Applied Chemical Engineering

AI-Driven Process Control for Enhancing Safety and Efficiency in Oil Refining

Manjusha Tatiya

Department of Artificial Intelligence and Data Science, Indira College of Engineering and Management, Indira Chanakya Campus (ICC), Parandwadi, Pune - 410506, Maharashtra ,India

Babaso A. Shinde

Department of Artificial Intelligence and Data Science, Marathwada Mitramandal’s Institute of Technology, Lohgaon, Pune - 411047, Affiliated to Savitribai Phule Pune University, Maharashtra, India

Navnath B. Pokale

Department of Artificial Intelligence and Data Science, Dr. D. Y. Patil Institute of Technology, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India; Dnyaan Prasad Global University (DPGU), School of Technology and Research - Dr. D. Y. Patil Unitech Society, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India

Mahesh Sarada

Department of First Year Engineering, PCET’s Pimpri Chinchwad College of Engineering and Research, Ravet, Pune - 412101, Maharashtra ,India

Mahesh M. Bulhe

Department of Electronics and Telecommunication Engineering, Bharati Vidyapeeth College of Engineering, Navi Mumbai – 400614, Maharashtra, India

Govindrajan Murali

Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields, Vaddeswaram, Guntur (Dt) - 522502, Andhra Pradesh, India

Vidhi Rajendra Kadam

Department of Computer Engineering, Bharati Vidyapeeth College of Engineering, Navi Mumbai – 400614, Maharashtra, India

Anant Sidhappa Kurhade

Department of Mechanical Engineering, Dr. D. Y. Patil Institute of Technology, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India; a.kurhade@gmail.com ; Dnyaan Prasad Global University (DPGU), School of Technology and Research - Dr. D. Y. Patil Unitech Society, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India

Shital Yashwant Waware

Department of Mechanical Engineering, Dr. D. Y. Patil Institute of Technology, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India; a.kurhade@gmail.com 9 Dnyaan Prasad Global University (DPGU), School of Technology and Research - Dr. D. Y. Patil Unitech Society, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India

DOI: https://doi.org/10.59429/ace.v8i4.5792

Keywords: Artificial intelligence; predictive maintenance; process optimization; digital twin; oil refining; anomaly detection

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Abstract

Artificial Intelligence (AI) is reshaping the oil refining sector by improving process safety, energy efficiency, and product quality. This work evaluates real-time AI applications such as predictive maintenance, anomaly detection, and autonomous process optimization using machine learning, deep learning, reinforcement learning, and natural language processing. A systematic review of recent industrial case studies and simulations shows AI can reduce equipment downtime, emissions, and operational costs while enhancing decision-making and regulatory compliance. Despite these advantages, the adoption of AI in refineries faces challenges such as cybersecurity risks, legacy system integration, and lack of explainable models. Future research should focus on scalable and transparent AI frameworks that align with industry-specific needs.

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[87]. Deshpande SV, Pawar RS, Keche AJ, Kurhade A. Absolute time surface finish measurement of stepped holding shaft by automatic system. Journal of Advanced Manufacturing Systems. 2025 Jan 17.

[88]. Kurhade AS, Siraskar GD, Bhambare PS, Murali G, Deshpande SV, Warke PS, Waware SY. Simulation and Analysis of Heat Transfer in Counter-Flow Helical Double-Pipe Heat Exchangers Using CFD. International Journal of Modern Physics C. 2025 Jan 10.

[89]. Parkar A, Yadav RS, Chopade R, Dhavase N, Dhumal JR, Mankar SP, Patil S, Ghuge K, Giri B, Kurhade AS. Automating the Two-Dimensional Design of Heating, Ventilation, Air Conditioning, and Refrigeration (HVACR) Ducts using Computer Programming Language: An Algorithmic Approach. Journal of Mines, Metals and Fuels. 2025 Jan 7:211-20.

[90]. Kurhade AS, Siraskar GD, Darade MM, Murali G, Katkar TR, Patil SP, Charwad GA, Waware SY, Yadav RS. Enhancement in Heat Transfer with Nanofluids in Double-Pipe Heat Exchangers. Journal of Mines, Metals and Fuels. 2025 Jan 7:165-72.

[91]. Kurhade AS, Chougule SM, Kharat PV, Kondhalkar GE, Murali G, Raut PN, Charwad GA, Waware SY, Yadav RS. Integrated Approach to Enhance Vehicle Safety: A Novel Bumper Design with Energy-Absorbing Mechanisms. Journal of Mines, Metals and Fuels. 2025 Jan 7:27-35.

[92]. Raut PN, Dolas AS, Chougule SM, Darade MM, Murali G, Waware SY, Kurhade AS. Green Adsorbents for Heavy Metal Removal: A Study on Zinc Ion Uptake by Tinospora cordifolia Biocarbon. Journal of Mines, Metals and Fuels. 2025 Jan 7:21-5.

[93]. Yadav R, Nimbalkar A, Kirpekar S, Patil PJ, Dalvi SA, Jadhav PA, Kurhade AS, Wakchaure GN. Effect of Transformed-Induced Plasticity Steel Plate Thickness on Ultimate Tensile Strength of Butt Welded Joint using Nd: YAG Laser. International Journal of Vehicle Structures and Systems. 2024 Dec 31;16(6).

[94]. Yadav RS, Gandhi P, Veeranjaneyulu K, Gaji R, Kirpekar S, Pawar D, Khairnar YS, Patil S, Kurhade AS, Patil SP. Influence of Plate Thickness on the Mechanical Behaviour of Mild Steel Curved Plates: An Experimental Study. Journal of Mines, Metals and Fuels. 2024 Dec 11:1319-27.

[95]. Kurhade AS, Bhambare PS, Siraskar GD, Mukesh S, Dixit PS, Waware SY. Computational Study on Thermal Management of IC Chips with Phase Change Materials.

[96]. Kurhade MA, Dange MM, Nalawade DB. Fuzzy Logic Modeling of Heat Transfer in a Double Pipe Heat Exchanger with Wavy (Corrugated) Twisted Tape Inserts. International Journal of Innovations in Engineering Research and Technology.;2(1):1-8.

[97]. Kurhade AS, Siraskar GD, Raut PN, Dolas AS, Murali G, Dalvi SA, Waware SY, Yadav RS. Investigating the Impact of Oxygenated Additives on Exhaust Emissions from Unleaded Gasoline Vehicles. jmmf. 2025 Feb. 24;73(2):333-44

[98]. Purandare P, Yadav RS, Nema AA, Kulkarni A, Kirpekar S, Giri B, Patil PA, Jagdale M, Kurhade AS. Comparative Study of Helical Coil, Spiral Coil and Conical Coil (90O) Heat Exchanger for Single Phase Fluid Flow. jmmf. 2025 Feb. 24 ;73(2):377-84.

[99]. Kurhade AS, Siraskar GD, Dalvi SA, Kharat PV, Jadhav NA, Shelkande VD, Murali G, Waware SY, Yadav RS. Passive Cooling of EV Batteries Using Phase Change Material: A Simulation Study. jmmf . 2025 Feb. 24 ;73(2):447-54.

[100]. Kurhade AS, Kharat PV, Chougule SM, Darade MM, Karad MM, Murali G, Charwad GA, Waware SY, Yadav RS. Harnessing the Power of Plastic Waste: A Sustainable Approach to Fuel Production. jmmf . 2025 Feb. 24;73(2):467-73.

[101]. Kurhade AS, Siraskar GD, Deshmukh MT, Patil PA, Chaudhari SS, Kadam AA, Dolas AS, Mahajan RG, Waware SY, Yadav RS. Impact of PCM on Heat Dissipation from IC Chips. Journal of Mines, Metals & Fuels. 2025 Mar 1;73(3).

[102]. Ramani P, Reji V, Sathish Kumar V, Murali G, Kurhade AS. Deep Learning-Based Detection and Classification of Moss and Crack Damage in Rock Structures for Geo-Mechanical Preservation. Journal of Mines, Metals & Fuels. 2025 Mar 1;73(3).

[103]. Chippalkatti S, Chekuri RB, Ohol SS, Shinde NM, Barmavatu P, Shelkande VD, Murali G, Kurhade AS. Enhancing Heat Transfer in Micro-Channel Heat Sinks through Geometrical Optimization. Journal of Mines, Metals & Fuels. 2025 Mar 1;73(3).

[104]. Kurhade AS, Siraskar GD, Chekuri RB, Murali G, Pawar P, Patil AR, Waware SY, Yadav RS. Biodiesel Blends: A Sustainable Solution for Diesel Engine Performance Improvement. Journal of Mines, Metals & Fuels. 2025 Mar 1;73(3).

[105]. Kurhade AS, Bhavani P, Patil SA, Kolhalkar NR, Chalapathi KS, Patil PA, Waware SY. Mitigating Environmental Impact: A Study on the Performance and Emissions of a Diesel Engine Fueled with Biodiesel Blend. jmmf [Internet]. 2025 Apr. 16 [cited 2025 Apr. 28];73(4):981-9.

[106]. Wakchaure GN, Vijayarao P, Jadhav TA, Bhamare YM, Jagtap A, Gaji R, Chavan Patil AS, Kamble SD, Jagtap SV, Yadav RS, Kurhade AS. Performance Evaluation of Trapezoidal Ducts with Delta Wing Vortex Generators: An Experimental Investigation. jmmf [Internet]. 2025 Apr. 16 [cited 2025 Apr. 28];73(4):991-1003.

[107]. Wakchaure GN, Jagtap SV, Gandhi P, Chavan Patil AS, Kandharkar S, Kokare NN, Bhamare YM, Kamble SD, Jadhav A, Yadav RS, Kurhade AS. Heat Transfer Characteristics of Trapezoidal Duct using Delta Wing Vortex Generators. jmmf [Internet]. 2025 Apr. 17 [cited 2025 Apr. 28];73(4):1053-6.

[108]. Chougule SM, Murali G, Kurhade AS. Failure Investigation of the Driving Shaft in an Industrial Paddle Mixer. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1247-56.

[109]. Kurhade AS, Sugumaran S, Kolhalkar NR, Karad MM, Mahajan RG, Shinde NM, Dalvi SA, Waware SY. Thermal Management of Mobile Devices via PCM. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1313-20.

[110]. Chougule SM, Murali G, Kurhade AS. Finite Element Analysis and Design Optimization of a Paddle Mixer Shaft. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1343-54.

[111]. Waware SY, Ahire PP, Napate K, Biradar R, Patil SP, Kore SS, Kurhade AS. Advancements in Heat Transfer Enhancement using Perforated Twisted Tapes: A Comprehensive Review. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1355-63.

[112]. Patil Y, Tatiya M, Dharmadhikari DD, Shahakar M, Patil SK, Mahajan RG, Kurhade AS. The Role of AI in Reducing Environmental Impact in the Mining Sector. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1365-78.

[113]. Chougule SM, Murali G, Kurhade AS. Dynamic simulation and performance evaluation of vibratory bowl feeders integrated with paddle shaft mechanisms. Advances in Science and Technology Research Journal. 2025;19(7):179-96.

[114]. Rao SS, Sugumaran S, Ameresh H, Amruth E, Thamke VP, Waware SY, Patil PA, Kurhade AS. Impact of Regularly Spaced Cut Sections on the Heat Transfer Efficiency of Helical Strip Inserts in Circular Pipes. jmmf [Internet]. 2025 Jun. 4 [cited 2025 Jun. 6];73(6):1517-25

[115]. Sanadi A, Shinde S, Burgute G, Purandare P, Ramtirthkar C, Jadhav Sachin Z, Awati SS, Yadav R, Kurhade A. Assessing the Impact of Exhaust Gas Recirculation on the Emission Profile of a Diesel Engine Operating on Mohua Oil: An Experimental Study. jmmf [Internet]. 2025 Jun. 4 [cited 2025 Jun. 6];73(6):1535-42.

[116]. Chaudhari SS, Shahakar M, Gholap P, Dhamdhere PB, Agrawal SS, Mahajan RG, Kurhade AS, Waware SY. Enhancing Energy Efficiency in Metallurgical Operations Using AI: A State of the Art Review. jmmf [Internet]. 2025 Jun. 4 [cited 2025 Jun. 6];73(6):1595-616.

[117]. Waware SY, Ahire PP, Ghutepatil PR, Biradar R, Kadam AA, Kore SS, Kurhade AS, Ghunake KB. Enhancing Heat Transfer in Tubular Heat Exchanger Using Minijet Technology. jmmf [Internet]. 2025 Jun. 4 [cited 2025 Jun. 6];73(6):1699-706.

[118]. Chougule SM, Murali G, Kurhade AS. Design and Analysis of Industrial Material Handling Systems using FEA and Dynamic Simulation Techniques: FEA AND SIMULATION-BASED DESIGN OF MATERIAL HANDLING SYSTEMS. Journal of Scientific & Industrial Research (JSIR). 2025 Jun 18;84(6):645-53.