AI for Optimizing Compressor Loops: Enhancing Crack Gas Compressor Performance

Project Overview

Enhancing efficiency and reducing costs for a major petrochemical manufacturer
Client: Large petroleum refinery and petrochemical manufacturer
Challenge: Optimize 5-stage Crack Gas Compressor system for improved efficiency and reduced costs
Approach: Data-driven intelligence leveraging advanced analytics and machine learning

Key Challenges

In the process industries, several key challenges can significantly impact operational efficiency and safety. Here are the main challenges we address:
  • High power consumption due to lower stage efficiencies
  • Excessive wash oil and Boiler Feed Water consumption
  • Fouling issues in inter-stage coolers
  • Need for real-time performance monitoring

Our Solution

Discover how our advanced AI/ML solutions can transform your operations. From data analysis to real-time KPI tracking, we provide comprehensive tools to enhance efficiency and safety.

A detailed image showcasing a data analytics dashboard with complex charts and graphs, highlighting key performance indicators (KPIs) and trends derived from four years of operational data. The image should convey insights and data-driven decision-making.
Advanced Data Analysis
We analyze four years of your operational data, uncovering hidden patterns and trends. This provides actionable insights for strategic decision-making and process optimization.
A visual representation of machine learning models, specifically GBT and BART, predicting efficiency improvements. The image should illustrate the predictive power of these models in optimizing business processes.
Predictive Efficiency Models
Our machine learning models, including GBT and BART, accurately predict efficiency gains. This enables proactive adjustments and resource allocation for maximum operational performance.
An image depicting a Design of Experiments (DoE) setup, visualizing the 'Golden Fingerprint Envelope' concept. The image should represent the systematic approach to identifying optimal process parameters.
Golden Fingerprint Envelope
We use Design of Experiments to identify the 'Golden Fingerprint Envelope, ' optimizing process parameters for peak performance and consistent results across your operations.
A dynamic, real-time dashboard displaying key performance indicators (KPIs) with interactive elements. The image should convey the ability to monitor and optimize performance in real-time.
Real-Time KPI Tracking
Our real-time dashboard provides instant visibility into critical KPIs. This allows for immediate adjustments and continuous optimization, ensuring peak operational efficiency and safety.

Key Results and Benefits

  • Optimized Crack Gas Compressor Loop parameters
  • Reduced power consumption across all 5 stages
  • Decreased wash oil and Boiler Feed Water usage
  • Mitigated fouling in inter-stage coolers
  • Implemented real-time performance insights
  • Established proactive maintenance framework

Conclusion

  • Industry & Focus: Optimization of the Crack Gas Compressor system.
  • Approach Taken:
    • Leveraged data-driven intelligence for system enhancement.
    • Applied advanced analytics to optimize performance.
  • Key Outcomes:
    • Substantial cost savings through improved efficiency.
    • Enhanced operational reliability with proactive maintenance.
    • Set a new industry standard for predictive maintenance.
  • Industry Impact:
    • Demonstrates the value of AI-driven optimization in industrial operations.
    • Positions the client as a leader in proactive maintenance strategies.

Capabilities

Industries

Resources

Company

Linkedin

© 2025 Process Point. All rights reserved.