Reactor upsets cost production days. Distillation upsets waste energy and product quality. Heat exchanger fouling chokes plant throughput. ProcessIQ gives your engineers real-time AI diagnostics across reactors, separators, heat exchangers, and safety systems — on demand, any shift.
ProcessIQ covers the full chemical processing chain — from reactor operations through separation, heat transfer, and utility systems. Every area loaded with failure modes, safety considerations, and regulatory context.
A reactor upset or distillation deviation can cost days of production time and trigger safety review cycles. ProcessIQ helps your engineers isolate root cause — process, mechanical, or instrumentation — before the deviation cascades.
Unplanned shutdowns in chemical plants typically cost $50,000–$200,000 per day when you factor in lost production, restart costs, and regulatory reporting. ProcessIQ reduces time-to-diagnosis from days to minutes.
ProcessIQ's chemical diagnostics incorporate OSHA Process Safety Management and EPA Risk Management Plan context. Corrective actions are documented with the rigor safety audits require.
Column performance problems — flooding, off-spec product, high energy use — are frequently caused by upstream feed conditions, not the column itself. ProcessIQ traces the signal upstream to find where the real problem lives.
Shift engineers and operators carry process knowledge that disappears at changeover. ProcessIQ captures and applies that institutional knowledge to every shift — keeping diagnostic quality consistent around the clock.
Start a free diagnostic on your chemical plant equipment. Reactors, distillation, heat exchangers — ProcessIQ covers it all.
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