1 Where money leaks
Process plants bleed cash in four ways: unplanned shutdowns, energy waste, raw-material over-consumption and late decisions. INFI 90 turns each leak into a measurable loop.

2 Loop 1: Stop the stop
A 100 ms scan places all I/O on a redundant INFI-NET. Statistical alarms watch standard deviation; a 1.2 σ drift triggers a 30-minute early warning. A 450 kt-a urea plant cut yearly outages from 38 to 27, lifted OEE by 3.5 % and saved USD 1.3 M in maintenance.

3 Loop 2: Code the kilowatts
The Energy Load Scheduler writes real-time power price, load forecast and process limits into a mixed-integer problem that re-solves every 15 min. A 450 kW blower now avoids peak tariffs, shedding 1.5 MWh a day. Annual saving: USD 65 k, pay-back in 8 months.

4 Loop 3: Lock the recipe
Adaptive PID plus Smith predictor keeps chemical ratio error within ±0.4 %, down from ±2.1 %. On a 100 kt-a line the change saves 420 t of feed-stock, worth USD 300 k.

5 Loop 4: Pay-as-you-grow
Slide-in modules let capacity expand by 4-, 8- or 12-slot racks without stopping the furnace. Capital is staged over three years, releasing 38 % initial cash – about USD 200 k – for working capital.

6 From data to dollars
Built-in OPC UA pushes OEE, energy per tonne and MTTR into SAP. Managers see “Lot 20250703 cost +1.8 % due to sticky valve” on a phone and dispatch work-order the same hour. Decision cycle shrinks from weeks to minutes.

7 The ledger
For a 300 kt-a chemical site the yearly balance looks like this:

ü Avoided outage: USD 1.3 M

ü Energy trim: USD 0.65 M

ü Material saving: USD 0.3 M

ü Deferred cap-ex: USD 0.2 M (one-time)
Total ≈ USD 2.45 M first year; full pay-back in 10 months. Savings compound annually.

8 Bottom line
INFI 90 is not only a DCS – it is a data-to-finance loop that turns cost cuts into line items on the P&L. While competitors still count last month’s kilowatts in Excel, users already book next quarter’s margin gain.

For I/O lists, algorithm sheets or a pilot ROI calculator, contact May at Amikon Limited: sales5@amikon.cn