Control Software
Intelligence for Your Existing DCS
Metafuels links with your existing distributed control system in days rather than months. No added PLC hardware or OT network rebuild. Adaptive AI setpoints reach controllers through OPC-UA or Modbus.
Current Jet-Cut Yield
58.4%
Core Modules
Three Modules, One Unified Stack
All modules use one sensor-data layer and digital twin, letting findings build across the stack.
Yield Optimizer
Continuously tunes reactor inlet heat, space velocities, and recycle ratios to increase jet-cut fraction per methanol unit. Coordinates H2 supply timing to lower hydrogen cost as well.
Catalyst Lifetime Manager
Monitors coking and sintering decline in each of the four catalyst beds. Forecasts regeneration windows 72 hours early, enabling planned maintenance without halting output.
Compliance Monitor
Monitors blend attributes live against ASTM D7566 Annex A7, EU ReFuelEU Aviation limits, and customer-specific freeze-point specifications. Warns ahead of off-spec material reaching fractionation.
DCS Links
Works With Your Existing System
MtJ facilities commonly use ABB, Emerson, Siemens, or Yokogawa DCS platforms. Metafuels provides certified OPC-UA links for each, plus Modbus RTU for older equipment. Field engineers complete integration within a four-week commissioning window.
OPC-UA DA/HDA server and client modes for ABB 800xA, Emerson DeltaV, Siemens PCS 7, Yokogawa CENTUM VP
Modbus TCP/RTU for legacy programmable logic controllers; no gateway hardware required
Data residency on-premise or in an air-gapped cloud enclave, compliant with IEC 62443 Level 2
Shadow-mode operation for 30-day validation before switching to closed-loop control
Model Learning
Improves With Each Production Run
Following every campaign, Metafuels retunes process models with measured plant outcomes. Deactivation rates observed in your reactor geometry and feedstock quality establish ground truth for the subsequent cycle. Benefits accumulate throughout deployment life.
Learning is federated: plant data remains within your infrastructure. Metafuels aggregates anonymized thermodynamic residuals only to sharpen the base model across the fleet, subject to explicit contract exclusions for commercially sensitive operating conditions.
Deployment Choices
Cloud SaaS or On-Premise, OT Policy Decides
Operators may keep all process data on site, while others assign software upkeep to us. Either operating model is available.
SaaS (Cloud-Hosted)
Metafuels runs the AI inference engine in a dedicated regional cloud enclave. Sensor data is encrypted during transfer and storage. Updates and model enhancements install automatically. Suited to greenfield plants and operators lacking dedicated OT IT teams.
On-Premise
The complete stack runs on operator-provided hardware inside the plant OT boundary. Internet egress is unnecessary after initial commissioning. Signed model-update bundles arrive via protected unidirectional transfer. Mandatory at sites governed by national critical infrastructure rules.
See It on Your Plant Data
Provide a two-week historian export. Our application engineers run a shadow-mode simulation and return an estimated yield improvement before commercial discussions start.