Aeration runs at a fixed rate
Aeration takes over 50% of a wastewater plant’s energy (industry benchmark). Demand-tracking blowers cut aeration energy 20–40% (industry range).
Run your treatment process on real-time data, not fixed setpoints.
ProcessMiner connects to your existing sensors and controls, predicts where aeration, dewatering, and nutrient processes are trending, and recommends setpoints that hold performance at lower cost.
Read the transcript
Your process data is already telling you what’s wrong. The problem is hearing it in time. ProcessMiner sits on the historian you already run and shows where quality is heading, for the grade you’re making. It ranks what’s driving a deviation, and recommends the setpoint to move to. In open or closed loop, your operators stay in control. One platform, on your own data.
3 processes, one plant
Where the money leaks out of a treatment operation
Industrial influent carries far more load than municipal sewage, so the aeration basin works harder. Blowers draw most of the plant’s electricity, while oxygen demand swings through the day and a fixed-speed blower can’t follow it.
Dewatering sets the disposal bill
Wetter cake means more truckloads to haul. Overdosing polymer is the safe default, and another line on the bill.
Clarifiers and nutrients run on margin
Sludge blankets drift between manual checks. Tighter nitrogen and phosphorus limits push operators to add chemicals for margin.
30-second clips
See it in a treatment plant
Three short clips, sound on. Each shows one part of the platform at work on treatment plant data.
Predicts where aeration, dewatering and nutrient processes are heading every 30 seconds, ahead of the lab.
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Your lab tells you what already happened. By the time the result comes back, the product’s already made. Real-Time Prediction forecasts where quality is heading every thirty seconds, for the grade you’re running. When the trend heads out of bounds, your team gets one specific correction. Inside the band, it stays quiet. So you correct course before product goes out of spec.
Ranks the top 10 likely causes from about 200 plant tags when performance drifts.
Read the transcript
Quality’s out of spec. Somewhere in hundreds of tags, one or two variables did it. Finding them by hand takes hours. Root Cause Analysis looks at every tag at once, drops the ones along for the ride, and ranks the top ten. One click opens the trend. PM Vector shows the move back. Your team spends the shift fixing it, not hunting for it.
Explains why blower energy is high from your process data, root cause findings and SOPs.
Read the transcript
Your best operator has decades of answers. Most were never written down. So when something moves on night shift, who do you call? PM AI Agent answers in plain language, from your live process data, root cause findings and SOPs, and cites every source. Every answer is generated inside your environment, and you decide what it sees. Your best operator’s judgment, on every shift.
Pilot results
Proven in live treatment plants
Each pilot ran on a working plant’s own data. Every move the platform recommends is bounded by permit limits.
13% → over 20%
Sludge cake solids
Wastewater dewatering pilot, no added polymer
~2×
Dewatering capacity
Same operating hours, wastewater dewatering pilot
28% → 77%
Clarifier blanket time in its target band
Water reclamation pilot, open-loop recommendations
Pilot results, each measured against that plant’s own baseline. Results vary; past performance is not a guarantee of future results.
Free Data Health Assessment
Start with your highest-cost process.
Start with a free Data Health Assessment. We’ll take a closer look and let you know exactly what your own data can do.
For qualified pilots, we can supply the sensors and the server.
Questions, answered
Frequently asked questions
Do you work with municipal treatment plants?
Our deployments and pilots span industrial wastewater and water reclamation. Industrial is the focus: treatment at pulp and paper, chemical and other manufacturing sites, where treatment performance hits the parent facility’s P&L directly. The platform works the same way in a municipal plant, but budget and procurement cycles there make it a slower fit.
How was the 13% to over 20% cake dryness result achieved?
In a wastewater dewatering pilot, the platform learned dewatering behavior from the plant’s own sensor data and recommended the process conditions that hold it at its best. Cake dryness rose from 13% to over 20%, with no added polymer, which also protects the biological treatment upstream, since excess polymer returns in the filtrate.
Can the platform control aeration blowers directly?
Yes, through the VFDs already on the motors, when you choose closed loop. Every deployment starts in open loop, with recommended setpoints your operators verify; blower control moves to closed loop only on the variables and hours you authorize, and can be switched off from the floor at any time.
Does an on-premises deployment limit what the platform can do?
No. The full platform, including prediction, root cause analysis, and PM Vector, runs on a single CPU-based server inside your network, and records are timestamped for regulatory reporting. Nothing leaves your firewall, which is why critical-infrastructure sites choose it.
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Have a question?
Whether it's our platform, your process, or a free Data Health Assessment you'd like to start, let us know.