Measure the Unmeasurable with AI Sensors
AI Sensors (soft sensors) use advanced models to estimate critical process variables in real time – delivering insights that lab tests or analyzers can’t provide.
Why AI Sensors Matter
Many critical variables can’t be measured easily or cost-effectively:
- Lab analysis is accurate but delayed by hours or days.
- Online analyzers provide real-time data but are expensive and require constant maintenance.
- Indirect indicators (like pH or FOS/TAC) are low-cost but often inaccurate.
The result: delayed decisions, wasted costs, and less stable operations.
What are AI Sensors?
AI Sensors are virtual sensors trained on historical and real-time process data. They act as “digital assistants” for your operations, predicting variables that are hard or impossible to measure directly.
With AI Sensors, you can:
- Estimate values like VFA, ammonia, or sludge quality in real time
- Fill gaps between slow lab results
- Replace or supplement costly physical sensors
- Gain actionable insights for smarter decisions
How AI Sensors Work
Data Pre-Processing
Clean, filter, and prepare operational data.
Model Development
Build predictive models using statistical and machine learning methods.
Real-Time Predictions
Apply models online, continuously updating with adaptive learning.
Applications
VFA monitoring in digesters
Ammonia control loops in wastewater treatment
Continuous tracking of difficult-to-measure variables (sludge quality, chemical concentrations)
Key Benefits
- Real-time, high-frequency predictions
- Actionable insights integrated into dashboards and digital twins
- Greater process stability and proactive control
- Significant cost savings compared to analyzers and manual sampling
- Continuous model refinement for sustained accuracy
Deliverables
- Custom Predictive Models: Tailored to your plant’s variables
- Reliable Predictions: High-confidence estimates for critical process data
- Continuous Refinement: Models evolve as conditions change
- Seamless Integration: Deployed directly within opsCTRL and Digital Twin systems
Book a Demo
See for yourself what inCTRL’s advanced digital solutions and software can do for your facility.