Antwerp, Belgium – December 2025 – Solvay SA, a global leader in specialty chemicals, has announced an 18% reduction in batch rejects and 22% lower data logging costs after deploying the ABB AI04 input module across its ethylene oxide production plant in Antwerp. The upgrade, completed in Q4 2025, addressed critical precision gaps in the plant’s aging control system—where legacy modules struggled with signal interference and manual data recording errors, costing the company €420,000 annually in wasted materials.
The Challenge: Precision Loss and Compliance Headaches in Chemical Production
Prior to adopting the ABB AI04, Solvay’s Antwerp plant faced four pressing operational challenges:
- Inconsistent Process Control: Legacy 16-bit input modules couldn’t maintain the ±0.1°C temperature precision required for ethylene oxide synthesis. This led to 12% of batches failing quality checks, as slight deviations in reactor conditions altered chemical composition.
- Manual Data Logging Errors: Operators spent 15 hours weekly recording sensor data (temperature, pressure, catalyst levels) in spreadsheets, leading to 3–4 data entry errors per week. These errors complicated compliance with REACH and FDA regulations, risking €150,000 in potential fines.
- Signal Interference: Electromagnetic interference (EMI) from nearby compressors corrupted 8% of sensor signals, causing false alarms and unplanned shutdowns. The old modules lacked galvanic isolation, making them vulnerable to voltage spikes.
- High Maintenance Downtime: Calibrating legacy modules required shutting down reactor lines, resulting in 60 hours of annual downtime and €180,000 in lost production.
“Chemical synthesis is a game of millidegrees and milliseconds—our old modules were costing us both quality and compliance,” said Pierre Dubois, Solvay’s Process Engineering Manager. “We needed a solution that could deliver lab-grade precision in a harsh industrial environment, while automating data logging for regulatory audits.”
ABB AI04 Input Module: The Precision Backbone for Chemical Process Control
After evaluating competitors from Siemens and Emerson, Solvay selected the ABB AI04 for its industry-leading precision, rugged design, and seamless integration with the plant’s existing ABB AC 800M DCS:
- 24-Bit Precision & 16 Channels: The AI04’s 24-bit analog-to-digital conversion delivers ±0.01% full-scale accuracy, 4x more precise than the legacy 16-bit modules. Its 16 differential input channels simultaneously monitor temperature, pressure, catalyst concentration, and pH levels—covering all critical reactor parameters.
- Galvanic Isolation & EMI Protection: 2.5kVrms isolation between channels and power supply eliminates EMI interference, reducing false alarms by 90%. This is critical for chemical plants with high-voltage equipment and dense sensor networks.
- Automated Data Logging & Compliance: The module integrates with ABB Ability™ Process Knowledge System (PKS), automatically logging sensor data with time stamps and audit trails. This simplifies REACH/FDA compliance, cutting documentation time by 70%.
- Hot-Swappable & Low-Maintenance: The AI04’s hot-swappable design allows calibration without line shutdowns, while self-diagnostic features alert technicians to sensor drift or wiring issues 4–6 weeks in advance. Its IP65-rated housing withstands harsh chemical fumes and temperatures (-40°C to +70°C).
- IEC 61158 Compatibility: Seamlessly connects to Solvay’s existing Profinet/Modbus TCP networks, requiring no rewiring or DCS software upgrades—reducing installation time by 50%.
Results: Precision-Driven Efficiency and Compliance
Six months post-deployment, Solvay’s Antwerp plant achieved transformative results:
| Metric |
Before ABB AI04 |
After ABB AI04 |
Improvement |
| Batch Reject Rate |
12% |
9.8% |
18% Reduction |
| Data Entry Errors |
156/Year |
8/Year |
95% Reduction |
| Compliance Documentation Time |
20 hrs/Week |
6 hrs/Week |
70% Savings |
| Maintenance Downtime |
60 hrs/Year |
12 hrs/Year |
80% Reduction |
| False Alarms |
42/Month |
4/Month |
90% Reduction |
“The AI04 has redefined what we expect from an input module,” Dubois said. “We’re now hitting process targets within 0.05°C consistently, and audit preparation that used to take weeks now takes days. It’s not just a component—it’s a compliance and quality tool.”
Elena Petrova, ABB’s Global Product Manager for Process I/O Modules, highlighted the AI04’s role in chemical industry digitalization: “Chemical manufacturers face unprecedented pressure to improve yield, reduce waste, and meet strict regulations. The AI04 series delivers the precision and intelligence needed to turn data into actionable insights—critical for Industry 4.0.”
Solvay plans to deploy the ABB AI04 across 5 more European plants by 2026, targeting a group-wide 15% reduction in batch rejects and 25% lower compliance costs.
