Chemical &
Specialty Chemicals
Bring precision and safety to every batch and process change with models that reveal the right path forward.
Big Picture
Precision for Every Batch, Every Time
Chemical and specialty chemical processes are highly sensitive to small shifts in conditions, raw material properties, and control strategies. Onyx 360 provides engineering-backed insight into how these systems behave before changes reach production, helping manufacturers improve batch consistency, increase process safety, and strengthen operational reliability without risking live operations.
Case Study
Connected Performance for Chemical
Enabling Utilities Optimization at Chemical Plant Complex
Challenge
A major chemical facility depended on a complex steam distribution network supplying more than 20 process units. Disturbances from downstream operations created significant steam header variability, making boiler control difficult and reducing efficiency. The plant needed a safer, more predictable way to optimize header performance without impacting production.
Solution
Built a rigorous 1st-principles dynamic simulation of the utilities system—including boilers, commercial cogen, and steam headers—to accurately replicate real system dynamics. Using this environment, engineers designed and tested improvements off-line, ultimately implementing 30 feed-forward loops to reject disturbances caused by load changes.
Results
- >$500K annual savings from improved steam header stability
- Identified underperforming field devices and verified replacements
- Reduced variability increased overall reliability
- Simulator doubled as a training tool for startup and shutdown
500K
annual
savings
Utilities optimization through dynamic simulation
Digital twin for boilers, cogen, and steam headers
Engineering + training benefits in one solution
3D Simulation for Chemical Facilities
Visualize equipment configurations, train personnel on critical procedures, validate workflow changes, and support safe handling practices in immersive 3D environments tailored to chemical operations.
Operational Readiness at Greenfield Ammonia Plant
Challenge
A new ammonia plant was constructed in a remote region where experienced operators were scarce. With process conditions reaching 400–450°C and 180 atmospheres, the startup carried a significant operational risk. The project required a way to prepare operators, test procedures, and reduce hazards long before the physical plant came online.
Solution
Developed a Multi-purpose Dynamic Simulation of the full ammonia process, delivering pre-startup simulation accuracy within 1% of post-startup steady-state values. The simulator supported training for startup, shutdown, and partial-trip scenarios and was delivered months ahead of first production, allowing operators to train extensively and build confidence in difficult, high-risk operations.
Results
- 60+ operators trained before startup
- Higher safety and operational readiness
- Early exposure to startup scenarios reduced risk and uncertainty
- More efficient commissioning with fewer surprises
- LEL Excursion found in virtual commissioning that could have resulted in plant disaster.
- Plant engineer “…this paid for the simulator investment”
60+
operators trained on critical operations
Full-plant ammonia model
(with 1% steady-state accuracy)
Major risk reduction for a hazardous process in remote location
3D Simulation for Chemical Facilities
Visualize equipment configurations, train personnel on critical procedures, validate workflow changes, and support safe handling practices in immersive 3D environments tailored to chemical operations.
Benefits
What Chemical Manufacturers Gain
Faster Scale-Up & Tech Transfer
Validate process behavior from R&D through full production.
Batch-to-Batch Consistency
Control variability and protect quality across every formulation.
Higher Process Safety
Understand the impact of changes before implementation.
Optimized Reaction & Process Conditions
Improve yield, purity, and heat integration with data-backed decisions.
Regulatory Confidence
Simulate and document procedures to strengthen compliance posture.
Reduced Energy & Resource Use
Optimize steam, cooling, and raw material consumption.
Fewer Upsets & Shutdowns
Predict and prevent off-spec batches and abnormal conditions.
Stronger Workforce Readiness
Train teams safely using virtual environments and modeled scenarios.
Use Cases
Where Connected Performance Delivers Impact
- Reaction kinetics modeling and optimization
- Batch-to-continuous process evaluation
- Raw material variability impact assessment
- Heat transfer and energy usage optimization
- Safety-critical procedure training (startup, shutdown, emergency)
- Plant layout changes and new equipment validation
- Scale-up, tech transfer, and formulation changes
- Digital twins for continuous process monitoring