DecarbonX: How AI and Decarbonization-Centered Maintenance Are Transforming Industrial Asset Care

By Ed Cherednik, Executive Director of the DecarbonX Program (Angara Global)

Written with AI agent assistance

Jan 14, 2025

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When it comes to maintaining petrochemical equipment, the industry has long treated maintenance as a kind of necessary evil—an unwelcome interruption that disrupts production and consumes significant budgetary resources. For decades, the prevailing scenario involved waiting until a piece of equipment was heavily fouled (or at direct risk of failure) and then finally scheduling a cleanup or overhaul. As a result, plants have operated with relatively reliable equipment in terms of catastrophic failures, but much of that same equipment runs in a “clogged” state—enduring hidden fouling deposits, elevated fuel consumption, inhibited heat transfer, clogged water circuits, and correspondingly high CO? emissions.

Today, such a conservative approach is increasingly difficult to justify. First, intense market competition means that any efficiency loss directly undercuts profitability. Second, rising environmental awareness—and the global imperative for decarbonization—demands that petrochemical facilities reduce their carbon footprint, without compromising production targets. At first glance, this dual objective may seem contradictory, but new digital tools are revealing that greater operational efficiency and a reduced environmental impact can, in fact, go hand in hand.

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DecarbonX, developed by Angara Global, stands out as one of the first comprehensive platforms explicitly designed to achieve this dual effect. With its proprietary analytics “chassis,” a Swarm-AI engine, and a core philosophy of Decarbonization-Centered Maintenance (DCM), DecarbonX helps turn maintenance practices from mere formalities or reactive measures into strategic initiatives for keeping equipment clean, saving fuel, and cutting CO? emissions. In practice, this is accomplished not only through advanced machine learning algorithms, but also through a profound shift in asset management philosophy—incorporating new standards, revisiting project engineering norms, and optimizing maintenance planning.

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From Traditional Reliability to Decarbonization

For decades, maintenance in petrochemical enterprises has centered on a single principle: minimize the risk of catastrophic breakdowns. Imagine a typical plant housing 500–800 heat exchangers. If some of those exchangers begin losing efficiency due to fouling, yet do not actually fail, the classical logic does not treat that scenario as an “urgent” problem. The equipment remains functional—just not at optimal capacity—leading to higher fuel consumption and reduced heat transfer.

This situation is a covert but massive source of loss. From an energy standpoint, every unit of heat-transfer efficiency “devoured” by fouling translates into extra tons of CO? emitted when burning fuel. Compounding the issue, process engineers often incorporate design “margins” in new equipment (essentially “extra room” for fouling). So long as the system “still runs,” companies are reluctant to spend money on cleaning.

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Decarbonization-Centered Maintenance (DCM) overturns this paradigm. Under DCM, clean equipment is no longer viewed as a mere “cosmetic bonus.” Instead, it is recognized as a critical factor in lowering the carbon footprint and raising a plant’s profitability. DCM compels us to look at a typical heat exchanger or column not just in terms of “Will it break or not?” but rather “How much economic and environmental damage is this still-operable but fouled equipment causing?”

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The Roots of DecarbonX: From “Dirty” Equipment to “Cognitive” Cleaning

The DecarbonX project essentially started with one straightforward (yet rarely implemented) premise:

“Clean equipment always performs better than dirty equipment. So why aren’t we keeping it continuously clean?”

That seemingly simple question concealed a large-scale problem:

????????????????? ??????????????? Conventional chemical methods of cleaning tend to be ineffective against stubborn, carbon-based fouling that can accumulate (and even harden) over years.

????????????????? ??????????????? Mechanical methods typically require dismantling equipment and can stretch on for weeks, resulting in major production losses.

????????????????? ??????????????? Mindset inertia: “If there’s no catastrophic risk, let’s not touch the equipment now—our scheduled turnaround is coming up in a year or two.”

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By clarifying the root of this dilemma, the DecarbonX team went on to develop an entirely new solution: Cognitive Cleaning. This isn’t just a better chemical formula, but an approach where the applied cleaning agents create a controlled mechanical effect that breaks down fouling without dismantling the heat exchanger. To achieve this, however, a thorough understanding of fouling deposits and process conditions is essential—meaning that data collection and analysis must be enhanced and move toward real-time.

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This realization led to the concept of a modern digital platform that merges knowledge of the physical and chemical properties of fouling with continuous online monitoring. And at this juncture, it became apparent that without a sweeping transformation of the entire maintenance system—from organizational structures to budgeting approaches—no chemical solution alone could fulfill its potential. Hence the emergence of Decarbonization-Centered Maintenance (DCM), accompanied by a formal standard designed to convert scattered “pain points” into a unified, systematic approach.

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The Essence of DCM: Managing “Dirt” to Shrink the Carbon Footprint

DCM views technical maintenance as a central mechanism for decarbonization. It posits that most companies face a variety of barriers that hinder an effective approach to cleaning and lowering emissions. Within DecarbonX, these barriers are referred to as “green,” “blue,” and “gold”:

????????????????? 1.???????????? Green Barriers (Operational) – A classic scenario in which the equipment technically “runs,” but runs poorly. For instance, a heat exchanger might be heavily fouled yet lacks an official directive for cleaning because “it isn’t broken.” In such cases, the drop in heat-transfer coefficient leads to increased energy use and elevated CO? emissions.

????????????????? 2.???????????? Blue Barriers (Technical) – Emerge when designers or procurement officers preemptively assume fouling (e.g., designing equipment with oversized dimensions to “absorb more dirt”), effectively normalizing poor heat-transfer performance. Such choices both boost capex spending and intrinsically lead to higher energy consumption.

????????????????? 3.???????????? Gold Barriers (Managerial) – Relate to corporate culture and financial practices. Even if engineers know that their equipment is fouled and hurting efficiency, they often cannot justify extra cleaning expenditures if no immediate risk of failure exists. Without budgetary recognition of how big the payoff from reducing fouling truly is, companies continue to “save” on maintenance costs while unknowingly burning millions more in fuel expenses (and CO?).

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According to DCM, addressing all three barriers is necessary if a facility hopes to significantly cut carbon emissions and ramp up operational efficiency. This is where DecarbonX comes in: it provides a methodology and toolkit that tackle these barriers step by step, from diagnostic analysis (Phase 1) to strategic planning (Phase 4) and final implementation (Phase 5).

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The Five-Phase DecarbonX Methodology: From Diagnosis to Execution

Despite its technological complexity (AI, Swarm agents, streaming data from SCADA/DCS, etc.), DecarbonX proceeds along a clear five-step roadmap.

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Phase 1. Degradation Risk Diagnostics

Rather than relying on scattered data from past repairs or on generic engineering standards, DecarbonX constructs a comprehensive map of each critical unit—heat exchangers, columns, furnaces, water circuits—assessing typical degradation mechanisms (fouling, corrosion, etc.) and pinpointing where hidden vulnerabilities may lie. Often at this stage, “blind spots” emerge that were never before considered problematic.

Example: At one plant that aimed to extend turnaround intervals from 2 to 4 years, DecarbonX detected more than 25 “unaccounted-for” potentially problematic exchangers. By performing targeted sampling and analyzing water and thermal data, the team revised the maintenance plan accordingly and safely achieved a 4-year cycle.

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Phase 2. Real-Time Risk Monitoring

With these “pain points” identified, DecarbonX connects to SCADA/DCS data streams, capturing telemetry from sensors (e.g., temperature, pressure, flow, water quality) and analyzing it near real-time. If the system sees troubling trends—say, a sudden pressure drop or changes in the water chemistry—it issues a warning well before a critical threshold is reached.

Example: At an ethylene plant, this approach allowed operators to optimize cleaning intervals. Some exchangers could safely continue running without immediate cleaning, saving $1.2 million, while others were flagged for early intervention to avert a negative impact on production.

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Phase 3. Root Cause Analysis (RCA)

Here, the platform merges sensor logs with fouling sample analysis (chemical composition, correlation with corrosion byproducts or contaminated water, etc.). This deep investigation reveals the “root” factors: a malfunctioning coalescer, a misapplication of corrosion inhibitors, a water-treatment contract that’s underperforming, and so on. This phase is crucial because it targets the source of the problem, rather than merely treating symptoms.

?Example: At a polycarbonate facility, DecarbonX discovered a hydrocarbon leak into the steam circuit that could have caused a major incident. The culprit was a defective coalescer. Swift action averted costly downtime and shaped a new internal standard for investigating similar anomalies.

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Phase 4. Response Strategy Development

Once the real culprit is uncovered, DecarbonX helps craft an array of “countermeasures”—ranging from refined water-treatment protocols to new fouling control recipes. The platform consistently balances cost, risk, and potential benefits, while factoring in environmental metrics (e.g., exactly how much a given measure will shrink the carbon footprint).

Example: On a large ethylene complex at risk of a 4% production drop during a sweltering summer, DecarbonX recommended a coordinated plan of proactive cleaning and minor equipment replacements during short downtime windows. The plant successfully navigated 90 hot days without losing ethylene throughput.

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Phase 5. Strategy Execution

Ultimately, even the best ideas require solid implementation. DecarbonX assumes a “conductor” role: it creates work orders, ensures the proper chemical dosages, verifies subcontractor tasks, and logs the outcomes. Afterwards, the system analyzes feedback—what worked, what didn’t, where the plant saved on downtime—and how fouling and corrosion patterns changed. This forms a continuous improvement loop.

Example: For a Crude Distillation Unit (CDU), operators introduced a hybrid cleaning strategy (chemical + mechanical) and cut downtime from 14 days to 4, resulting in 30 days of extra “on-line” operation per year.

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Swarm AI: Collective Intelligence vs. “Information Graveyards”

Coordinating such a process—and handling vast data sets—requires a robust digital core. DecarbonX implements Swarm AI, a concept in which a multitude of “smart agents” each handle specialized tasks. Some agents might analyze fouling samples, others might track water trends or correlate thermal profiles with design specs, while still others crawl through archives of engineering standards and historical reports.

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All these agents interact to form a “living” collective intelligence that constantly learns from each newly observed phenomenon or completed project. In traditional machine learning, one large model might attempt to do everything. Here, many localized “intelligences” converge to produce recommendations within a unified decision-making platform. This architecture grants DecarbonX remarkable adaptability: it can swiftly adjust to new data sources, new complexities, and new equipment, leaving no “narrow but significant” detail outside its view.

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Equally important, Swarm AI unlocks the hidden value of old archives and technical documentation, which may have been accumulating at a facility for decades. Instead of leaving it all to gather dust, the data is integrated into the knowledge base—serving as the foundation for more accurate forecasting and precisely tailored recommendations.

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The DecarbonX Center: A “Medical” Approach to Industrial Equipment

Another vital aspect of the DecarbonX ecosystem is the DecarbonX Center, operating much like a hospital for industrial assets. Where traditional engineering teams previously dealt with problems in isolation—hiring a subcontractor to clean, ordering chemicals, scheduling a window—now the process is orchestrated holistically:

–????? Diagnosis: Identifying “diseases” (fouling, corrosion, leaks) and their potential sources.

–????? Treatment: Applying “Cognitive Cleaning” technologies or more targeted fixes (e.g., adjusting inhibitor dosage).

–????? Prevention: Implementing continuous online monitoring so that problems cannot silently build up.

–????? Check-Up: Conducting periodic, in-depth assessments of equipment “health” to catch any early warning signs or performance drifts.

–????? Rehabilitation: If some components are reaching end-of-life, DecarbonX assists in planning modernization or replacement aligned with decarbonization and business goals.

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This integrated “medical model” changes how companies and service providers interact. Instead of serving merely as “firefighters,” engineers become something akin to equipment “therapists” and “nutritionists,” preserving the “well-being” of assets—and saving millions of dollars in the process.

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Real-World Examples: Making It Work “in the Field”

A theoretical framework alone can’t convey the full significance of DecarbonX. Below are a few real-world success stories:

????????????????? ??????????????? Ethylene Plant: Facing possible production losses of up to 4% during a 90-day summer peak, the facility deployed DecarbonX’s predictive analysis and integrated cleaning strategies on key exchangers and furnaces. Result: no loss of throughput and a positive revenue boost during the critical season.

????????????????? ??????????????? Polycarbonate Production: A hydrocarbon leak was discovered in the steam circuit, which could have led to a massive accident. By correlating chemical sample data, the platform found the root cause in a failing coalescer, avoiding both downtime and safety risks. The solution also spurred a new standard protocol for investigating such leaks.

????????????????? ??????????????? Major CDU Block: A more flexible cleaning approach cut the downtime per train from 14 days to 4, yielding 30 additional productive days annually. Part of the improvement involved using “Cognitive Cleaning” on high-carbon fouling layers.

????????????????? ??????????????? Network of 300+ Heat Exchangers: Integrating DecarbonX uncovered serious inaccuracies in a water-treatment contractor’s reports. Thanks to localized monitoring, the plant substantially improved corrosion tracking, ultimately reducing tube-bundle replacements by 30% and extending maintenance intervals to 4 years.

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From Pilot Projects to Enterprise-Wide Adoption

Many organizations begin by piloting DecarbonX on a single unit or a handful of problem exchangers—what the industry calls a “quick win.” Once the platform demonstrates its viability (fuel savings, minimized downtime, measurable environmental benefits), companies are inclined to scale up to an enterprise-level rollout. This involves integrating the platform into CMMS or ERP systems and codifying new internal standards for maintenance and decarbonization.

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Global players have already tested the approach, with audits by DNV confirming DecarbonX’s accuracy and effectiveness. Ultimately, DecarbonX stops being just an external add-on and becomes part of the plant’s “nervous system,” continuously analyzing data, forecasting outcomes, and issuing actionable directives to keep operations clean and efficient.

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Future Prospects: Broadening the Boundaries of DCM

Today, DecarbonX is primarily focused on tackling fouling and corrosion—especially in heat-transfer equipment and certain types of columns. Nevertheless, the platform is evolving rapidly: advanced corrosion management, coverage of compressors and reactors, and a wider variety of equipment types are all on the development roadmap. This expansion makes perfect sense, as any disruption in one part of a petrochemical system can ripple through the entire production chain.

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Moreover, there is active work on advanced environmental metrics that will directly quantify (in CO?-equivalent terms) the losses caused by fouling and the gains from eliminating them. Such tools provide management with a potent argument for budget reallocation: instead of funneling money into “cosmetic” environmental investments with minimal real-world impact, they can prioritize initiatives that slash emissions and strengthen the bottom line.

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Why It Matters: The Synergy Between Economic and Environmental Benefits

Decarbonization is not just about renewable energy or shifting to green power sources. A major portion of the potential lies in optimizing existing processes and eradicating systemic inefficiencies. Even a few percentage points of improved heat-transfer efficiency can translate into millions of dollars saved and a significant reduction in carbon emissions.

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Decarbonization-Centered Maintenance demonstrates that “cleaning and maintenance” need not remain an afterthought, addressed only upon major breakdowns. They can become a powerful catalyst for modernization, boosted efficiency, and lower CO? outputs. Where an engineer might previously have struggled to financially justify additional cleaning to upper management, DecarbonX now provides hard data: the size of fouling-related losses, the extra fuel needed, and exactly how much CO? can be saved by timely intervention.

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Conclusion: A New Era in Asset Management

We are living in a time when petrochemical companies can no longer afford to run “at full capacity but dirty,” simply ignoring accumulated issues. Fierce competition and more stringent environmental regulations demand both improved efficiency and reduced carbon footprints. DecarbonX, grounded in the DCM standard, provides a comprehensive framework that merges AI, rigorous engineering, and sustainability goals:

–????? Smart Diagnostics of every piece of equipment and production unit.

–????? Ongoing Monitoring (sensor data, water quality, thermal parameters, etc.) in near-real-time.

–????? Root Cause investigation that goes beyond superficial fixes to address underlying issues.

–????? Strategic Planning that accounts for risk, cost, and environmental impact.

–????? Practical Execution using cognitive fouling-cleaning methods and flexible turnaround scheduling.

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Real-world implementations showcase immediate benefits: lower costs, higher reliability, and a marked drop in emissions.

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Looking ahead, it’s not hard to envision that DCM’s philosophy could become the new industry norm. Could it be “obsolete” to suggest that a refinery should operate as cleanly and efficiently as possible, avoiding energy waste, excessive fouling space, and unchecked corrosion? Hardly. In fact, these attributes are rapidly becoming essential for survival in an era defined by ever-tougher environmental laws and competitive pressures.

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DecarbonX is not merely applying a new digital veneer atop old methods. It is reshaping how maintenance is performed, involving every management level—from plant operators to the board of directors. If in the old days, maintenance was associated with cost and disruption, now it emerges as a continuous source of improvement, enhanced profitability, and—critically—a more sustainable future.

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Thus, we move from a paradigm of “maintenance for reliability” to “maintenance for reliability and decarbonization.” And this shift already demonstrates that cutting emissions and saving money can coexist. Leveraging Swarm AI and in-depth equipment knowledge, DecarbonX transforms once-forgotten “information graveyards” (old reports, unconnected sensor readings) into a dynamic, ever-evolving database where every “green” initiative has transparent figures and clear payback milestones.

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Ultimately, it’s this blend of science, engineering, and organizational culture that gives industry a real chance to move toward “clean” efficiency—without resorting to the utopian idea of shutting down all production or performing mere “green PR” with no real changes. DecarbonX is paving the way for a scenario in which environmental responsibility and business priorities are aligned, and maintenance evolves from a dreaded cost center into a strategic advantage.

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For Enterprise Client Use

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Contact: For more information or to arrange a pilot, please visit Angara Global or reach out to the DecarbonX Center of Excellence.