Aeration energy, sludge dewatering, and nutrient compliance are big cost levers in a treatment plant. ProcessMiner connects to your existing sensors and controls, predicts where each process is trending, and recommends setpoints to hold performance while saving costs.
Three processes, one plant
We work with wastewater treatment operations at manufacturing sites, including pulp & paper, food & beverage, and chemical plants, where treatment performance hits the parent facility's P&L directly.
Blowers can draw 50–60% of a plant's electricity, and most run flat-out regardless of real-time oxygen demand. Matching blower speed to actual demand, through the VFDs already on the motors, is often the fastest energy win in the plant.
Cake dryness decides how much mass leaves on every truck. Polymer is typically dosed conservatively with no real-time dryness feedback, driving up both chemical cost and hauling volume. In one deployment, ProcessMiner found the settings that lifted cake solids from 13% to over 20%, with no added polymer.
Nitrogen and phosphorus limits push operators to overdose alkalinity, carbon, and coagulant for safety margin. The same real-time control that optimizes aeration also floats the oxygen target with ammonia load, holding nutrients in permit with less chemical.
Measured results
Cake dryness figure from a ProcessMiner wastewater deployment. Aeration energy reduction reflects industry-cited ranges for demand-tracking VFD control. Results vary by facility, process, and data quality; past performance is not a guarantee of future results.
The platform connects to your existing sensors and controls, predicts where each process is heading, and recommends, or automates, the setpoints that match actual demand, instead of running everything at a fixed safe maximum.
Riding the demand curve
A wastewater deployment typically scopes around 200 process tags, a fraction of a paper machine's footprint. When performance deviates, the platform ranks the contributing variables so the team adjusts the right lever first.
Root cause, ranked
For critical-infrastructure and regulated facilities, the full platform runs on a single CPU-based server inside your network. Nothing leaves your firewall, and every reading is timestamped and auditable.
Answers grounded in your data
Pilot-ready
For qualified pilot deployments, we can supply the sensors and the server. We'll validate against your plant's own baseline and you keep the results either way.
Sensors and server hardware available for qualified pilots. On-premises deployment for regulated sites.
Get in touch
Whether it's our platform, your process, or a free in-depth process data analysis and pilot you'd like to see in action, let us know.