INSUS predicts catalyst deactivation, connects performance drift to changing process conditions and recommends operating adjustments that help protect yield, control energy use and extend catalyst life. Process teams keep the decision.
01
Catalyst performance changes over time.
02
Deactivation can reduce yield before the lab confirms it.
03
Predict the drift and act before performance is lost.
The problem
Catalyst performance affects conversion, selectivity, yield, energy use and operating cost. As catalysts age, feedstock quality changes, equipment fouls or setpoints drift, the operating window can move away from its best range. Fixed replacement schedules and reactive adjustments often mean yield, by-products or energy penalties appear before the team has a clear early signal.
The shift
Process and production teams stay responsible for every setpoint and regeneration decision. What changes is whether catalyst deactivation risk and remaining useful life are visible before yield or quality is materially affected.
Today
With INSUS
How it works
This fits OptiStudio as process and quality decision support beside existing reactor controls. Access is read-only. It does not automatically change setpoints or replace APC.
Connect
Connect read-only to DCS/SCADA and historian data, process parameters, laboratory results, catalyst information, production records, feedstock data and available maintenance or regeneration history.
Understand
Analyze relationships between catalyst behavior and temperature, pressure, flow, feedstock characteristics, process conditions, equipment state and product-quality results.
Predict
Estimate catalyst degradation, remaining useful life and emerging performance drift so engineers can investigate before yield or product quality is materially affected.
Advise
Recommend operating adjustments expected to maintain conversion and selectivity, reduce unnecessary energy use and protect productive catalyst life within defined process and safety constraints.
Verify
Compare predicted catalyst and process outcomes with laboratory and production results so the model can be validated and refined for the specific reactor and catalyst system.
Getting started
For chemical manufacturers that already collect process, catalyst, laboratory and production data. Delivered through OptiStudio as catalytic-process decision support. Expert Services can help with data assessment and validation. Advisory and read-only. No new hardware where those records already exist.
Related for chemicals
Catalyst optimization sits beside batch energy forecasting and water optimization on the same chemical operation.
Catalyst activity declines over time and can reduce yield before the lab confirms it. This use case predicts deactivation and recommends operating adjustments for process-team review.
DCS/SCADA and historian signals, process temperatures, pressures and flows, laboratory results, catalyst information, feedstock characteristics and regeneration or replacement history. No new sensors when those records already exist.
No. It is decision support. Process engineers review every recommendation. Existing control systems and APC remain in charge.
Yes. Estimating deactivation and remaining useful life can support more informed regeneration and replacement planning than fixed schedules alone.
Yes. Where feedstock or raw-material data is available, it can be included so models reflect how feed variability affects catalyst and process performance.
Through OptiStudio as process and quality decision support. Expert Services can support data assessment, integration and validation with your process team.
Performance depends on reliable process, laboratory and catalyst history. Recommendations are reactor- and catalyst-specific. The system does not guarantee yield or energy improvements.
Chemicals · Catalyst optimization
Use your own process and laboratory history to predict catalyst deactivation, understand process drift and give engineers a data-driven basis for protecting yield and catalyst life.
