Stabilise reactions, secure fertiliser production

Fertiliser production combines highly exothermic chemical reactions, evaporation, granulation and drying, where temperature, moisture, dosing and energy balance directly determine final product quality.

Even minor deviations can lead to excessive dust, unstable granulation, energy overconsumption or material yield losses.

Indao transforms data from neutralisation units, evaporation, granulation, drying and utilities into reliable operational indicators and concrete recommendations.

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Why fertiliser processes are different

Complex thermo-chemical processes where energy, reaction dynamics and product physical properties are tightly interconnected.

Highly exothermic reactions

Acid/base neutralisation directly impacts thermal stability, safety and conversion efficiency

Processes driven by moisture and thermal behaviour

Granulation, drying and cooling determine density, mechanical strength and storage behaviour

Product quality directly linked to the process

Particle size distribution, hardness, dust and homogeneity depend on real operating conditions

The challenges you face

  • Reaction control: stabilising neutralisation, controlling temperature and limiting reaction drifts
  • Granulation & product quality: controlling particle size, mechanical strength, fines and agglomeration
  • Energy & utilities: optimising steam, hot gas, drying and heat recovery in energy-intensive processes
  • Emissions & environmental compliance: controlling NH₃, NOx, dust and ensuring traceability of environmental performance
  • Unit availability: clogging, deposits, drum instabilities, material variability and unplanned downtime

The limits of your current tools

  • Control often based on isolated variables rather than overall process behaviour
  • Difficulty linking reaction conditions to final granule quality
  • Quality analyses performed too late to effectively correct the process
  • Siloed data across DCS, lab, maintenance and energy systems
  • Lack of operational models to anticipate granulation drifts or thermal overload

What you gain

Operational results, not just more dashboards

More stable granulation

Reduced particle size variability and improved mechanical strength

Reduced material losses

Early detection of drifts impacting dust, recycling loops and overall yield

Improved energy performance

Optimisation of thermally intensive phases
→ reduced steam and fuel consumption

Better emissions control

More precise monitoring of conditions affecting NH₃, NOx and dust

Higher unit availability

Anticipation of clogging and process instabilities
→ fewer unplanned shutdowns

Controlled integration

Progressive, secure deployment aligned with existing field practices

What Indao delivers in practice

We design advanced analytics solutions that truly improve fertiliser process performance, with AI as a support : explainable, controlled and field-oriented.

Real-time tracking of neutralisation, evaporation and drying conditions considering material and energy regimes
Continuous estimation of key indicators such as residual moisture, granulation stability and particle size evolution
Cross-analysis of reactions, thermal conditions and granulation performance to identify stabilisation levers
Identification of energy losses across dryers, evaporators and heat generators to improve kWh per ton produced
Structured historisation of operating conditions to support quality and environmental audits
Seamless connection to existing systems (DCS, energy monitoring, lab, maintenance) without disrupting operations

See clearly. Act decisively. Optimise sustainably.

Decisions that have already proven their impact

  • Process Performance Optimization

2Valorise

Optimising the steam network to maximise cogeneration plant performance
  • Energy

CoCEPTIO

Structuring and leveraging HVAC data to improve energy efficiency
  • Process Performance Optimization

CRM Group

Identifying key parameters in hot rolling to better control process performance
  • Data-driven Decision-Making

EKO-MYŚL

Centralising waste and energy data to improve operational control

Want to make decisions differently?

Let’s explore how your data can become a concrete operational lever.

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Whatever your segment in the chemical industry

Concrete levers at the core of your processes

Acids

Optimise highly thermal and corrosive processes by stabilising critical operating parameters and improving energy efficiency

PVC

Improve control of polymerisation conditions and reduce process variability to ensure product consistency

Industrial gases

Better control compression, separation and liquefaction to reduce energy intensity and improve reliability

Plastics

Correlate process parameters, energy and product quality to stabilise transformation performance

Specialty chemicals

Enhance batch reproducibility and reduce variability in complex processes

Petrochemicals

Improve operational stability of continuous units through early drift detection