Optimize your plant with customized process dashboards

The Process Monitor, part of Stami Digital, is a steady-state online process model that includes Stamicarbon’s state-of-the-art heat and material (H&M) balances, and thermodynamic and kinetic urea models.

The Challenge

Optimal plant operation depends on the proper functioning of equipment and instrumentation and on optimal settings of critical plant parameters, many of which cannot be measured directly or continuously. 

Our Solution

The Process Monitor is a tailor-made process plant model (digital twin) running in parallel to the real plant. It uses Stamicarbon’s unique thermodynamics and kinetics models to provide real-time and continuous insights into equipment and instrument performance. 

Stami Digital Process Monitor

The model produces Key Performance Indicators and soft-sensor information using real-time distributed control system (DCS) data and a first principles-based process model fitted to your historical plant operation. These KPIs and soft sensors include key variables critical for understanding the actual performance of the plant, such as the N/C ratio, reactor yield, etc. shown on dashboards as part of the Process Monitor application. 

The Process Monitor is available 24/7 for your day-to-day process optimization.

With the Process Monitor you can: 

  • Easily access actual insights into your plant performance
  • Initiate corrective actions without delay
  • Receive timely remote support for troubleshooting
  • Increase capacity by optimizing the plant
  • Improve process knowledge of operators/plant staff

The first step in installing the Process Monitor solution includes performing an advanced assessment of your plant condition, process control and process dynamics. During the assessment, a process plant model is built and tuned specifically to your urea plant.
The model results are validated during the assessment, taking into account a wide range of operating conditions.

Stami Digital Process Monitor dashboards
Process Monitor dashboards

Why the Process Monitor?

Stamicarbon combines your plant data with our expertise in urea to develop a model of an entire plant, including downstream and recycle sections. This model allows for real-time calculation of key process parameters, equipment and instrument performance parameters, and ammonia emissions.

It calculates about 6,000 variables and about 350 process streams within seconds. This information can be used to improve the performance of the plant (increase throughput, reduce energy consumption, lower emissions) or prevent degradation of plant performance by initiating and directing troubleshooting and maintenance activities.


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