INSUS forecasts energy consumption for each chemical production batch from process, recipe, raw-material, production and energy data, helping teams plan production, control costs and identify abnormal energy use earlier. Energy and process teams keep the decision.
01
Every batch can have a different energy profile.
02
Energy overruns are often visible only after production.
03
Forecast the next batch before it runs.
The problem
Heating, cooling, mixing, compression, distillation and drying make batch energy demand highly variable. Consumption changes with recipe, raw materials, equipment state, schedule and ambient conditions. When energy is reviewed only through historical averages and end-of-batch reports, teams struggle to know what the next batch will need or why a run used more than expected.
The shift
Energy and process teams stay responsible for every schedule and setpoint decision. What changes is whether the expected energy profile of an upcoming batch is visible before it runs.
Today
With INSUS
How it works
This fits OptiStudio as energy and process decision support beside existing batch and utility systems. Access is read-only. It does not automatically change setpoints or schedules.
Connect
Connect read-only to DCS/SCADA and historian data, energy meters, MES/ERP records, batch recipes, production schedules and raw-material information already available to the plant.
Understand
Analyze relationships between energy consumption and recipe, production quantity, process parameters, raw materials, equipment conditions and production sequence.
Predict
Estimate the expected energy consumption of upcoming batches and identify deviations or over-consumption patterns against the plant's own baseline.
Advise
Provide advisory recommendations on batch sequencing, scheduling or controllable operating factors that may reduce unnecessary energy use while respecting quality and throughput constraints.
Verify
Compare predicted and actual consumption so the model can be validated and refined against the plant's recipes, equipment and operating practices.
Getting started
For chemical manufacturers that already collect batch, process and energy data. Delivered through OptiStudio as batch-energy decision support. Expert Services can help with data assessment and validation. Advisory and read-only. No new hardware where metering already exists.
Related for chemicals
Batch energy forecasting sits beside catalyst and water optimization on the same chemical operation.
Batch energy demand varies with recipe, materials and process conditions. This use case forecasts expected consumption and flags abnormal use for energy and process-team review before or during production.
DCS/SCADA and historian data, energy meters, batch recipes, production schedules and raw-material information. Laboratory or quality results help where they explain energy drivers. No new sensors when those records already exist.
No. It is decision support. Energy and process teams review forecasts and recommendations. Integration with plant systems is read-only.
Yes. Deviations from the expected batch energy profile can be flagged against the plant's own baseline for investigation.
Yes. Forecasts can help teams evaluate batch sequencing and when to run energy-intensive work, subject to quality, capacity and safety constraints.
Through OptiStudio as energy and process decision support. Expert Services can support data assessment, integration and validation with your plant team.
Forecast quality depends on reliable batch and metering history. Recommendations are process-specific. The system does not guarantee energy-cost reductions or replace utility-procurement decisions.
Chemicals · Batch energy forecasting
Use the process, production, material and energy data you already have to forecast batch-level consumption, support planning and identify inefficient batches earlier.
