Resources

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 real continuous stirred-tank reactor hardware, and chemical manufacturing is its first vertical.

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 runs on continuous stirred-tank reactors today. The same architecture extends to batch reactors, plug flow reactors, distillation columns, crystallizers, and evaporators. Chemical manufacturing is the first vertical.

PID reacts to the error it sees right now. MPPI (Model Predictive Path Integral) control couples machine learning with predictive optimization to anticipate where the reactor is heading and pick the best move before a disturbance lands. The payoff is higher yield, lower energy use, and faster recovery from upsets, with PID still underneath as the safety net.

Yes. Acaysia connects to existing PLCs from Rockwell, Siemens, and other major vendors over the standard protocols, OPC UA and EtherNet/IP. No rip-and-replace; it drops in alongside what you already run.

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 responds in under 100 milliseconds, automatically reverting to proven PID control or a safe shutdown when it detects an anomaly.

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.