Contact Us

Energy & Materials

Enhancing Plant Performance at Scale Using Digital Twin for a leading Integrated Petrochemical Manufacturer, Asia
Increased yield and production
Enhanced uptime of equipment and plant assets
Reduced energy consumption

Annual cost savings

Business Challenge​

To remain ahead in a highly competitive and efficiency-driven market, the leadership aimed to elevate digital maturity—moving beyond basic data collection to intelligent, real-time performance monitoring and optimization. The key challenge was to transform fragmented, under-leveraged data into dynamic intelligence that could drive real-time performance orchestration, increase yield, enhance energy efficiency, and increase asset reliability, while setting the stage for autonomous decision-making and future-ready operations.

Solutions Deployed

We deployed a digital twin solution powered by mcube, to transform plant monitoring from reactive to intelligent and insight-driven.

Key initiatives included:
  • Building a digital replica of the plant, integrated with a real-time data lake capturing sensor and process data.
  • Enabling real-time monitoring of plant health, KPI’s, and equipment conditions.
  • Implementing detailed visibility across all major systems—feedstock, cracking, polymerization, storage, and utilities.
  • Empowering teams with visual dashboards, performance baselines, alerts, and root cause diagnostics.

Benefits

$8M in projected savings/revenue augmentation driven by:

  • Increased production and improved yield
  • Reduced energy consumption
  • Enhanced uptime of equipment and plant assets
  • Faster issue detection and response
Real-time analytics & Advanced Automation for Cracker, Texas US

1.7%

Increase in Ethylene Production (kt/y)

52%

Increase in furnace run-length (d/run)

46%

Reduction in Decoking time (h/y)

Annual cost savings

Business Challenge​

In response to rising global competition in the steel industry, plant management initiated efforts to optimize operations, focusing on enhancing productivity and maximizing product yield.

Solutions Deployed

Real-time Advisor & Furnace Coil Monitor
  • Optimized plant reliability, profitability and performance
  • Maximized furnace run-length and avoidance of coil overheating

Benefits

  • 1.7% increase in ethylene production significantly increasing plant productivity.
  • 52% increase in furnace run-length, significantly reducing OPEX.
  • 46% reduction in decoking time, significantly increasing efficiency.
Collectively delivering annual savings of 7.8M USD.
AI Plant Control for Steel-works utilities, Germany & Switzerland

3%

Increase in product yield (Argon recovery)

2%

Reduction in Energy Consumption

60-80%

Reduced effort to implement and maintain model

Annual cost savings

Business Challenge​

Operators need to optimize product yield to efficiently meet demand. A potential Linear Model Predictive Control (LMPC) solution should be deployed quickly, with continuous model updates requiring minimal effort.

Solutions Deployed

AI Plant Control (AIPC)​
  • Robust operations across operational modes with different machines in operation
  • Model extension for gas case: two weeks only

Benefits

  • 3% increase in argon recovery, significantly increasing plant productivity.
  • 2% reduction in energy consumption, with the potential for more saving over time as model learns and improves its performance.
  • 60-80% reduced effort to implement & maintain model,  compared to non-AI driven LMPC models.

These improvements collectively delivered annual savings of 300k USD

TCG Digital is happy to join forces with Linde Engineering, a significant milestone for the process industry. Linde Engineering and TCG Digital intend to join forces to offer AI-based self-learning optimization and automation solutions for process plants. These will enable production sites to move towards autonomous operations. They will continuously determine the most profitable production mode for each of the process plants and automatically transition each of the plants to this optimal mode. To achieve this, it is intended to combine TCG Digital’s mcube™ AI platform for real-time optimization with Linde Engineering’s proprietary AI Plant Control platform for automatic start-up, production changes, and closed-loop control of process plants. By leveraging TCG Digital’s Analytics & AI knowledge with Linde Engineering’s Advanced Automation experience we are confident to provide significant value for process plant operators.

We were looking for a partner that is able to provide a cloud agnostic AI and optimization platform for large and critical applications complying with the highest IT security requirements. With TCG Digital we found such a partner and were impressed about the speed and agility of our partner.

Thomas Heinzerling

Senior Vice President,
Linde Advanced Operations Services

We are glad to have found a partner combining huge experience in process plant operations and advanced automation who has developed robust AI based closed-loop control software.

Debdas Sen

CEO, TCG Digital

Whitepaper Overview

This whitepaper highlights the use of hybrid modeling in industries such as manufacturing, oil and gas, and supply chain management. It combines data-driven and physics-based models to enhance operational decision-making, optimize processes, and improve system performance through predictive insights and advanced analytics.

Download Whitepaper

Whitepaper Overview

This whitepaper explores how analytics can significantly boost productivity and profitability in manufacturing by optimizing processes, reducing waste, and improving decision-making. It highlights the use of data-driven insights to enhance operational efficiency, lower costs, and drive continuous improvement across the manufacturing value chain.

Download Whitepaper

Whitepaper Overview

This whitepaper explores how advanced analytics and optimization technologies can drive efficiency and reduce costs in the oil and gas industry. It highlights the role of AI and data-driven decision-making in improving exploration, production, and supply chain processes, ultimately enhancing operational performance and profitability.

Download Whitepaper


November 17, 2020

Lummus Digital Joint Venture formed by Lummus Technology and TCG Digital to Accelerate Digital Transformation

  • A new business will be branded Lummus Digital
  • The partnership combines a leading process licensing portfolio with a proven Big Data and AI platform to lead digital transformation in the refining, petrochemical, and gas processing sectors
  • The focus will be on digitalizing operations and assets, to ensure higher profitability, efficiency, reliability, and safety

HOUSTON and NEW YORK, Nov. 17, 2020  – Lummus Technology and TCG Digital today announced that the companies have entered into a strategic joint venture to form Lummus Digital (www.lummusdigital.com). The joint venture will work with Lummus’ existing and potential customers to implement digital analysis and operative solutions in their refining, petrochemical, and gas processing assets and across the hydrocarbon processing value chain

“Our focus on innovation continues with this joint venture,” said Dr. Purnendu Chatterjee, Founder Chairman of The Chatterjee Group. “We strive to deliver sustainable value to our esteemed clients with modern technology and deep process innovation, giving them the edge with digitalization in these difficult times. This joint venture will co-create and innovate with other areas of the group like TCG Crest, our research university, LabVantage and Haldia Petrochemicals.”

“Lummus Digital is another new and critical initiative we are launching to ensure our position as a leader of our industry and at the forefront of innovation,” said Leon de Bruyn, President and Chief Executive Officer of Lummus Technology. “With TCG Digital, we are partnering with a company that has a proven track record in digitalization and generating data-driven value for its clients in multiple industries. We are confident that Lummus Digital will leverage the strengths and capabilities of both companies to digitalize our customers’ operations and assets.”

Lummus Digital will explore the refining, petrochemical, and gas processing market in India where substantial growth is expected. The company will also start its operations in the US, Middle-East, and Europe immediately.

“We are excited that this partnership will allow TCG Digital and Lummus Technology to build on their core competencies and strengths, addressing the fast-evolving needs of the refining and petrochemicals industry,” said Debdas Sen, Chief Executive Officer of TCG Digital.  Mr. Sen added, “We serve the biggest downstream petroleum and petrochemical companies, helping them derive maximum value from their assets and investments through cutting edge digitalization and AI. Lummus Digital will leverage the mcube™ data platform to drive operational excellence, improve plant safety, enhance reliability, and increase margins.”

Lummus Digital will work with refining, petrochemical, and gas processing operators to provide big data, advanced analytics, artificial intelligence, process simulations, proprietary know-how, and 24/7 advisory services. The solutions are designed to: maximize economic benefit through digitalization; ensure operators and technicians are equipped with the insights to improve efficiency and reliability of their operations and assets; enhance the safety of the operating staff; bolster decision-making capabilities of the management, and; provide flexibility to quickly adapt operations to changing market dynamics.

Towards the end of June 2020, Haldia Petrochemicals Limited (HPL), a part of The Chatterjee Group (TCG), and Rhone Capital acquired the US-based Lummus Technology, at an enterprise value of $2.725 billion from McDermott International. With this new chapter, Lummus and HPL have been in a stronger position to provide world-class technologies and solutions to the clients of Lummus in India and abroad and deliver on their value proposition. This acquisition set the stage for the joint venture between TCG Digital and Lummus Technology.

Lummus is a leading master licensor of proprietary gas processing, refining, petrochemical, and gasification technologies as well as a supplier of catalysts, equipment, and related services. These technologies are critical in the refining of crude oil into gasoline, diesel, jet fuel, and lubes; the manufacturing of petrochemicals and polymers; as well as the gasification of coal into syngas.

TCG Digital and Lummus Technology are portfolio companies of The Chatterjee Group (TCG), which has an enviable track record as a strategic investor across sectors. Founded by Dr. Purnendu Chatterjee in the mid-’80s, the Group focuses on knowledge-based industries and owns and controls companies as long-term investments in several sectors including Petrochemicals, Pharmaceuticals, Biotech, and Digital Technology.

The joint venture has developed a distinct brand that reflects the identity and expertise of both companies. Lummus Digital has also launched a website, where you can learn more about this new business.

About Lummus Technology With a heritage spanning more than 110 years and a focus on innovation that has resulted in approximately 130 technologies and 3,400 patents, Lummus Technology is the global leader in developing and implementing process technologies. We are a Master Licensor of petrochemical, refining, gasification, and gas processing technologies, and a supplier of catalysts, proprietary equipment, and related services to customers worldwide. To learn more about the new Lummus, visit www.LummusTechnology.com.

About TCG Digital TCG Digital is the flagship technology solutions company of ‘The Chatterjee Group’ (TCG), a multi-billion dollar, multi-national corporation. We leverage hyper-contemporary technologies and deep domain expertise to engage enterprises with full-spectrum digital transformation initiatives in operational support systems, AI/ML, IoT NLP, advanced analytics, Big Data strategy,  enterprise mobility, app dev, and testing, cloud and micro-services, and automation, security. To learn more, visit www.TCGDigital.com.

Source: PR Newswire