Module 05  ·  AI Digital Twin

The Living Digital Twin

The continuously calibrated AI Digital Twin — a living digital representation of the refinery. Twin keeps every module synchronized with reality at all times through automated calibration, soft sensors, ML anomaly detection, and a natural-language interface backed by the process model.

05.1 · Overview

Refinium Twin

Refinium Twin is the foundational intelligence engine of the platform. It maintains a continuously updated, AI-calibrated digital representation of the complete refinery — keeping every module (Plan, Finance, Process, RTO, PC&S) synchronized with reality at all times. Without Twin, the other modules would gradually drift from the plant; with Twin, they never do.

05.2 · Why It Matters

Key Capabilities at a Glance

01
Continuous Calibration
AI-driven calibration runs continuously against live DCS, historian, and analyzer data. Reactor severity, fouling coefficients, column tray efficiency, and catalyst activity are all kept current — automatically.
02
Soft Sensors That Replace Hardware
Octane, cetane, sulfur content, catalyst activity, fouling factor, column flooding margin, blend quality — predicted in real time from the calibrated model with confidence intervals.
03
ML Anomaly Detection
Detects divergence between model-predicted and plant-measured behavior. Identifies root causes, quantifies margin impact, and recommends corrective action.
04
Natural Language Interface
A conversational AI assistant grounded in the process model. Ask plain-language questions, get model-backed answers with the underlying simulation as evidence.
05
Full Audit Trail & Governance
Every calibration, every model update, every parameter change is versioned, audited, and reversible. Role-based access and approval workflow built in.
06
Model Health Scoring
Calibration age, data quality indicators, parameter bounds, and drift alerts give operators a continuous view of the digital twin’s health.
05.3 · Technical Depth

Full Capability Set

Every capability included in Refinium Twin.

Data Reconciliation
Mass balance closureEnergy balance closureComponent balance closureGross error detectionSensor validationRedundancy analysisData quality flagsOutlier removalCross-instrument validationHistorical reconciliation
AI Calibration Engine
Continuous model calibrationReactor severity tuningFouling coefficient estimationColumn tray efficiencyCatalyst activity trackingML anomaly detectionModel health scoringCalibration age monitoringParameter bounds enforcementModel drift alerts
Soft Sensors & Predictive Analytics
Product octane predictionCetane soft sensorSulfur content predictionCatalyst activityFouling factorColumn flooding marginHeat recovery lossBlend quality predictionConfidence intervalsData quality indicators
Natural Language Interface & Governance
Conversational AI assistantPlain-language queriesModel-backed explanationsPredictive constraint alertsUpload guidanceFull audit trailApprove/revert workflowVersion controlRole-based accessDaily performance reports
05.4 · Use Cases

Refinium Twin in Action

Scenario
FCC gasoline yield has dropped — why?
Twin detects a divergence between model-predicted and actual FCC gasoline yield. The AI layer identifies catalyst activity decline as the root cause, quantifies the margin impact, and generates a recommended corrective action with full economic context from Finance.
Scenario
What is the actual octane of the gasoline pool right now?
Twin runs the soft-sensor stack against live plant data and returns the predicted octane with a confidence interval — replacing the need for continuous lab analysis.
Scenario
Ask the AI: "Why did our hydrogen demand spike last hour?"
The natural-language assistant traces the spike to the simulator, identifies the FCC feed shift as the cause, and presents the model-backed evidence — complete with the underlying mass balance.
05.5 · Integrated Platform

How Refinium Twin Connects

Refinium Twin is part of the integrated Refinium platform. Every module shares the same continuously calibrated refinery model.

Refinium Process
Twin continuously calibrates the Process model against live plant data.
Refinium Plan
When Twin updates calibration, Plan automatically refreshes its LP coefficients.
Refinium RTO
RTO solves against the live calibrated model that Twin maintains.
Refinium PC&S
During startup, Twin keeps the model in sync with the warming plant.

See Refinium Twin on Your Refinery

Request a personalized demo. We will walk through Refinium Twin on your refinery's actual configuration.

Request Demo