INSUS helps chemical plants see where water is consumed, detect abnormal usage and recommend improvements for cooling, treatment, dosing and reuse using operational data the plant already generates. Operations teams keep the decision.
01
Water demand changes with production and process conditions.
02
Leaks, over-treatment and inefficient cooling waste water and money.
03
Predict, detect and prioritize water-use improvements.
The problem
Water supports cooling, heating, steam, processing, washing, rinsing and wastewater treatment. Management is often fragmented across systems. Static controls and reactive checks can leave over-treatment, undetected leaks, inefficient cooling and avoidable freshwater intake invisible until costs or quality issues appear.
The shift
Operations and utilities teams stay responsible for every dosing, blowdown and reuse decision. What changes is whether demand, abnormal use and the main drivers of water intensity are visible before losses persist.
Today
With INSUS
How it works
This fits OptiStudio as utilities and process decision support beside existing water and cooling systems. Access is read-only. It does not automatically change dosing or control loops.
Connect
Connect available water-flow, consumption, quality, pressure and temperature data with DCS/SCADA, historians, MES, LIMS, utility records, production data and maintenance history.
Understand
Analyze relationships between water use and production volume, process conditions, cooling demand, treatment requirements, water quality and equipment behavior.
Predict
Forecast water demand and flag unusual patterns in flow, consumption or water quality that may indicate leaks, equipment problems or process inefficiencies.
Advise
Recommend operating options for cooling-tower operation, chemical dosing, treatment, blowdown and reuse while respecting defined water-quality and process requirements.
Verify
Compare forecasts and recommendations with actual metering, quality and production results so the model can be refined for the plant's water systems.
Getting started
For chemical manufacturers that already collect water, process and production data. Delivered through OptiStudio as water-system 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
Plant-wide water optimization sits beside batch energy forecasting and catalyst optimization on the same chemical operation.
Water use across cooling, treatment and process steps is often fragmented. This use case forecasts demand, flags abnormal usage and recommends operating options for utilities and process-team review.
Water-flow and consumption measurements, water-quality information, DCS/SCADA and historian data, production data and relevant dosing or maintenance records. No new sensors when that metering already exists.
No. It is decision support. Operators and engineers review every recommendation. Existing control systems remain in charge.
Yes. Cooling operation, dosing, treatment, blowdown and reuse can be included where data exists. Dedicated cooling-tower work can also start from the cooling-tower optimization use case.
Water Use Intensity measures water consumption relative to production output, such as cubic metres per tonne of product. It is a practical KPI for tracking water efficiency against the plant's own baseline.
Through OptiStudio as utilities and process decision support. Expert Services can support data assessment, integration and validation with your plant team.
Usefulness depends on accessible water and process metering. Recommendations are plant- and system-specific. The system does not guarantee water-cost or chemical-cost reductions.
Chemicals · Water optimization
Use your existing water, process and production data to forecast demand, detect abnormal use and give teams a clearer basis for cooling, treatment, dosing and reuse decisions.
