Core TechnologySimulation and In-House AI

We transfer field measurement data into a DWSIM digital model, where our in-house AI compares operating scenarios to identify optimal conditions.

Conventional approach

Site survey → Experience-based analysis → Improvement proposals

The AERO-ONE approach

Field measurement → Data analysis → Simulation → AI optimization → Improvement review → Investment return analysis

Digital twin

We recreate the entire factory
as a model.

We model the process digitally in DWSIM, and our in-house AI varies operating conditions to find the optimum.
It runs at once the scenarios that would take a person days to compare.

On site

Simulation Screens

Digital Twin — The process is replicated in the simulator.
Digital Twin — The process is replicated in the simulator.
Scenario Comparison — Results are compared as operating conditions change.
Scenario Comparison — Results are compared as operating conditions change.
Composition

A Four-Stage Process

01

Field Measurement Data

We collect power, pressure, temperature, and flow data for each piece of equipment.

02

DWSIM Digital Model

We replicate the process in the simulator.

03

AI scenario search

We vary the operating conditions and compare multiple cases.

04

Results Validation

We check whether those conditions will actually work on site.

Simulation

Without stopping production,
we test different conditions.

We can compare dozens of operating conditions against the same criteria without shutting down the factory.

BEFORE CHANGEPre-ValidationWe calculate cost savings before making changes
to reduce unnecessary investment.
NO DOWNTIMENo-Downtime ReviewWithout stopping production,
we can test different conditions.
COMPARABLELike-for-Like ComparisonWe compare multiple improvement measures
under the same conditions.

Physical Feasibility Assessment

AI ENERGY DIAGNOSIS — AERO-ONE
Architecture

Cross-Validation

Without physical laws constraining the calculations, AI can produce impossible answers.
That is why DWSIM checks physical feasibility.

DWSIM · Physics-Based

Thermodynamic Baseline Development

We model aging equipment to analyze in detail the gap between its theoretical maximum efficiency and measured efficiency.
We use data to validate in advance the energy savings and emissions reductions from measures such as variable-frequency drives and waste heat recovery.

AI · Data-Driven

Demand Forecasting and Predictive Maintenance

The AI learns from historical operating data to forecast future demand and recommend optimal operating schedules.
It analyzes energy consumption patterns in real time to detect the onset of efficiency losses and waste early.

Field sensor data and physical constraints work together
to identify the safest, most practical operating conditions in real time.

REAL-TIME OPTIMIZATION (RTO)
FAQ

Frequently Asked Questions

What is DWSIM?
It is a process simulator that models chemical and energy processes. It represents components such as piping, heat exchangers, and pumps to calculate how results change under different conditions.
What if the model differs from the actual factory?
That is why measurement comes first. We calibrate the model with values measured on site before changing the conditions. We do not use models built without measured data.
What exactly does the AI do?
It compares more operating scenarios than a person could feasibly run one by one and narrows them down to promising conditions. Final decisions rely on field measurements.
Is our factory data sent outside?
How data used for measurement and analysis will be handled is discussed and specified in the contract.