As global industries grapple with the imperative for sustainable transformation, Modcon Systems Ltd., headquartered in London, emerges as a trailblazer in delivering intelligent, efficient, and environmentally responsible solutions for the process sector. With over five decades of engineering excellence, Modcon is shaping the future of industrial operations through its strategic integration of Artificial Intelligence (AI), Machine Learning (ML) and advanced photonics-based sensing technologies.
Founded in 1972, Modcon brings over 50 years of expertise in process analyzers and optimization to some of the world’s most complex industrial environments. Today, the company is leveraging cutting-edge technologies to meet the United Nations Sustainable Development Goals (SDGs), which encompass environmental protection, economic growth and social progress.
One of the key challenges in hydrocarbon processing and hydrogen production is the presence of explosion-prone, high-risk zones, where real-time quality control is essential to maintain operational efficiency and safety. Traditional installations of analyzers in these hazardous zones have required explosion-proof infrastructure, which increases both installation complexity and maintenance costs, while also posing serious risks to personnel during servicing.
Modcon’s photonics-powered remote sensing approach offers a game-changing alternative. By decoupling the sensor from the analyzer and relocating measurement systems to secure, non-hazardous areas such as central control rooms, Modcon eliminates the need for protective enclosures in hazardous areas. This not only enhances safety but also significantly reduces capital and operational expenditures, all while maintaining the high fidelity of real-time process analytics.
Fiber optics play a crucial role in this architecture—either as passive, intrinsic sensors or as transmission media for analytical signals from the field to the control center. Their adaptability makes them ideal for high-demand industrial environments, especially where precision, safety, and reliability are non-negotiable.
Recent breakthroughs in optical analysis methods have enabled in-situ measurements under high-pressure and corrosive conditions, traditionally considered off-limits. These capabilities are further enhanced by AI-driven software that compensates for cross-interference and dynamic process variability, ensuring sustained measurement accuracy in real-world, rapidly changing production environments.
At the heart of Modcon’s value proposition is the seamless fusion of smart software and advanced sensor technology. The company’s Modcon.AI platform leverages neural networks and deep reinforcement learning (DRL) to create adaptive, self-learning models. These models do not rely solely on static historical data but are continuously trained on real-time feedback, mimicking human learning processes and thriving in dynamic operational settings.
Each system is equipped with a digital twin that reflects live process conditions, receiving inputs from both remote field sensors and laboratory data. This twin simulates outcomes across various production scenarios, recommends optimal setpoints and aligns process adjustments with performance targets and cost optimization goals.
More than just a response to regulatory or environmental pressures, Modcon’s strategy represents a deliberate and forward-thinking vision—a blueprint for a safer, smarter, and more sustainable industrial future. By harmonizing photonics, fiber-optic infrastructure, AI, and chemometrics, Modcon empowers the process industry to not only meet present challenges but also ensure long-term sustainability.
As industries worldwide navigate the twin transitions of decarbonization and digitalization, Modcon remains at the leading edge—providing the tools and technologies needed to drive safe, intelligent and resource-efficient operations in the decades ahead.
Dynamic models powered by deep reinforcement learning (DRL) are calibrated using inputs from remote sensors and laboratory results. The system’s digital twin is updated in real time, allowing for accurate simulation and prediction of product quality across different process streams. It proposes optimal setpoints, validates against key performance indicators (KPIs), and ensures the process runs at maximum efficiency with minimal cost.
Modcon’s strategy for sustainable development is not merely a reaction to global trends—it’s a proactive blueprint for the future. By fusing photonics, fiber optics, AI and chemometrics into integrated systems, the company is enabling process industries to meet their current demands without compromising the resources needed by future generations.
As global industries confront the dual challenges of decarbonization and digitalization, Modcon stands at the forefront with technologies that support safe, intelligent and sustainable operations.
