Process Point successfully implemented an advanced data-driven intelligence solution for a leading Asian manufacturer of ammonium nitrate, explosives, and detonators. By developing a comprehensive monitoring and control system, we significantly improved personnel safety and operational efficiency in their high-risk production environment.
Client Profile
Our client is a leading explosives manufacturer based in Asia, with a significant production capacity and a key focus on ensuring personnel safety in a high-risk environment.
Industry: Explosives Manufacturing
Location: Asia
Production Capacity: 100 Million detonators and 114, 000 MT of Bulk Explosives per year
Key Challenge: Ensuring personnel safety in a high-risk manufacturing environment
Business Challenges
The client faced several critical issues in their explosives manufacturing plant:
High personal safety risks requiring minimized onsite personnel
History of near-miss accidents due to inadequate monitoring and controls
Outdated control systems and automation
Narrow operational windows for humidity, temperature, and static electricity control
Need for real-time monitoring and timely alerts to prevent accidents
Process Point's Innovative Solution
Our team developed a sophisticated, multi-faceted approach leveraging advanced data analytics and machine learning:
Comprehensive Data Collection: Gathered data from various process units, HVAC systems, boiler and steam systems, cooling water systems, and dust control in coating, loading, and bagging areas
Advanced AI/ML Models: Built models to improve operations of critical systems
Real-time Monitoring: Developed systems for key process parameters with timely alerts
Predictive Analytics: Created models for optimizing utility systems and energy consumption
Process Visualization: Implemented assets with real-time visualization of current operating values
Key Features of the Solution
Integrated monitoring of multiple plant systems and processes
Real-time alert system for critical parameters
Predictive models for system optimization and energy efficiency
Improved humidity and temperature control
Visualization tools for easy monitoring of operating values
Substantial reduction in humidity variations, improving product quality and safety
Significant decrease in process temperature variability, enhancing process stability
Measurable savings in power consumption (MWh/year) across multiple units
Conclusion
By addressing the complex challenges of safety and efficiency in explosives manufacturing with a tailored, data-driven approach, Process Point demonstrated its expertise in applying cutting-edge technology to solve critical industrial problems. This success story exemplifies our commitment to delivering high-impact solutions that prioritize safety while driving operational excellence and business value for our clients in high-risk manufacturing environments.
