducing operating and maintenance costs. Historically, engineers had to manually combine data entries in spreadsheets, spending ...

Case Studies

CO and Nox Prediction for Boilers

Predicting the end-of-cycle (EOC) for a heat exchanger due to fouling is a persistent challenge for refineries. By proactively forecasting when a heat exchanger requires cleaning, refineries can implement risk-based maintenance planning, optimizing processing rates, and reducing operating and maintenance costs. Historically, engineers had to manually combine data entries in spreadsheets, spending ...

Case Studies

Compressor Performance Monitoring

Predicting the end-of-cycle (EOC) for a heat exchanger due to fouling is a persistent challenge for refineries. By proactively forecasting when a heat exchanger requires cleaning, refineries can implement risk-based maintenance planning, optimizing processing rates, and reducing operating and maintenance costs. Historically, engineers had to manually combine data entries in spreadsheets, spending ...

Case Studies

Mixing Studies

Introduction Embark on a journey into the heart of our technological expertise, Mixing Facility. In the realm of the Chemical sector, optimizing tank configurations for increased yields is paramount. Challenges arise in determining the optimum configuration of mixing tanks, selecting the appropriate impeller type, impeller position, and impeller clearance to enhance yields through the mixing proce...

Case Studies

Development of gas void fraction sensor system

Introduction Embark on a journey into the heart of our technological expertise, Mixing Facility. In the realm of the Chemical sector, optimizing tank configurations for increased yields is paramount. Challenges arise in determining the optimum configuration of mixing tanks, selecting the appropriate impeller type, impeller position, and impeller clearance to enhance yields through the mixing proce...

Case Studies

Foam Transportation Loop

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Foam Transportation Loop

Aeration and foaming occur during bottle filling process causes spillage of material leading to loss of material and less filling. Experiments were carried to gain more insight into fundamental mechanical of aeration and foaming during bottle filling.

Case Studies

Coffee Bean Dryer

Project aimed to create an efficient drying process that would not burn the coffee beans. To achieve this, Tridiagonal created a computational fluid dynamics (CFD) model and conducted a pilot plant proof of concept at TRL-3. Following the pilot plant success, the company conducted a simulation study and experimental study to further refine the CFD model. Then we manufactured and shipped a large dr...

Case Studies

Solid-liquid mixing in rotary drums

Rotary drums are commonly used for mixing of solids with liquids. Objective is to develop understanding of the solids liquid mixing process in the rotary drum using experimental techniques.

Case Studies

Paraffin Wax Stripping in Field-Scale Pipelines

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Sand Control Screen Erosion and Flow Performance

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Restart and Gelling study in 4-inch pipeline

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Multiphase & Single-phase flow study for sand transport in inclined well

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Liquid metal Transport

Mercury migrates from source rocks, metal-rich fluids, oil producing organisms and it accumulates in oil & gas pipeline. Mercury pollutes the marine eco-system by biomagnification and corrodes the pipeline.

Case Studies

Erosion-Corrosion Testing

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Erosion Testing

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Control Valve Erosion Test

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Automated Inflow Control Device Erosion Test

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Mixed Flow Pump

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

SMX Static Mixer

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Esterification Reactor

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Impeller Design – PSD

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Polymerization Reactor

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Neutralization Tank

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Asthma Inhaler

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Drug Diffusion

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

PBT Batch Reactor

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Prediction of power output in natural gas-fired power generation plant

Predicting power output in natural gas-fired peaker power plants is critical due to their intermittent operation and high economic significance. These plants, which supply power sporadically and at a premium price, pose a unique challenge for grid operators. We aim to forecast power output based on environmental conditions, enabling more informed decisions about plant activation and power purchasi...

Case Studies

Cooling Tower - Analysis of Temperature & Total Power Prediction (Production across different area under Cooling Tow..........

In the realm of cooling tower operations, the interplay between temperature signals and equipment power consumption is pivotal for optimizing efficiency and economy. Understanding the nonlinear relationship between temperature signals and power usage is essential for enhancing performance and minimizing operational costs. This analysis aims to identify key temperature signals within the cooling to...

Case Studies

Predicting CO and NOx emissions from turbines

In the realm of gas turbines, predicting emissions of carbon monoxide (CO) and nitrogen oxides (NOx) holds significant importance for regulatory compliance and environmental stewardship. This project focuses on developing predictive models that can accurately forecast CO and NOx emissions from gas turbines under varying operating conditions. By analyzing key factors such as combustion temperature,...

Case Studies

Development of Energy Yield models for Turbine

In the chemical and petrochemical industries, the development of energy yield models for turbines is crucial for optimizing efficiency and reducing environmental impact. This project focuses on identifying key process parameters (KPIs) that significantly influence turbine performance and energy yield. By understanding these parameters, engineers can develop predictive models and implement soft sen...

Blogs

Strategizing your Predictive Maintenance Journey

With the increasing adoption of Digital Transformation and Industry 4.0, it's nearly impossible to talk about it without considering Predictive Maintenance. Be it Oil & Gas, Chemicals, Metals-Mining, renewables, or the Bio-pharma industry - everyone starts the journey with the implementation of Predictive Maintenance. Being an essential part of Digital transformation, it can be a simple plug-a...

Blogs

Integrated Sustainability Opportunities in the Metals & Mining Industry

The metals and mining industry stands as one of the world’s most energy-intensive sectors accountable for significant emissions and environmental impact.

Case Studies

Nox and CO Prediction for Boiler

Effective prediction of NOx and CO emissions from boilers is crucial for regulatory compliance and environmental protection. Key process parameters (KPIs) correlated with emission levels include combustion temperature, fuel composition, air-to-fuel ratio, and flue gas recirculation rates. By analyzing both historic and real-time data, it is possible to predict NOx and CO emissions accurately. This...

Case Studies

Chromatography and Transition Analysis

Chromatography and Transition Analysis play a pivotal role in various industries, particularly in the purification of substances and the separation of complex mixtures. However, ensuring the reliability and effectiveness of chromatography columns presents ongoing challenges. Over time, column substrates degrade, necessitating periodic refreshment to maintain optimal performance. Despite the signif...

Case Studies

Aggregate and Analyze Alarms

Aggregate and Analyze Alarms is a critical process in industrial settings aimed at enhancing operational efficiency and equipment reliability. This process involves consolidating alarm data from various sources to identify patterns and trends, facilitating engineers' analysis and troubleshooting efforts. By uncovering relationships between alarms, operators can gain deeper insights into underlying...

Case Studies

Continuous Process Verification

Continuous Process Verification is a cornerstone of quality assurance in manufacturing, ensuring that processes consistently meet predefined specifications. However, maintaining effective monitoring in the face of product changes, instrument calibration drift, and process upsets poses significant challenges. Additionally, establishing universal rules for Critical Process Parameters (CPPs) and Stat...

Case Studies

Shift Handover Report

The Shift Handover Report serves as a vital communication tool to ensure the seamless transition of operations between shifts in a manufacturing environment. Its primary objective is to facilitate the maintenance of continuous, safe, and compliant operations by effectively transferring critical process information from outgoing to incoming operators. By providing a structured framework for conveyi...

Case Studies

Overall Equipment Effectiveness (OEE) Reporting

Overall Equipment Effectiveness (OEE) reporting is essential for identifying process bottlenecks and maximizing production efficiency across a manufacturing site. By providing a comprehensive understanding of equipment performance, OEE reporting helps streamline operations and improve productivity. However, standardizing and scaling OEE analysis across diverse assets ensures consistent performance...

Case Studies

Identification, Categorization, & Reporting of Performance Losses

Manufacturing companies must systematically track, categorize, and report performance losses to identify inefficiencies and justify improvement projects. This process enables the identification of underperforming elements within the production line and provides a basis for targeted enhancements. By doing so, companies can streamline operations, enhance productivity, and allocate resources more eff...

Case Studies

Asset Utilization (OEE) Monitoring

Asset Utilization (OEE) Monitoring aims to analyze the performance of batch processes by identifying time spent in various phases. This analysis helps reduce unproductive process time, such as during cleaning and maintenance, and highlights differences in manual re-cleaning events between shifts. By quantifying opportunities to reduce waiting times, OEE monitoring supports improved efficiency and ...

Case Studies

Batch Quality Prediction

Batch quality prediction is crucial for optimizing manufacturing processes and ensuring efficient resource utilization. By accurately predicting batch quality, manufacturers can adjust process inputs in real-time, improving yield and reducing waste. This proactive approach helps minimize energy consumption and raw material usage, leading to more efficient and cost-effective production.

Case Studies

Accelerate Biopharmaceutical Scale-Up

Accelerating the scale-up of biopharmaceutical production is essential for bringing new therapies to market more quickly and cost-effectively. Predicting cell growth accurately at scale, based on data from laboratory and pilot studies, is a complex task. This complexity is compounded by the need to integrate data from various sources. Streamlining this scale-up process can significantly reduce dev...

Case Studies

Continuous Drug Product Quality by Design (QbD) Model

The Continuous Drug Product Quality by Design (QbD) model aims to ensure consistent product quality from development through to commercial production. One significant hurdle in this process is maintaining information integrity during the technical transfer from R&D to production. Additionally, implementing effective process monitoring within a multivariate design space presents complexities. D...

Case Studies

Batch Tracking and Cycle Time Analysis

Reducing cycle time in batch manufacturing is challenging due to the complexity of defining and analyzing process phases to identify variations and idle times between batches. Additionally, pinpointing areas for process and capital improvements requires detailed understanding and analysis. Effective batch tracking and cycle time analysis are essential to uncover inefficiencies, minimize idle times...

Case Studies

Pump Health Monitoring

Inability to detect and anticipate pump performance issues can result in prolonged shutdowns, revenue loss, and potential environmental or safety hazards.

Case Studies

Filter Membrane Predictive Maintenance

Ineffective Clean-In-Place (CIP) procedures or fouling of filter membranes can lead to various operational challenges, including increased cycle times, lost yield, or poor product quality. Additionally, detecting and modeling long-term deterioration in filter membrane performance poses significant challengess. This use case focuses on developing predictive maintenance strategies for filter membran...

Case Studies

Compressor Health Monitoring and Maintenance

Inability to detect and anticipate compressor performance issues can have detrimental effects, including unplanned shutdowns, revenue loss, and safety hazards.This use case aims to address these challenges by implementing comprehensive health monitoring and maintenance strategies for compressors. By leveraging advanced monitoring technologies, we can proactively identify potential issues, minimize...

Case Studies

Pharma/LifeSciences industry

To ensure optimal performance and longevity of heat exchangers, it's essential to address several challenges. Firstly, optimizing the maintenance schedule is crucial for minimizing downtime and maximizing efficiency. Additionally, heat exchangers tend to foul over time, which can significantly reduce their effectiveness. Moreover, maintenance events should be economically driven to prioritize reso...

Case Studies

Process Monitoring of Desulfurization Unit and Sulfur content Prediction

Live monitoring of KPIs in a desulfurization unit ensures sulphur content in desulfurized gas oil is kept within target limits. By predicting sulphur content (mg/kg) based on real-time data, operators can optimize the desulfurization process. Additionally, predicting power output in natural gas-fired peaker plants, which operate intermittently and command higher prices per kilowatt-hour, helps gri...

Case Studies

Leaching Rate Prediction in Manganese Ore Processing

Developing an accurate predictive model for the complex nonlinearity of electric-field-enhanced pyrolusite leaching presents a significant challenge. The manganese leaching process involves crushing and grinding the pyrolusite ore (MnO2) to increase its surface area. This use case focuses on creating a predictive model for leaching rates in manganese ore processing. By addressing the nonlinear dyn...

Case Studies

Mineral Industry

Achieving optimal zinc recovery in the mineral industry is challenging due to the direct impact of processing efficiency on recovery rates. The interaction of key parameters in complex ways makes it difficult to pinpoint their specific effects on recovery. This use case focuses on optimizing the zinc ore beneficiation process to enhance recovery rates. By analyzing and understanding the interactio...

Case Studies

Predictive Maintenance of Flash Evaporator

In the chemical industry, flash evaporators are crucial assets that require careful monitoring and maintenance to minimize runtime failures and downtime. However, the operations plant team faces numerous operational challenges due to frequent failures of critical assets like evaporators. This use case focuses on implementing predictive maintenance strategies for flash evaporators to address these ...

Case Studies

Bearing Failure Analysis

The recent bearing failures in the induced draft fan of the boiler system at a power plant have raised concerns. The challenge lies in determining the root cause, especially with limited events and no deviations observed in other critical variables. This use case focuses on conducting a comprehensive analysis of the bearing failures to identify the underlying cause. By leveraging advanced analytic...

Case Studies

Pump Health Monitoring

This use case focuses on developing advanced techniques for the identification of internal cracks in aluminium billets. By leveraging innovative approaches and data-driven methodologies, we aim to streamline the crack detection process, enhancing efficiency and reducing costs. In the process industry, maintaining the condition of pumps is crucial to prevent unscheduled downtime and avoid the costs...

Case Studies

Identification of Internal cracks in Aluminium Billets

Detecting internal cracks in aluminium billets poses significant challenges due to the complexity of crack formation and the difficulty in maintaining process parameters at optimal levels. Conventional methods such as failure analysis or ultrasonic testing are either time-consuming or costly, further complicating the inspection process.

Case Studies

Energy Analysis & Optimization of Kneader in Green Anode Plant

The kneading process in a green anode plant involves numerous parameters and complex dynamics, necessitating a comprehensive understanding of its intricacies. However, identifying the parameters that most significantly impact the energy consumption of the kneader and cooler remains a challenge. This use case focuses on conducting energy analysis and optimization of the kneader. By delving into the...

Case Studies

Pitch Demand & Anode Density Prediction in Green Anode Plant

Anode density is intricately linked to the composition and properties of anode paste, where pitch plays a pivotal role. Accurate prediction of pitch demand is crucial to ensure optimal availability for production while achieving desired anode density. This use case tackles the challenge by developing predictive models to forecast pitch demand and anticipate anode density. Download the PDF to explo...

Case Studies

Chemical & Structural Properties Analysis of Coke & Pitch

Understanding key parameters like quinoline insoluble, softening point, VBD, real density, and moisture content is vital for assessing coke and pitch quality. However, statistical metrics for these parameters can significantly impact production, potentially affecting anode and metal quality. This use case explores the analysis of these properties and their production impact.

Case Studies

Aluminum production – Optimized Feed Strategy for ALF3

Maintaining precise bath temperature (958±2°C) is crucial for efficient aluminum production. However, existing controllers often struggle to regulate temperature, causing fluctuations in both temperature and ALF3 mass. This use case explores developing an optimized ALF3 feed strategy to address these challenges. By leveraging advanced control algorithms, we aim to minimize fluctuations and enhance...

Case Studies

Aluminum production – Optimized Feed Strategy for ALF3

Achieving high magnetic flux density and low magnetic core loss in electrical steels is contingent upon various metallurgical and operational factors, including texture, grain size, chemical composition, and coiling temperature. However, optimizing the rolling process to meet these requirements presents a significant challenge. This project focuses on addressing this challenge by optimizing rollin...

Case Studies

Data Driven Root-Cause Analysis

The occurrence of two electrodes being remelted from a single ingot has resulted in the rejection of defective ingots, with one deemed acceptable and the other rejected due to transverse cracks. This project aims to conduct a thorough root-cause analysis using data-driven methodologies. By analyzing relevant data points and patterns, we seek to identify the underlying factors contributing to the d...

Case Studies

Nozzle Clogging Prediction during Continuous Casting

Nozzle clogging is a major contributor to oxide inclusions in steel, impacting the cleanliness of the final product. These clogs frequently interrupt the casting process, resulting in downtime and diminished productivity. This project is dedicated to developing predictive models for anticipating nozzle clogging during continuous casting. By leveraging historical data and advanced analytics, operat...

Case Studies

Silicon Content Prediction of Hot Metal in Blast Furnace

The silicon content of molten iron serves as a crucial indicator of temperature trends within a blast furnace. However, the wide variation in silicon content and the time delay in offline analysis pose challenges for operators in assessing the furnace's thermal operating conditions. This project focuses on developing predictive models to anticipate silicon content in hot metal, leveraging real-tim...

Case Studies

Hanging Prediction in Blast Furnace

Operating under intricate and dynamic conditions, blast furnaces are susceptible to hanging events influenced by numerous parameters. However, the interior of a blast furnace is inaccessible and challenging to monitor directly, hindering the real-time detection of hanging incidents. This project focuses on developing predictive models to anticipate hanging events in blast furnaces. By leveraging a...

Case Studies

Real-Time Deployment of BTP Prediction Model in Sinter Plant

Ensuring the quality and productivity of sinter production in the iron industry relies heavily on monitoring and maintaining the Burn-Through Temperature (BTP) position and temperature. However, critical data such as %coke, coke fines, and sinter bed were previously unavailable, posing challenges to effective monitoring and prediction. This initiative focuses on deploying a real-time BTP predictio...

Case Studies

Predictive Maintenance of Heat Exchanger

Fouling, the unwanted deposition of materials on heat transfer surfaces, poses a significant threat to the efficiency of heat exchangers in process heating and cooling applications. By insulating heat transfer surfaces and impeding heat exchange, fouling undermines overall efficiency. Predicting the end-of-cycle (EOC) for a heat exchanger due to fouling is a persistent challenge across industries....

Case Studies

Predict Conveyor Belt Tensioning Date

In managing a vast network of conveyor belts, determining optimal tensioning schedules poses significant challenges. Existing tools often fall short in characterizing and predicting conveyor belt failures accurately. Moreover, relying on calendar-based tensioning can lead to unnecessary expenses. This project aims to address these challenges by developing predictive models to forecast conveyor bel...

Case Studies

Truck Fleet Maintenance Management

With each truck averaging a value of over $3 million, these assets are indispensable to mining operations. This initiative focuses on implementing proactive maintenance strategies to monitor and maintain the health of truck fleets effectively. By leveraging advanced monitoring systems and predictive maintenance techniques, operators can maximize uptime, extend asset lifespan, and ensure the smooth...

Case Studies

Predictive Modeling for Iron Ore Quality during Mining Operations

In the realm of mining operations, predicting the final quality of iron concentrate is pivotal for optimizing production processes. This project focuses on forecasting the percentage of silica present in the iron ore concentrate, a key determinant of its quality. By leveraging real-time data and predictive modeling techniques, engineers can anticipate silica levels in the concentrate, enabling pro...

Case Studies

Identification, Categorization, & Reporting of Performance Losses

Manufacturing companies face the challenge of efficiently tracking and categorizing performance losses to pinpoint problematic areas and justify improvement projects. This task often falls on Process Engineers, who can spend up to one week per month aggregating loss data for a single unit. This initiative aims to streamline this process by implementing automated systems and standardized methodolog...

Case Studies

Pump Health monitoring

Detecting and anticipating pump performance issues are critical in preventing prolonged shutdowns, revenue loss, and environmental/safety threats. This initiative focuses on implementing proactive health monitoring systems for pumps to address these challenges. By leveraging advanced analytics and real-time data, potential issues can be identified early, allowing for timely intervention to minimiz...

Case Studies

Induced-Draft Fan Predictive Maintenance

In industrial settings, ensuring the uninterrupted operation of induced-draft fans is essential for maintaining profitability. However, relying solely on routine maintenance schedules can overlook potential failures and incur unnecessary expenses. Additionally, visualizing maintenance trends, particularly concerning fan vibration, becomes challenging due to dust scale build-up. This initiative foc...

Case Studies

Clinker Production Reports

Aggregating clinker production data by shift is a standard practice in cement plants, yet its quantification poses challenges due to varying modes of operation. The diverse operational methods employed make it difficult to accurately quantify production figures, hindering efficient reporting. This initiative aims to streamline clinker production reporting processes by implementing standardized met...

Case Studies

Free Lime Modeling

Balancing lime addition to minimize both NOx emissions and free lime in clinker poses a significant challenge. With lab samples typically providing feedback with delays of 1-2 hours, operators face difficulties in timely adjustments. Excessive lime addition results in fuel wastage, while inadequate addition leads to poor-quality clinker. This initiative focuses on developing a predictive modeling ...

Case Studies

Burning Zone Temperature Prediction

In the quest for quality production, controlling temperature variations within the kiln's burning zone is paramount. The challenge lies in the diverse temperature ranges across the kiln, complicating monitoring and regulation. Low temperatures risk excess free lime, while excessive heat can compromise product quality and refractory lining integrity. This initiative focuses on predictive temperatur...

Case Studies

Kiln Stoppage Investigation (Mining & Cement Industry)

Kiln stoppages present a formidable challenge, resulting in substantial production loss and revenue impact. With a multitude of potential causes, investigating and identifying preventive measures for future occurrences can be complex. This initiative is dedicated to mitigating kiln stoppages by implementing proactive measures. Through comprehensive analysis and innovative strategies, we aim to min...

Case Studies

Grinding Mill Predictive Maintenance

This initiative targets the optimization of grinding mill maintenance to prevent unplanned downtime, a critical factor for profitability. Traditional maintenance schedules often overlook potential failures or result in unnecessary expenses. Moreover, continuous mill operation leads to wear and tear, causing production delays. By implementing predictive maintenance strategies, organizations can pro...

Case Studies

Cement Fineness Prediction

Maintaining optimal fineness in cement production is paramount for ensuring product quality and meeting production targets. However, conventional lab testing methods often entail significant time delays, impacting the timely control of Blaine size and potentially leading to compromised quality, missed production targets, and revenue loss. This initiative focuses on leveraging predictive modeling t...

Case Studies

Cement Grinding Mill KPI Monitoring

Effective monitoring of key performance indicators (KPIs) in grinding mills is crucial for preventing prolonged shutdowns, revenue loss, and potential environmental or safety hazards. This initiative aims to detect and anticipate issues proactively to maintain operational continuity and safeguard against disruptions. By implementing robust monitoring systems, organizations can optimize mill perfor...

Case Studies

Pump Health Monitoring

In the pursuit of operational excellence, this analysis focuses on optimizing pump performance to mitigate prolonged shutdowns and revenue loss. By implementing scalable, maintainable, and repeatable monitoring approaches, it aims to enhance economic performance, safety, reliability, and compliance. Identifying failure events and their durations facilitates timely corrective actions, enabling orga...

Case Studies

Cooling Tower - Analysis of Temperature & Total Power Prediction

Unlocking efficiency in cooling tower operations entails understanding the interplay between temperature signals and equipment power. This analysis delves into identifying which temperature signals significantly impact power consumption, paving the way for predictive modeling to optimize compressor power.

Case Studies

Fired Heater Monitoring and % O2 Prediction in Flue Gases

Monitoring fired heaters and predicting the percentage of O2 in flue gases is vital for optimizing combustion efficiency and minimizing emissions. Key data collected includes flow sensor readings of fuel gas, air, and crude oil, as well as temperatures of crude inlet, outlet, and sub-outlet streams. By performing correlation and trend analysis on this data, critical process parameters (KPIs) can b...

Case Studies

Debutanizer Column (Distillation Column) monitoring

Effective monitoring of a debutanizer column is essential for maximizing the LPG content in the top product and optimizing overall distillation performance. Continuous monitoring of the C4 fraction in the bottom products ensures process efficiency and quality control. Implementing a predictive model to estimate the butane fraction in the bottoms enhances performance by allowing for real-time adjus...

Case Studies

Nox and CO Prediction for Boiler

Effective prediction of NOx and CO emissions from boilers is crucial for regulatory compliance and environmental protection. Key process parameters (KPIs) correlated with emission levels include combustion temperature, fuel composition, air-to-fuel ratio, and flue gas recirculation rates. By analyzing both historic and real-time data, it is possible to predict NOx and CO emissions accurately. This...

Case Studies

Heat Exchanger Predictive Maintenance

Predicting the end-of-cycle (EOC) for a heat exchanger due to fouling is a persistent challenge for refineries. By proactively forecasting when a heat exchanger requires cleaning, refineries can implement risk-based maintenance planning, optimizing processing rates, and reducing operating and maintenance costs. Historically, engineers had to manually combine data entries in spreadsheets, spending ...

Blogs

Reduce your Carbon Footprint using Smart Optimizer Framework (ANN)

The global target of 1.5 C is now becoming a major focus for every industry, enacting strict corrections to reduce the carbon footprint across the value chain. Especially when it comes to process-manufacturing space (oil and gas, metals/mining, chemicals, pharma), we have reached to an alarming situation, where control of the emissions and optimization of the resource consumption is a must to have...

Blogs

Connected Analytics for Sustainability in Refinery Operations

With the advent of Technology, Oil and Gas Industry has transformed itself to adapt the best of analytics practices to extract maximum profit, without much expense at the productivity losses. Where, analytics practices include the use of Machine Learning/AI, Hybrid Modeling, Advanced Process Control (APC) and APM to mitigate the existing challenges of production losses, optimization, asset availab...

Blogs

Digital Transformation – Revolutionizing the Process Industry

“Technology is best when it brings people together” “Technology is best when you use it wisely” “Data is the real evidence” That’s right, today in this world of the digital era, we are all surrounded by digital technologies, tools & data. Everyone of us is now becoming a part of it, some driving it, and some being driven by it. For some, it’s incremental and for some it’s disruptive. But we al...

Blogs

Chemical 4.0 Solutions and Implementation Partner

Tridiagonal Solutions Chemical 4.0 practice leverages Industry 4.0 tech stacks to implement Manufacturing Excellence and Digital Transformation solutions. We bring a combination of tools, techniques, expertise, and solutions to support various initiatives (such as APM, APC, Digital Twin, Remote monitoring, Sustainability, etc.) of our customers. We work with a strong partner ecosystem and its stat...

Blogs

80-20 Principle – A Key Metric to apply in Manufacturing Data Analytics

You can’t avoid it now! – The opportunity landscape of Data Analytics is increasing day-by-day in every industry. Many organizations have done huge investments in building and aggregating a data layer, whether it is in MES, Historian or a data lake. The value of data is being unlocked and leveraged for getting better insights. The innovative organizations are exploring the complexity of the proble...

Case Studies

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Blogs

Achieving Operational Excellence in Metals and Mining with Data Fabric Implementation

In the dynamic and complex landscape of metals and mining operations, achieving operational excellence is crucial for sustaining competitiveness and driving long-term success. The effective implementation of a data fabric architecture, supported by an ISA95-based equipment hierarchy, offers an opportunity to incrementally transform implementation of solution to streamline processes, optimize resou...

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Blogs

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