Context

At its Engis site, Prayon operates sulfuric acid installations that generate significant quantities of recoverable steam. The balance between steam production and steam consumption plays a key role in the site’s overall energy performance.

Historically, the control of the steam network relied mainly on the expertise of operational teams, without a tool enabling real-time analysis of all interactions between production units, storage constraints, and energy demand.

Challenge

  • Partial operational visibility over the steam network
  • Difficulty quantifying the impact of control settings
  • Non-optimal gas/sulfur ratio during certain operating phases
  • Energy consumption with room for improvement

Solution

Indao was deployed to analyze and control the site’s sulfuric acid installations, boilers, and steam network.

The platform enables:

  • the implementation of operational dashboards
  • real-time monitoring of steam production and consumption
  • the use of predictive models to detect performance deviations
  • root cause analysis
  • optimization of gas/sulfur ratios

Operational data such as sulfur supply, storage levels, and site energy consumption is also integrated to improve decision-making.

Results

  • Improved visibility over the steam network and its control
  • Optimization of production setpoints
  • Reduction of the gas/sulfur ratio
  • Measurable improvement in the site’s energy efficiency

Testimonial

“Easy to use, tangible results, and a wide range of applications. Indao enables us to optimize our energy management and fine-tune our gas/sulfur settings.”

Nicolas Dony
Process Engineer, Prayon

Let’s explore how to reduce energy consumption, stabilise quality and improve availability with advanced analytics (AI as support)