LUMMUS DIGITAL
Proof Points
Outcomes our customers have defended in the P&L. Production deployments. Day-one results. Sustained intelligence — across refining, petrochemicals and process industries.
Hindustan Petroleum Corporation Limited (HPCL)
EFINING · INDIA · LC-MAX DIGITAL SUITE
Turning residue into margin
$2.5/bbl
LC-MAX® GRM uplift
Equivalent to ~$275M annual value at 110 KBPD capacity.
+10%
Distillate yield gain
$1–2M/yr
Phase 2 digital upside
The challenge
- High startup & safety risk during pre-startup and feed cut-in
- Fragmented visibility across critical LC-MAX® process systems
- Inconsistent catalyst, inventory and mass-balance tracking
- Limited visibility into early feed characterisation and yield estimates
- Manual, time-intensive readiness and performance calculations
- Cross-functional misalignment during a critical startup phase
The LC-MAX® Digital Suite, deployed in two phases. Phase 1: a production-ready digital foundation live before feed cut-in — integrating real-time plant data with proprietary licensor process models, delivering a unified operational view and automating critical engineering calculations.
Phase 2 builds on this foundation with advanced hybrid models combining first-principles knowledge with data-driven learning, driving ongoing optimisation in yields, energy performance, and operational efficiency.
- System production-ready before feed cut-in
- 2,000+ automated calculations every 2 hours
- Real-time monitoring of catalyst health, reactors, hydrogen systems
- Trade-offs (yield vs. energy) quantified before each decision
- Single, trusted operational view from pre-startup through stabilised operation
The challenge
Hydrocracker Performance Monitoring
Reinventing hydrocracker performance
A 400,000 bpd full-conversion refinery set out to strengthen hydrocracker reliability, preserve catalyst health, and improve energy efficiency — under tight operating windows, at high severity, and with limited real-time visibility into unit health.
By deploying Lummus Digital’s integrated performance monitoring and advisory platform, the operator delivered measurable gains across unit stability, energy recovery and catalyst lifecycle — establishing a scalable digital foundation for continuous, sustained performance improvement.
$4M+/yr
Annual value identified
2–3mo
Catalyst cycle extension
Through earlier detection of thermal excursions and WABT drift — deferring $15–25M in reload costs.
2–3%
Energy efficiency improvement
Across critical heat exchange and fired-heater equipment.
The challenge
- Limited real-time visibility into hydrocracker and reactor health
- Delayed detection of catalyst degradation and thermal issues
- 2–5% throughput gap vs. design from hidden constraints
- Excess energy consumption — $3–5M/year in recoverable value
- Each day of unplanned downtime = $1–2M in lost margin
An integrated digital performance-monitoring and advisory platform purpose-built for hydrocracker operations. Real-time data from control, historian and engineering systems consolidated into a single operational view — supported by advanced engineering models and normalised KPIs.
150+ structured KPIs unified from disparate systems. Threshold-based and predictive alerts. Centralised dashboards for operators, engineers, and management on a single shared view.
The impact
- 40–60% faster issue detection — hours, not days
- Improved reactor stability through early WABT detection
- 60–70% reduction in manual reporting effort
- Better asset utilisation through constraint visibility
- Scalable foundation for AI APC and predictive maintenance
Olefins Complex Digital Twin
TROUBLE SHOOTING . WHAT-IF ANALYSIS
OLEFINS • ASIA-PACIFIC • DIGITAL TWIN PROGRAMME
Turning resilience into value.
$49M
COMPRESSOR INCIDENT SAVING
100%
CAPACITY PRESERVED
>$4M
FLARE OPTIMISATION SAVINGS
The challenge
- Significant production loss risk from compressor reverse rotation events.
- Vibration issues on 2 of 3 demethanizer reflux pumps requiring a month of off-reflux operation.
- Overly conservative steady-state flare analysis suggesting multi-million dollar complex header mitigation options.
- Requirement for unified “what-if” actions to avoid plant trips and vent losses.
- Digital twin replicated compressor incidents to model surge response and recommend scenario actions.
- Validated operational actions to maintain ethylene product specs (0.78 mol% H2-rich stream) without reflux.
- Predicted realistic temperature profiles along the flare header system to optimize mitigation design.
- Unified platform for collaborative analysis and flexibility.
The impact
- $49M saved by avoiding 30 days of production loss during the compressor rotation event.
- 100% throughput maintained throughout repair with ethylene product loss to vent completely avoided.
- >$4M in CAPEX avoided by utilizing higher fidelity temperature modeling vs. standard steady-state.
- Validated model performance allowed the plant to operate without trips during the outage.
MORE PROOF POINTS
Engagements across the value chain
Production deployments at major operators across India, the Middle East, and the Americas — each engagement with measurable outcomes defended in the P&L.
Look, Listen & Feel (LLF)-
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Transform your Asset Management from a Cost Center To a Revenue Generator
ePOD Electronic Proof of Delivery-
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Smart Logistics Management Solution for Efficiency, Transparency & Control
Haldia Petrochemicals (HPL), implemented the Electronic Proof of Delivery (ePOD), to enhance logistics and supply chain management. The solution provides near real-time tracking, automates delivery documentation, and ensures secure blockchain transactions.
Catalyst R & D
Faster Hydrocracking Catalyst Discovery With Agentic AI
Petrochemical R&D is being transformed by Agentic AI through accelerated discovery and optimization of hydrocracking catalysts using a semi-autonomous, human-in-the-loop workflow. By combining AI-generated hypotheses, multi-agent reasoning, and predictive screening, the approach reduces trial-and-error experimentation while balancing selectivity, activity, lifecycle, and cost.
