How accurate are the models?

Physics-informed models tuned with plant data routinely achieve <2% error on key process variables across operating ranges.

Will the twin replace our APC?

No. Twins complement APC by providing what-if and validation capabilities the APC isn't designed for.

Chemicals / Digital Twin for Chemical Processing

Digital Twin for Chemical Processing

Q: Do twins run in our DCS environment or in the cloud?

Both — typically the twin core runs near the DCS for low-latency integration, while analytics and tuning live in the cloud.

Q: Will the twin replace our APC?

No. Twins complement APC by providing what-if and validation capabilities the APC isn't designed for.

We engineer real-time digital twins for chemical batch and continuous reactors — letting operators run what-if scenarios safely, optimize yields, and de-risk process changes before committing physical batches.

Talk to a Solution Engineer View Case Studies

Average batch yield uplift

Real-time

Reactor state tracking and prediction

Physics-informed

Models combine first-principles + ML

Trusted by global innovators

Industry Overview

Digital Twin for Chemical Processing: Engineered End-to-End

Digital twins for chemicals are most valuable when they let operators safely explore decisions that would be too expensive or dangerous to test physically. We build twins designed for that — and integrated with the DCS systems operators actually use.

Industry Challenges

What Stops Most Teams From Solving This Today

Common friction points we hear from chemicals teams scoping this kind of platform.

Run-to-Run Variability: Small process variations hurt yield and increase risk in unpredictable ways.
Operator Conservatism: Without safe sandboxing, operators avoid even good optimization opportunities.
Disconnect From DCS: Twins that don't speak to the DCS in real time become PowerPoint art.
Model Maintenance: Off-the-shelf twins decay quickly without continuous tuning to actual plant data.

Our Approach

Our Engineering Approach

We engineer for the operational reality — not the demo.

Physics-Informed Models

First-principles models tuned with plant data for transferable accuracy.

Operator Sandboxes

Safe what-if exploration without risk to the physical process.

DCS-Native Integration

Real-time bidirectional integration with Honeywell, Emerson, and ABB DCS systems.

Capabilities

Production-grade features the platform ships with from day one.

Real-Time Twin

Live digital twin tracking reactor temperature, pressure, and composition.

What-If Scenarios

Operator-friendly what-if exploration with safe rollback.

Yield Optimization

Continuous optimization with operator-in-the-loop suggestions.

Safety Envelope Monitoring

Real-time monitoring of safety envelopes with predictive alerts.

Process Recipe Validation

Validate new process recipes against twin before physical execution.

Model Tuning

Continuous tuning of model parameters against actual plant data.

Operator Console

Process operator-friendly UI with twin overlay on DCS view.

Reporting & Lineage

Per-batch lineage and reporting tied to twin predictions.

How It Works

Reference Architecture

How data and decisions flow end-to-end.

DCS Integration

Real-time bidirectional integration with Honeywell, Emerson, ABB DCS.

Twin Core

Physics-informed plus ML twin running real-time alongside the process.

Optimization Layer

Continuous optimization with operator-in-the-loop suggestions.

Sandbox Layer

Operator-facing what-if exploration with rollback safety.

Reporting & Tuning

Per-batch lineage, model tuning, and reporting.

Engineering Stack

Technology Stack

A pragmatic stack chosen for reliability, speed, and ease of operation.

Modeling

ModelicaJuliaSimPyomoCustom physics

ML

PyTorchJAXscikit-learn

DCS Integration

OPC-UAHoneywellEmersonABB

Backend

PythonRustPostgreSQLTimescaleDB

Apps

Next.jsReactTailwindWebGL

Infra

KubernetesVaultTerraform

Measured Impact

Quantified outcomes from production deployments.

Batch yield uplift

Real-time

Twin update cadence

Operator-safe

What-if sandbox

Physics-informed

Model approach

Specialty Reactor Digital Twin

A specialty chemical manufacturer needed to optimize batch yields on a high-value reactor without risking hazardous excursions.

The digital twin let operators run 'what-if' scenarios safely, increasing batch yields by 8% while reducing the risk of hazardous pressure excursions and improving quality consistency batch over batch.

Case Study

Use Cases

Where This Earns Its Keep

Common deployment patterns we see across customers.

Batch Reactor Optimization

Yield and quality optimization for batch chemical reactors.

Continuous Process Optimization

Real-time optimization for continuous chemical processes.

Safety & HAZOP Validation

Validate safety strategies against twin before plant changes.

New Recipe Validation

Validate new process recipes against twin before physical execution.

Operator Training

Use the twin as an operator training environment.

M&A Due Diligence

Twin-based diligence on acquisition target plant performance.

Integrations

Integrates With Your Existing Stack

We connect to the systems your teams already know.

DCS

Honeywell ExperionEmerson DeltaVABB 800xA

Historian

OSIsoft PI

ERP

SAP S/4HANA

CMMS

Maximo

Compliance-First Development Services Backed by Global Standards

We build secure, scalable products designed for privacy, interoperability, and regulatory readiness from day one across every sector we serve.

Service Organization Control 2

Verified controls for security, availability, and confidentiality of enterprise data systems.

Information Security Management

Adhering to the international gold standard for managing information security risks.

Quality Management Systems

Ensuring consistent quality in software delivery and operational process optimization.

Our Edge

Why Global Leaders Choose Us

We combine deep technical expertise with industry-specific knowledge to deliver solutions that aren't just functional, but transformational.

Enterprise-Grade Security

We implement rigorous security protocols and compliance standards (HIPAA, GDPR, SOC2) across all industrial solutions to protect sensitive data.

High-Performance Scaling

Our architectures are built to handle massive data loads and user bases, ensuring seamless performance whether you're serving ten or ten million.

Accelerated Time-to-Market

Leveraging our suite of internal tools and proven frameworks, we reduce development cycles and get your product to market 40% faster.

Embedded AI Integration

Beyond simple wrappers, we build deep-learning integrations and predictive analytics directly into the core of your industry-specific workflows.

Engagement Model

Predictable, structured delivery from kickoff through long-term ownership.

Discovery & Scoping

We map the existing systems, constraints, and stakeholders to scope a focused 8–12 week first delivery.

Architecture & Pilot

A working slice on a representative environment — proving the data flow end-to-end before scaling.

Production Engineering

Hardened services, observability, access controls, and audit logging go live behind your IAM.

Operate & Iterate

We stay on as the embedded engineering team — closing tickets, tuning models, and shipping new value.

Voices of Success

We don't just build products; we forge lasting partnerships. See how we've helped industry leaders transform their vision into technical reality.

"I can clearly see how Agnotic has a unique way of handling end-to-end development. They are always active on quick chat and provide support quickly."

Aaron Phelan

Founder, Benchmark

"Agnotic is the best technical team we evaluated. Their engineering excellence made our work dramatically easier and allowed us to stay focused on what matters most for maternal care outcomes. They took full ownership of the technical execution, and we are always happy to continue working together."

Kim Smith

Founder, My Lauren

"Agnotic combines deep technical expertise with strong domain knowledge. They understand the business context, anticipate challenges, and make collaboration smooth and effective."