Soft Sensing

Maximize quality and output with robust online process models

Using available process data virtual analyzers calculate unmeasured parameters for closed loop controls.

Helping operation managers maintain realtime optimization

Virtual models based on historical data convert measured parameters such as temperature, pressure, and flow rate to rapidly predict variations in production qualities. Output from these models can be used in closed loop control systems to optimize production.

Directly see what happens in the plant

Directly see what happens in the plant

Soft sensors provide real-time feedback on your processes without investing in expensive online analyzers or waiting hours or days for manual laboratory test results

Improve asset performance

Improve asset performance

Process parameters calculated by soft sensors allow operators to maximize output by moving the average operating point much closer to operational limits. Higher impurity levels, within the operating limits, have a positive impact on the energy consumption.

Realtime monitoring of process health

Realtime monitoring of process health

Softsensors are used to compute, in real time, fouling in reactors and heat exchangers. This equipment health monitor reduces the risk for outages significantly. Running with equipment with less fouling will save millions per year on energy.

Realize significant cost savings

With the use of soft sensors based on good models and real time data, robust virtual sensors can be built in a cost-effective way to improve process controls.

IPCOS Case Study

Revamp of Inferential Models for Distillation Column

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Soft sensing: Revamp of inferential models for distillation column
Sulfur Dew Point Inferentials

Minimize energy consumption

A soft sensor to predict sulfur dew point at each stage of a Claus reactor was developed based on known factors and then fed into an APC system to minimize energy use and maximize conversion.

IPCOS Case Study

Sulfur Dew Point Inferentials

Read the case

Optimize product concentrations

Even for very slow process dynamics, a soft sensor/virtual analyzer can be developed to improve control of a property, and then used to optimize production output in conjunction with an APC system.

IPCOS Case Study

Controlling Properties with Very Slow Dynamics Using Virtual Analyzers and Step Response Models

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Controlling properties with very slow dynamics using virtual analyzers and step response models

Soft sensing end-to-end value


.. and more reduction of product quality variations


energy (steam) reduction in distillation columns when soft sensors used in combination with APC perform accurate quality control.


reduction of emissions (CO2, NOx, Cl,..) due to optimal combustion control (furnaces/boilers/…) powered by soft sensors

> 1M US$

energy savings when fouling of reactors and heat exchangers is detected at an early stage.

Other services


Advanced Process Control

APC systems maintain your operation at the optimal operating point. APC improves product yield, maximizes throughput, increases your plant’s efficiency under varying feedstock quality and operating conditions.

Process Modeling Predicts Safety Margins

Process Modeling

Turnkey models provide in-depth intelligence for improved analysis, troubleshooting, and operation

Emissions monitoring: Meet all emissions requirements

Emissions Monitoring

Meet environmental goals by tracking and reporting emissions & targets.


Machine Learning & Data Science

Data-driven models identify hidden patterns that can lead to increased quality and predictability.

Discover the advantages of getting real time feedback from your plant processes with the use of soft sensors!

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