Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Driving Yield Optimization Through Real-Time Analytics in a Petrochemical Complex
- Petrochemical Production
- Petrochemical complex producing ethylene, propylene, and aromatics for export markets in the GCC
- Driving yield optimization through real-time analytics
Obstacles Our Experts Have Transformed into Opportunities
A high-throughput petrochemical complex producing ethylene and propylene was falling short of its profitability targets, despite stable production volumes:
Inconsistent Product Yield
Product yield fluctuated by up to 4% per shift due to feedstock variations and delayed response to process deviations
Lagging Manual Reviews
Weekly performance reviews were manual and retrospective—operators adjusted based on lagging trends
Excel-Limited Process Insight
Process engineers relied on Excel for trend analysis, limiting visibility and predictive accuracy
Inefficient Energy Usage
Energy use was rising as units operated outside of optimal efficiency windows
No Unified Performance Dashboard
Management lacked a unified dashboard to visualize unit performance, energy KPIs, and loss metrics
Flying Blind Without Insights
The facility had massive optimization potential—but was flying blind when it came to actionable insights
Teec’s Expert-Led Solution
TEEC delivered its Strategic Process Optimization service as a digitally enabled performance improvement engine:
What Our Experts Did
Integrated real-time plant data (DCS, lab, historian) into a centralized analytics platform
Used machine learning and statistical models to identify ideal operating windows and process deviations
Built role-based dashboards with actionable KPIs for control room, process engineering, and plant leadership
Created a digital performance review loop—daily trends, weekly loss reports, and monthly optimization summaries
Established cross-shift targets with visual alerts and performance tracking to reduce variability
TEEC helped the plant move from reactive adjustment to continuous, data-driven optimization.
This wasn’t just an improvement in execution—it was a complete cultural shift toward reliability and efficiency.
Execution Approach by Teec’s Experts
- Connected real-time plant data sources (DCS, historian, lab results) into a centralized analytics platform
- Built a dynamic baseline of performance KPIs (yield, energy intensity, throughput) by unit and shift
- Validated data integrity and ensured time-alignment across tags for consistency
- Applied advanced analytics (regression, clustering, control charting) to uncover hidden correlations and process drifts
- Simulated ideal operating conditions for key units using TEEC’s process optimization templates
- Defined new target operating windows and logic-based alerts for key performance indicators
- Developed real-time performance dashboards segmented by unit, shift, and KPI group
- Integrated deviation alert systems with visual flags for operators and supervisors
- Enabled shift-based performance reviews with annotated trend charts and commentary logs
- Conducted training for engineers and operators on using the dashboard and interpreting insights
- Installed weekly review routines led by shift managers and production heads
- Delivered monthly optimization summaries with ROI estimations and improvement logs
Results & Impact
6.5% increase in ethylene yield sustained over three production cycles
Reduced energy consumption per ton by 9.4%, equivalent to $900K in annual savings
Process deviation alerts cut operator response time by 80%
Reduced shift-to-shift variability across targeted KPIs by over 30%
Integrated Value Through Teec’s Data-Driven Solutions
Process Performance Enhancement
