Dangote Refinery targets $60m saving with new AI technology

Dangote Petroleum Refinery and Petrochemicals has announced plans to be the first industrial facility to utilize Honeywell Technologies' new artificial intelligence platform, Forge Plant Cognition. This advanced technology is expected to generate over $60 million in annual gross operational benefits at full refining capacity, according to preliminary assessments.

Forge Plant Cognition merges Honeywell's process engineering expertise with NVIDIA's artificial intelligence capabilities and Dell Technologies' computing infrastructure to enhance refining efficiency, maximize output, and bolster operational reliability.

The platform, set to debut globally at the Lekki-based refinery, one of the world's largest, aims to demonstrate the potential of artificial intelligence in improving the performance of complex industrial facilities. Dangote Refinery's Managing Director and Chief Executive Officer, David Bird, highlighted the company's commitment to innovation, operational excellence, and the development of Nigerian engineering talent.

Bird emphasized that the adoption of this technology aligns with the refinery's ambition to cultivate local professionals capable of operating complex industrial facilities to international standards.

Unlike traditional monitoring systems that generate recommendations based on analyzed operating data, Forge Plant Cognition integrates real-time plant information with engineering knowledge, advanced calculations, and physics-based models. This enables it to identify constraints and aid in faster operational decision-making. The technology is designed to detect potential equipment failures before they escalate, pinpoint production bottlenecks, and provide recommendations for corrective actions to enhance throughput, product yields, and overall performance.

Honeywell's President of UOP, Rajesh Gattupalli, described the collaboration as a prime example of how artificial intelligence can revolutionize large-scale industrial operations. The deployment of Forge Plant Cognition is expected to drive higher productivity, reliability, and profitability across industrial facilities. Gattupalli noted that the project underscores the transformative potential of AI in driving performance and value in industrial environments.

This initiative is in line with Dangote Refinery's goal of building a workforce comprising more than 70% Nigerians, thereby reducing dependence on external expertise and bolstering local technical capacity.