With the successful deployment of an AI-driven optimization solution for Aramco, one of the world’s leading integrated energy and chemicals companies, Emerson has begun a collaboration integrating of their Aspen Hybrid Models into Aramco’s existing refinery planning framework, resulting in the creation of one of the world’s largest multi-site, multi-period optimization models.

By combining first-principles models, deep domain expertise, and purpose-built industrial AI, Aspen Hybrid Models capture nonlinear relationships in yield and quality responses, significantly enhancing the accuracy of refinery planning models. The deployment has already achieved yield and quality prediction accuracy of up to 98.5 percent in key refinery units.

ENHANCING MODEL ACCURACY ACROSS PLATFORMS

These hybrid AI models have been implemented in Continuous Catalyst Regeneration (CCR) and Platformer Units, where they are enabling more precise feedstock blending, minimizing gaps between planning and execution, and improving the accuracy of margin forecasting across Aramco’s global refining network.

Current efforts are focused on expanding the hybrid modeling approach to hydrocracker units across Aramco’s assets. This expansion is expected to further enhance model accuracy and demonstrate the scalability and robustness of this AI-driven optimization strategy across the enterprise.

“This deployment represents a significant milestone in Aramco’s AI strategy and our long-standing relationship with Emerson,” says Ahmad Alkudmani, director of the global optimizer department at Aramco. “We are committed to leveraging innovative technologies for smarter, more efficient refining optimization. With improved model accuracy, we are enhancing planning decisions, reducing the manual adjustments required from our engineers, and uncovering new value across our global assets.”

REAL PERFORMANCE BENEFITS

Key benefits Aramco aims to achieve with Aspen Hybrid Models include: 

  • 98.5 percent yield and quality prediction accuracy: Substantially increasing yield volume and enhancing stream quality across diverse feedstocks, operating conditions, and throughputs
  • Efficiency through optimized feedstock blending: Diversifying feedstock selection and blending recipes to enable more profitable and sustainable operations
  • Reduced planning-execution gaps: Minimizing discrepancies between plans and actual plant performance, reducing the need for manual adjustments
  • Enhanced model accuracy: Capturing complex non-linearities in critical unit operations such as reactors
  • Improved operational efficiency: Automating model updates and reducing manual tuning requirements
  • Scalable global solution: Maintaining model applicability across a wide range of refinery operations worldwide

Aramco is using Aspen Hybrid Models built and deployed in Emerson’s AspenTech Performance Engineering and Manufacturing and Supply Chain product suites. As a result, Aramco was able to create highly accurate nonlinear optimizations using thousands of converged simulation cases built upon rigorous first-principles models calibrated with actual plant data. The approach provides Aramco with a scalable, robust tool for global refinery planning.  

THE DRIVING FORCE OF DIGITAL INNOVATION

“Aramco continues to set the standard for operational excellence through digital innovation,” says Claudio Fayad, chief technology officer of Emerson’s Aspen Technology business. 

“This deployment of AI-driven Aspen Hybrid Models to optimize complex, multi-site, multi-period planning workflows demonstrates the tangible value of combining deep domain expertise with advanced AI. We’re excited to expand our strategic relationship with Aramco as they advance their digital transformation goals.”

PARTNER PROFILE: ASPEN TECHNOLOGY

Aspen Technology formed from the Advanced System for Process Engineering (ASPEN) Project—joint research between the Massachusetts Institute of Technology (MIT) and U.S. Department of Energy. The team explored technical innovations in response to the 1970’s energy crisis, developing the chemical industry’s first computer-based modeling and simulation technology. The innovations developed in those initial days had a transformative impact, providing the foundation for decades of industrial optimization advancements.

For more information, visit www.aspentech.com.


Emerson is a global industrial technology leader that provides advanced automation. With an unmatched portfolio of intelligent devices, control systems and industrial software, Emerson delivers solutions that automate and optimize business performance. Headquartered in St. Louis, Missouri, Emerson combines innovative technology with proven operational excellence to power the future of automation. For more information, visit www.emerson.com.