Houston, Texas  ·  Global Delivery
Apex DigitizationProcess Control · RTO · Digitization

Leading Experts in Process Control & Digital Transformation

Advanced process control, real-time optimization, and end-to-end digitization solutions designed to maximize margins, minimize costs, and deliver measurable operational excellence.

$100M+
Client Revenue Growth
+97%
Customer Success
15+
Years Expertise
100+
Industry Partnerships
Advanced Process Control Real-Time Optimization Digital Command Centers Video Wall Development Apex AI-Unit Optimizer Apex Profitalytics Apex True Balance Apex Plan-Genie Scheduling Optimizer Full Stack Development Advanced Process Control Real-Time Optimization Digital Command Centers Video Wall Development Apex AI-Unit Optimizer Apex Profitalytics Apex True Balance Apex Plan-Genie Scheduling Optimizer Full Stack Development
$100M+
Client Revenue Growth
+80%
Year-on-Year Improvement
+97%
Customer Success Rate
15+
Years of Expertise
01 / Advanced Process Control

Primary & Advanced Process Control Services

We develop tailored control strategies specifically crafted to address your business challenges and drive operational efficiency. Implemented via advanced process controllers, our APC solutions deliver measurably increased profitability and yield.

Multivariable Model Predictive Control (MPC) across crude, distillation, FCC, reformer, and polymerization units
Step testing, closed-loop identification, and first-principles hybrid modeling for accurate dynamic process models
DCS integration with Honeywell Experion, ABB 800xA, Emerson DeltaV, Yokogawa CENTUM, Siemens PCS7
APC performance monitoring, KPI dashboards, and long-term benefit sustainment programs
Aspen DMC+Honeywell ProfitShell SMOCMPC/DMCPID OptimizationOTS
Oil and gas plant pipes and processing equipment
DCS / SCADA Integration
APC Sub-Services

Complete APC Project Lifecycle

From process identification through commissioning and long-term sustain — we own the full APC project lifecycle with on-site teams and certified engineers.

📐
Process Identification & Modeling
Step testing, PRBS testing, FOPDT/SOPDT modeling, state-space identification and model validation
⚙️
Controller Design & Configuration
DMC, MPC, QDMC, LP-MPC design with economic objective functions and hard/soft constraint management
🎛️
Operator Training & OTS
High-fidelity operator training simulators for controller checkout, strategy validation, and operator familiarization
📊
Performance Monitoring
OSIsoft PI integration, controller health scoring, benefit tracking, and ongoing tuning support retainers
Start an APC Project
Live Interactive Demo

PID Demo

Tune FIC-101 on a live distillation column. Hold the overhead product flow within ±3% of setpoint for 20 seconds to stabilize the column and win the level.

Can you stabilize this column?
Score 0
Level 1
Time 60s
Distillation column T-101 — live process
Setpoint FIC PV — controlled Uncontrolled
FIC-101 active — tune the controller to hold the flow at setpoint
Flow indicator controller
FIC-101
Kp — proportional 1.8
Ki — integral 0.50
Kd — derivative 0.30
FIC PV
Setpoint
Control output
Deviation
Stability
Tune FIC-101 and keep the overhead product flow within ±3% of setpoint for 20 seconds to stabilize the column.
02 / Real-Time Optimization

Apex AI-Unit Optimizer & RTO Suite

Our self-learning optimization model optimizes both locally and in coordination with inter-unit operations to yield maximum value. It reconciles mass, volume, and properties to ensure accurate data before optimization — operating in open or closed loop modes.

Steady-state and dynamic RTO layers that continuously maximize yield and minimize energy across all units
LP/NLP economic optimization with rigorous process models and plant-wide constraint management
AI-based self-learning that continuously updates models to reflect current process behavior
Seamless integration with existing APC layers, DCS historians, and planning/scheduling tools
LP/NLP SolversEconomic OptimizationSelf-LearningClosed-LoopOpen-Loop
Apex Digital Factory

Proprietary RTO & Optimization Products

Our product suite integrates seamlessly with existing planners, schedulers, and optimizers to deliver real-time actionable insights linked directly to margin potential.

Oil and gas processing facility
Optimization
Apex AI-Unit Optimizer

Self-learning model that optimizes locally and across inter-unit operations. Reconciles mass, volume & properties before each optimization cycle.

Self-LearningOpen/Closed LoopInter-Unit
Oil refinery complex at dusk near waterway
Analytics
Apex Profitalytics

Unifies disparate data sources, eliminating silos. Delivers real-time profit-linked insights to the right decision-maker at the right time.

Real-Time KPIsProfit-LinkedData Unification
Petrochemical plant pipeline network
Reconciliation
Apex True Balance

AI-driven data quality detection and mass/density/volume/profit reconciliation. Outputs can feed Sigmafine and other mass balance tools.

AI Quality CheckMass BalanceSigmafine
Oil refinery plant with chimneys
Planning
Apex Plan-Genie

Provides visibility into planning model quality using AI self-learning. Ensures accuracy and avoids errors. Linearizes non-linear models for NLP compatibility.

Model ValidationNLPAI Self-Learning
Oil refinery with stacks and industrial equipment
Scheduling
Apex Scheduling Optimizer

Optimizes feed rates, cut points, product run-downs, blending, and lifting schedules within all logistical and process constraints.

Feed RatesBlendingLifting Schedules
Oil pump jack silhouette at sunset
Training
Training Services

Comprehensive programs for refining & petchem margins, energy efficiency, quality, production, and digitalization. On-site and remote delivery.

RefiningPetchemOn-site/Remote
Oil and gas industrial plant facility
Digitization
03 / Digitization Services

Digital Transformation & Application Development

We build the digital backbone of modern industrial and enterprise operations — from data pipelines and full application ecosystems to AI-powered analytics platforms, fully integrated and production-ready.

Full stack web & desktop applications — SCADA dashboards, KPI portals, maintenance management, and field apps
Data engineering — OSIsoft PI, SAP/Oracle ERP, MES integration, ETL pipelines, and unified data lakes
Cloud & edge deployment on Azure and AWS — IEC 62443 cybersecurity hardening for OT environments
AI/ML — predictive maintenance, soft sensors, virtual analyzers, and LLM-powered process assistants
React/Next.jsPythonOSIsoft PIAzure/AWSSAP/OracleKubernetes
Oil and gas refinery pipeline and processing network
Digital Command Center
Digital Command Centers

Operational Intelligence at Scale

We design and implement digital command centers for oil & gas, upstream and downstream operations, airports, and large enterprises seeking enhanced business intelligence and operational visibility.

🗺️
Value Stream Mapping
Transform business data into actionable insights and analytics enabling management to achieve goals with greater clarity and impact
📡
Real-Time Data Integration
Live feeds from DCS, historians, ERP, MES, and LIMS — unified into a single operational picture
📱
Mobile & Field Applications
Progressive web apps and native mobile tools for field operators, maintenance teams, and management dashboards
Request a Proposal
New Service

Digital Video Wall Development

Complete video wall ecosystems — from control room ergonomic design and hardware layout engineering to custom software, live data integration, and content management systems.

Industrial control room with a large video wall of monitors
⚫ OPERATIONS CENTER CDU-2 · FCC-1 · T-101
Daily Profit
$1.24M
↑ +4.2% vs prior day
Margin $/bbl
$8.74
target: $8.50 / bbl
Throughput
87.4k
bpd · 98.2% capacity
Product Yields
Naphtha
28.4%
Diesel
32.1%
Gasoline
22.8%
Kerosene
10.2%
Residue
6.5%
Profit Trend
ALARMS
2 active · 0 critical
APC STATUS
12/12 ON ✓
ENERGY
94.2 MMBTU/d
🎛️
Control Room Ergonomic Design
Multi-screen layout engineering for oil & gas, NOC, airport control, and enterprise command centers — 2×1 to 8×4 configurations
📊
Live Data Integration
Real-time feeds from DCS, historians, ERP, and SCADA displayed with custom visualization widgets and alert overlays
🖥️
Content Management System
Web-based CMS for managing screen layouts, data sources, alert thresholds, and scheduling — with role-based access control
🔌
AV & Hardware Integration
Video processors, display controllers, LED/LCD matrix integration, and complete signal management engineering
Control RoomsNOC / SOCAirport OpsLED / LCD WallsSCADA IntegrationCustom CMS
Request Video Wall Proposal
Industries

Deep Domain Expertise

Serving the world's most demanding process and industrial environments with purpose-built digital solutions.

Offshore oil and gas platform at dusk
Oil & Gas
Upstream · Midstream · Downstream
Petrochemical plant pipework and stacks
Petrochemicals
Crackers · Aromatics · BTX
Oil refinery complex beside a waterway
Refining
Crude · Distillation · Blending
Industrial polymer and chemical processing facility
Polymers
PE · PP · Specialty
Power generation and energy infrastructure
Power & Energy
Generation · Grid · Utilities
Aircraft wing above the clouds at an airport
Airports
Operations · Command Centers
Pharmaceutical laboratory and GMP environment
Pharmaceuticals
GMP · Compliance · Batch
Modern enterprise office and analytics workspace
Enterprise
BI · Analytics · Transformation
Technology Partners

Built On Industry-Leading Platforms

Our engineers are certified across the world's foremost industrial automation and process optimization technologies — delivering vendor-grade implementations on the platforms you already trust.

aspentech
Honeywell
Rockwell AUTOMATION
SIEMENS
ABB
Published Research

Recognized Industry Thought Leaders

Our engineers don't just implement — they publish. Our team's work appears in the industry's most respected peer-reviewed journals, advancing the science of process optimization and refining.

Hydrocarbon Processing Peer-Reviewed · May 2026
Coprocessing advanced biocrudes in the FCCU

Featured in the special renewables focus of Hydrocarbon Processing — the global benchmark journal for the refining and petrochemical industry — examining how advanced biocrudes can be coprocessed in the fluid catalytic cracking unit to advance refinery decarbonization.

Read the publication →

See the full list of our team's publications on Hydrocarbon Processing.

Our Methodology

The Approach Behind Our Success

A proven four-stage delivery methodology built on technical rigor, client collaboration, and measurable outcomes.

01
Gap & Benefits Analysis

Process audits, technology assessments, value quantification, and ROI modeling. We identify the highest-impact opportunities first.

02
Tailored Strategy Development

Architecture design, control philosophy, functional specifications, and technology selection — all reviewed and approved before work begins.

03
Execution Excellence

Agile delivery with weekly reviews, automated testing, on-site commissioning, and full documentation package at handover.

04
Continuous Support

Performance monitoring, model tuning, helpdesk support, and long-term sustain retainers to protect your investment.

Engineering Talent

Hire Expert Engineers On-Demand

Augment your team with vetted senior engineers across APC, RTO, digitization, full stack development, database engineering, and integration. Flexible from single-sprint to long-term embedded.

Hire APC / RTO / Process Control Engineers
APC / RTO Roles Available
APC / MPC EngineerRTO EngineerProcess Control EngSimulation EngineerDCS Config EngineerAPC Performance Eng
DCS Platforms
Honeywell Experion · ABB 800xA · Emerson DeltaV · Yokogawa CENTUM · Siemens PCS7 · OSIsoft PI · Aspen DMC+ · Profit Suite
All engagements start with a FREE Benefits Assessment
We identify your highest-value opportunities before any commitment is made. Most mobilizations within 2 weeks.
Hire Digitization Developers
Developer Roles Available
Full Stack DevDatabase EngineerIntegration EngineerData EngineerCloud / DevOpsVideo Wall DevAI / ML EngineerProject Manager
Tech Stack
React · Next.js · Node.js · Python · FastAPI · PostgreSQL · SQL Server · MongoDB · OSIsoft PI · SAP · Oracle · Azure · AWS · Docker · Kubernetes · Power BI · Kafka · RabbitMQ
Domain-First Engineers
Every developer on our team has real industrial experience. We write software that understands your process — not generic enterprise code.
Submit a Full Project Request
What Happens Next
✓  Response within 1 business day✓  Technical scoping call scheduled✓  Tailored proposal within 5 days✓  Mobilization within 2 weeks
FREE
Initial Benefits Assessment
All engagements begin with a complimentary gap & benefits analysis — no cost, no commitment required.
Engagement Models
Fixed-price projects · Time & Materials · Monthly retainer · Sprint-based · Long-term embedded engineers
Why Apex Digitization

What sets us apart

We bring a rare combination most firms cannot offer — engineers who have worked inside oil and gas plants and can also build the software to run them.

Process engineers who code

Our team has hands-on experience in refineries and petchem plants before ever writing a line of software. We understand your process — not just your data.

📐
Fixed-scope transparency

We define scope, deliverables, and success criteria upfront in writing. No surprise invoices, no scope creep. You always know exactly what you are paying for and what you will receive.

🎯
Outcomes, not hours

We measure success in margin gained, deviation reduced, and uptime improved — not in hours billed. Every engagement starts with a benefits assessment that quantifies value before you commit.

🔄
We stay after go-live

Most APC and digitization projects fail because the vendor disappears after handover. We offer sustain retainers, performance monitoring, and retuning — a controller that is not maintained degrades.

Mobilize in two weeks

We maintain a bench of available engineers so you are never waiting months to start. Most engagements can be scoped and mobilized within two weeks of first contact.

Start with a free assessment

Every engagement begins with a no-cost, no-commitment gap and benefits analysis. We identify your highest-value opportunities and quantify the ROI before you spend a dollar.

Book free assessment
15+
Years of combined process and digital engineering experience
FREE
Initial gap and benefits assessment, no cost, no commitment
2 wks
Typical time from first call to engineer mobilization
100%
Scope defined in writing before any work begins
Get In Touch

Start Your Transformation Today

Schedule your free consultation and benefits assessment. No commitment — a focused conversation about accelerating your business.

📧
Email
info@apexdigitization.com
📍
Headquarters
Houston, Texas 77057, USA
🌐
Delivery
Global · On-site & Remote

Every engagement starts with a free benefits assessment — we identify your highest-value opportunities before any commitment.

Request Free Assessment
Free Consultation Request