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Acaysia is a control system that optimizes physical processes for yield, energy, and throughput. It models each unit operation as a typed object and computes control moves in real time. It is proven on a lab-scale continuous stirred-tank reactor, with pilots in progress in chemical manufacturing.

Acaysia runs on a typed compositional ontology of unit operations. Each process is described by conserved quantities, ports, state variables, and manipulated variables. The controller reads the ontology rather than hard-coding one process, so the same architecture extends from reactors to columns to crystallizers.

Acaysia's control architecture works across unit operations. CSTR is the proven class, validated on Acaysia's own lab-scale test reactor. The same approach extends to other unit operations such as batch reactors, plug flow reactors, distillation columns, crystallizers, and evaporators. Chemical manufacturing is the first vertical.

MPPI (Model Predictive Path Integral) control uses machine learning and predictive optimization to anticipate reactor behavior and make optimal decisions, unlike traditional PID which only reacts to current errors. This results in better yield, energy efficiency, and faster response to disturbances while maintaining safety.

Yes, Acaysia integrates seamlessly with existing PLCs from Rockwell, Siemens, and other major vendors via standard protocols including OPC UA and EtherNet/IP. No rip-and-replace required - it's a drop-in solution.

Shadow Mode is the first phase of deployment where Acaysia observes your reactor operations without making control decisions. This allows the ML model to learn your specific process. The system then progresses through Advisory Mode (recommendations only) before optional Closed-Loop Control with full automation.

Acaysia's failsafe system responds in under 100 milliseconds, automatically reverting to proven PID control or safe shutdown procedures when anomalies are detected. This ensures enterprise-grade safety for all operations.

Yes. A Trust Arbiter checks every control move against plant limits, and the system falls back to existing PID control in under 100 milliseconds on any fault. The safety architecture is ASIL-D inspired and SIL compatible and never interferes with Safety Instrumented Systems.

Modeled scenarios show 1%+ yield improvement and 2-5% energy reduction. For a mid-size chemical plant, this translates to hundreds of thousands of dollars in annual savings, with payback periods often under 12 months.