Modcon Systems Ltd., a global leader in process analyzers and intelligent process optimization, announced the launch of its next-generation Modcon.AI platform. The system integrates live data from real-time in-situ analyzers directly into artificial-intelligence algorithms, enabling closed-loop optimization of complex industrial processes in refineries, petrochemical plants, and green-hydrogen facilities.

For decades, industrial optimization relied on historical process data, model-based simulations, and post-event analysis. While effective under steady conditions, these methods often lag behind the dynamic reality of today’s energy sector—where fluctuating feedstock quality, variable renewable inputs, and tightening environmental regulations demand continuous adaptability. The new Modcon.AI platform addresses this challenge by merging verified real-time analyzer measurements with deep-reinforcement learning (DRL) to deliver adaptive control decisions within milliseconds.

This convergence of measurement and intelligence ensures that AI operates not on assumptions, but on live physical data that reflect the actual process state. The result is a system that improves energy efficiency, enhances product quality, reduces emissions, and reinforces plant safety—all in real time.

Industrial AI only creates real value when grounded in precise, continuous measurements from process analyzers that close the loop between real-time data and intelligent process control.”

— Gregory Shahnovsky, CEO of Modcon Systems Ltd.

Marketing Technology News: MarTech Interview with Kevin Shectman, Senior Director of Product Marketing @ Braze

“Industrial AI becomes meaningful only when grounded in continuous and accurate measurement,” said Gregory Shahnovsky, CEO of Modcon Systems. “By connecting our MOD-series analyzers directly with adaptive learning models, we transform raw data into actionable intelligence that allows plants to run cleaner, safer, and smarter.”

The Modcon.AI platform leverages Modcon’s field-proven analyzers—including the MOD-1040 Optical Oxygen Analyzer, MOD-1060 Hydrogen Analyzer, and Beacon-3000 NIR Process Analyzer—all designed for harsh operating environments and certified to ATEX/IECEx Zone 1 and SIL-2 functional safety standards. These analyzers continuously measure oxygen, hydrogen, and hydrocarbon streams composition in high-pressure, high-temperature and corrosive streams, ensuring reliable performance where conventional instruments often fail.

Through secure Modbus and Ethernet communication protocols, analyzer data is transmitted to the Modcon.AI edge-analytics layer, where advanced neural networks process multiple input streams, detect anomalies, predict process deviations and recommend corrective actions. This architecture effectively closes the loop between measurement and control, allowing production units to self-adjust while maintaining human oversight and safety compliance.

Initial pilot implementations in refinery and hydrogen production units have demonstrated measurable impact:
* Up to 15% reduction in process variability, resulting in smoother operations and lower waste.
* 8% decrease in CO₂ emissions through optimized feedstock blending and combustion control.
* Extended catalyst life and reduced unplanned downtime through early anomaly detection.

The system’s design also enables predictive maintenance. By continuously monitoring process conditions and products quality, Modcon.AI alerts operators before process failures or fouling events occur—reducing maintenance costs and improving uptime. This predictive layer is built upon Modcon’s decades-long experience in field instrumentation, ensuring that AI insights remain rooted in the realities of industrial operations.

Beyond individual plant performance, Modcon.AI enables enterprise-level optimization. Plant operators can benchmark multiple facilities, compare efficiency indicators, and simulate “what-if” scenarios to evaluate the impact of operational changes on yield, energy use, and emissions. The modular platform is compatible with existing DCS, PLC, and cloud environments, offering flexible deployment across on-premise and hybrid architectures. All communication layers follow IEC 62443 cybersecurity standards, guaranteeing secure integration within critical infrastructure.

Shahnovsky emphasized that this development aligns with global efforts toward decarbonization and the energy transition: “Our mission is to make real-time data not just visible but actionable. Industrial decarbonization will not happen by adding more sensors—it requires intelligent analyzer systems that understand and react instantly. Modcon.AI is our contribution to achieving measurable sustainability through precision and automation.”

With over five decades of innovation in process analysis, Modcon Systems has supplied thousands of analyzers and optimization solutions across refineries, petrochemical complexes, and energy facilities worldwide. The new platform extends this legacy by adding an intelligent layer that connects measurement, predictions and control—representing a major step toward autonomous industrial operation.

By embedding AI into analyzer networks, Modcon positions itself at the forefront of Industry 4.0 and the emerging “Industrial Internet of Intelligence” (IIoI)—a paradigm where analyzers, controllers, and digital twins operate as a unified ecosystem. The company envisions this technology driving long-term improvements in safety, efficiency, and profitability for industrial producers globally.

Marketing Technology News: Martech & the ‘Digital Unconscious’: Unearthing Hidden Consumer Motivations