Highlighted Business Cases

Our highlighted business cases offer a clear overview of how our technology is being applied in real industrial environments. Each case outlines the operational challenge and the approach taken, providing insight into the potential value of data-driven monitoring.

Use-case: The impact of process disruptions on fouling

Customer: Leading international chemical manufacture
Location: Pipeline connected to the bottom outlet of a reactor
Installation: ToPerform™ Fouling Sensor installed three months before a scheduled turnaround.

Background

The pipeline under consideration is a critical point in the production process and a known hotspot for heavy fouling. Historically, this specific line is cleaned every two years during a major turnaround. Until now, fouling levels between turnarounds were managed reactively, with little actual insight into actual build-up patterns.

Sensor implementation

Three months prior to a planned turnaround, a ToPerform™ Fouling Sensor position was installed to test whether fouling could be measured in real-time. The objective was to track fouling build-up both during startup and throughout routine operations, testing the feasibility of continuous monitoring in this type of production location.

“The fouling on heat exchangers continues to be an ongoing challenge… All methods to decrease fouling require some insight in the mechanisms of the deposition process and the structure and attachment on the heat transfer surface.”

Source: Website yearly Heat Exchanger Fouling & Cleaning Conference1

Key findings

1. Startupfouling detection

Within the first few post-startup days, the ToPerform™ Fouling Sensor recorded a noticeable rise in fouling index, correlating with suboptimal flow and temperature conditions.

2. Processdisruptionsaccelerate fouling

During the initial four-month monitoring period, the process was interrupted multiple times. Each interruption coincided with a spike in fouling index values, indicating accelerated fouling during shutdown/startup cycles. This suggests that:

Fouling is not only a result of steady-state operations.

Transient conditions play a major role in fouling accumulation.

3. Approachingpre-turnaroundfouling levels

Sensor data revealed that the fouling index had reached ~85-90% of the levels seen prior to the last major cleaning cycle within just three months.

“We were surprised to see such high fouling levels so soon. It prompted a serious discussion about advancing our cleaning schedule.” – Operations Manager

4. Operationaldecision making

Based on the data, the plant is now evaluating a shift from fixed, calendar-based cleaning to condition-based maintenance. The ability to detect and quantify fouling during normal and abnormal operations is seen as a way to:

Prevent costly unplanned shutdowns.

Extend asset lifetime.

Increase overall process reliability and safety

Insights & Next steps

Insights

Process instability (not just total run time) is a major driver of fouling. Evidence from both start-up (with suboptimal flow and temperature conditions) and unplanned process interruptions shows that fluctuations and disturbances accelerate deposit formation.

Insight into when, how fast, and under what conditions fouling builds up enables smarter planning.
Beyond cleaning decisions, fouling insights can also support process control, enhance safety, and guide strategic maintenance planning.

Next steps

The customer is considering:

Installing additional sensors at other critical fouling locations.

Integrating ToPerform’s data into their existing DCS or predictive maintenance systems.

Using fouling insights to optimize the timing of cleaning procedures.

"We were surprised to see such high fouling levels so soon. It prompted a serious discussion about advancing our cleaning schedule."

- Operations Manager -

Use-case: Detection of wax fouling

Customer: Global plastic recycling manufacturer
Location: Production line for polymer regeneration
Installation: ToPerform™ Fouling Sensor on wax-prone pipeline section

Background

In the fast-growing plastic recycling industry, controlling fouling from wax build-up is essential for stable operations and efficient production. The client sought to gain insight into when and how wax fouling occurs, and how effective their cleaning strategies really are.

Sensor implementation

A ToPerform™ Fouling Sensor was installed on various parts of a critical part of the process line known for wax accumulation. The aim was to track fouling behavior under varying flow conditions and to analyze cleaning effectiveness.

Key findings

1. Fouling build-up detection

The sensor detected an increase in fouling index values during production, confirming suspicions of wax deposits forming over time.

2. Real-time differentiation of flow phases and types

The system successfully distinguished between the flow of process fluids and gas phases. Moreover, the fouling graphs clearly reflected the impact of cleaning measures. Together, these insights introduced a new dimension to process monitoring and enhanced overall understanding. .

3. Approachingpre-turCleaning effectiveness validations

Post-cleaning data clearly showed a drop in fouling index, validating that the cleaning procedure was effective, something previously only assumed. This way cleaning effectiveness also could be tracked.

Insights & Next steps

Insights

Wax fouling can now be quantified and tracked in real time.
Sensors provide clarity on the effectiveness of cleaning actions.
Differentiation of flow phases and types can support better process diagnostics.

Next steps

The customer is considering: