Control polymerisation without rigidifying operations

PVC production relies on sensitive reaction balances where polymerisation kinetics, thermal control and operating conditions directly influence particle size distribution, viscosity and material quality.

Even minor deviations can lead to product variability, yield losses or instabilities impacting both safety and industrial performance.

Indao transforms data from reactors, cooling systems and separation units into reliable operational indicators and concrete recommendations.

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Why PVC processes are different

Processes where reaction stability directly determines material quality and industrial performance.

Kinetics-sensitive reactions

Temperature, pressure and dosing strongly influence polymerisation dynamics and the final polymer structure

Strong dependence on thermal control

Heat transfer efficiency directly impacts reaction safety and process stability

Material quality directly linked to the process

Even small operational variations can affect particle size distribution, viscosity and product homogeneity

The challenges you face

  • Polymerisation stability: control of reaction kinetics, management of critical phases and prevention of runaways
  • Product quality & consistency: control of particle size distribution, viscosity, purity and batch-to-batch reproducibility
  • Energy & thermal control: optimisation of cooling/heating and stability of thermal balances
  • Traceability & quality requirements: accurate tracking of reaction conditions and reliable batch history
  • Operational performance: fouling, process variability, material losses and downtime linked to instabilities

The limits of your current tools

  • Process alarms based on fixed thresholds, poorly suited to polymerisation dynamics
  • Quality analyses performed a posteriori → delayed corrections
  • Siloed data across DCS, laboratory and quality systems
  • Difficulty linking operating conditions to final polymer properties
  • Limited continuous models to anticipate reaction behaviour and material quality

What Indao delivers in practice

We design advanced analytics solutions that truly improve PVC polymerisation control, with AI as a support : explainable, controlled and field-oriented.

Real-time tracking of polymerisation phases, considering process context, thermal conditions and operational variations
Continuous estimation of non-measured parameters (particle size distribution, reaction conversion, material quality) from process data
Analysis of interactions between reaction kinetics, heat transfer and operating conditions to identify stabilisation levers
Identification of energy-intensive sequences and adjustment of setpoints to improve thermal control and reduce utility consumption
Structured historisation of production conditions to analyse deviations and secure batch repeatability
Seamless connection to existing systems (DCS, historian, lab, quality) without disrupting operations

What you gain

Operational results, not just more dashboards

Improved polymerisation stability

Early detection of reaction instabilities
→ reduced quality deviations and material losses

More consistent product quality

Better control of parameters influencing particle size and viscosity
→ fewer non-conformities

Improved energy performance

Optimisation of thermally intensive phases
→ reduced utility consumption

Higher operational reliability

Reduction of incidents linked to process drifts and improved unit availability

Better process understanding

Clear insight into interactions between operating conditions and material properties

Controlled integration

Progressive deployment without changing operational routines or existing infrastructure

See clearly. Act decisively. Optimise sustainably.

Decisions that have already proven their impact

  • Process Performance Optimization

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  • Energy

CoCEPTIO

Structuring and leveraging HVAC data to improve energy efficiency
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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

Industrial gases

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

Plastics

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

Fertilisers

Optimise energy consumption of highly thermal processes while improving production consistency

Specialty chemicals

Enhance batch reproducibility and reduce variability in complex, high-quality-demand processes

Petrochemicals

Improve operational stability of continuous units by detecting performance losses early