Process Improvement

End-to-end refinery-wide process improvement

Transform plant performance with integrated solutions that help cut costs, enhance processes and improve efficiency and emissions reduction.

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Industrial heat exchanger system designed to improve fuel efficiency and optimize thermal performance.

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Transform plant performance with integrated solutions that help cut costs, enhance processes and improve efficiency and emissions reduction.

Request a Consultation

Process Enhancement and Simulation Software and Control Solutions

Process units operating in isolation can miss coordination opportunities that affect margin. Honeywell advance process control and plantwide enhancement software helps establish end-to-end visibility across controllers, material flows and constraint limits. Dynamic models pull live process data to help synchronize unit-level targets with facility objectives.

Our industrial process enhancement solutions are used widely to improve refining and petrochemical facilities, upstream oil and gas production, mining, chemical manufacturing, and many other industries. Your operations gain the tools to help balance inventories, route materials to high-value grades and tighten quality targets based on real-time conditions.

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Plantwide Optimizer

Our Plantwide Optimizer’s cascaded model predictive control (MPC) helps coordinate your plant’s unit-level controllers with its facility targets. Dynamic models can update minute by minute, while proxy variables help maintain feasibility across planning and control layers.

Material routing to high-value product grades
Component balance across integrated units
Quality giveaway reduction through target tightening

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Advanced Process Control (APC)

Our advanced process control software features layered improvement that can coordinate process controls in near real-time. The software can manage operating limits, pushing processes to constraints while helping maintain product specifications. Honeywell’s APC solutions can also integrate with unit-level controllers across vendors.

Helps improve throughput on constrained processes
Potential energy savings and emissions reductions
Helps enhance yield of high-value products
Benefit sustainment powered by Control Performance Analytics

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Production Management

Honeywell’s manufacturing execution software can connect your plant’s planning systems with day-to-day shop floor operations, helping reconciles production and inventory data to support more informed supply chain decisions.

Potential throughput and margin improvement
Potential reduction in losses and inventory levels¹
Helps enable faster, more profitable decisions on quality requirements

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Blending and Movement

Honeywell offers solutions to help improve blend recipes and tank logistics based on component costs and product specifications. As feedstock properties shift, facilities can update recipes in near real-time.

Helps plants meet specification targets with lower-cost component
Helps reduce quality giveaways, rework and improves right-first-time blending quality
Can improve blend recipe and inventory enhancement

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Operations Management

Our operational excellence software can digitalize field workforce activities and compliance processes, while industrial mobility tools connect operations teams with near real-time data.

Helps reduce unplanned downtime
Potential reduction in EHS incidents and non-compliance events
Potential increase in operational efficiency²

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UniSim Design

Model process units first-principles engineering and AI/ML before implementation. Our steady-state and dynamic simulation technology supports refining, chemicals and gas processing.

Potential improvement in engineering effectiveness³
Helps identify bottleneck and improve energy use
Front-end design and retrofit analysis

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Process Digital Twins

Digital twins help plant operators troubleshoot without disrupting production.

Create near real-time virtual replicas of your plant operations for performance monitoring and scenario analysis, including steady-state and dynamic simulation with soft sensor predictions.

Set operational targets based on current plant capabilities
Helps plants operate closer to constraints and reduce utility usage
Aids in faster root cause analysis and operational risk reduction

Helps reduce unplanned downtime

Customers using our Operations Management software report reductions in unplanned downtime.⁴
Potential gains in engineering effectiveness

Process simulation with UniSim Design helps improve material selection, leading to a increase in engineering effectiveness, as well as cuts in capital expenditure.⁵

Frequently Asked Questions About Industrial Process Improvement

Continuous processes with multiple interacting variables can see the greatest gains. This includes refining units like crude distillation and fluid catalytic cracking, chemical reactors, polymerization lines, gas processing plants and power generation. Fuel, gasoline and chemical blending and movement operations can also benefit from advanced control and recipe improvement. Industries served by advanced process control software include oil and gas, chemicals, pulp and paper, mining, metals and pharmaceuticals.

Rather than requiring a full replacement, our integrated solutions work with your current infrastructure, connecting with major DCS platforms and third-party systems via standard protocols like OPC. They pull data from historians, push setpoints to controllers and exchange information with planning systems.

Many deployments show improvement within weeks of go-live. APC projects can reduce energy use and improve yield in the first months.¹ Plantwide enhancement helps builds on APC gains and can unlock additional value as the scope expands.² Timelines vary based on process complexity and project scope: typical implementations range from a few months for single-unit APC to a year or more for facility-wide integrated solutions.

¹ Honeywell Advanced Process Control

²Honeywell Plantwide Optimizer

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