Case studies
What AquaMesh finds in a plant's own data.
Every one starts the same way: read what the plant already records, find what it is costing, and say what to do about it. Real plants are anonymized, and every figure is labelled as an identified opportunity, publicly reported operating scale, or an illustration of the method. The refinery and phosphate complexes are case studies on modelled plants — not customers — each with a full audit and a 3D twin.
Case study Integrated phosphate complex
$11.3M a year in the plant it already runs.
A case study on a modelled complex: 120 days of historian data across acid production, cooling water and water treatment, priced line by line and judged against each unit's own twin. Includes a 3D twin.
- found a year, no new hardware
- $11.3M
- from one filter line's gypsum
- $5.1M/yr
- values read
- 10.8M
Case study Refinery and petrochemical complex
$3.0M a year, mostly in the utilities.
A case study on a modelled complex: 150 days and 1,896 tags, nine causes priced line by line, and checked against the simulator that produced the data. Includes a 3D twin.
- found a year, no new hardware
- $3.0M
- causes found
- 9
- tags read
- 1,896
Case study Membrane-bioreactor water reuse
$42,050 from existing data. $92,200 with instrumentation.
No new hardware and no site visit — 1,001 tags and 7.2 million recorded values from the plant's own historian, ranked by what each finding costs per year and checked against the ranges the plant itself posts.
- saved, fully instrumented
- $92,200/yr
- saved from existing data alone
- $42,050/yr
- above the posted DO range
- 3.6×
Case study Corn wet milling · starch loss
One pound of starch per bushel is 160 tons a day.
An assessment of where starch escapes — separation, washing, CIP, dewatering — and how UV/Vis and NIR spectra catch it before it becomes wastewater load.
- bushels a day
- 320,000
- water a day
- 20.5M gal
- starch signal, NIR
- ↑2.8σ
Bring your own history.
If your plant keeps a historian, AquaMesh has something to read. A demo starts with your process, your goals and the data you already have.