AI integration at Nigerian refinery

The Nigerian Dangote refinery is using artificial intelligence to improve its operations as it prepares to boost its crude oil processing capacity. The refinery is adopting Forge Plant Cognition, an AI platform developed by Honeywell Technologies, to optimize refining processes and identify production constraints.

Potential savings and limitations

According to preliminary estimates from Honeywell, the AI solution could save over $60 million annually in operational costs when the refinery runs at full capacity. However, these figures are not guaranteed and depend on factors like operating conditions, crude oil type, and data quality. Implementation costs are also not included in the projections.

How the AI platform functions

Forge Plant Cognition combines real-time operational data with engineering knowledge and Honeywell’s industrial process expertise. It identifies bottlenecks, predicts anomalies, and suggests corrective actions to improve efficiency, product value, and system reliability. The platform relies on NVIDIA and Dell Technologies for AI computing and simulation tools to create digital replicas of the facilities.

Refinery expansion plans

Dangote is preparing to increase its refinery’s capacity from 650,000 to 1.4 million barrels per day by 2028. The AI platform is expected to support this expansion by improving operational efficiency. The projected savings apply specifically to the Lekki site and will be confirmed through actual performance data.

Local workforce development

The project includes a focus on training local workers. By embedding specialized knowledge into the tools used by engineers and operators, the platform is expected to help resolve technical issues and build in-house expertise. Dangote aims to have 70% of its workforce composed of Nigerians, though this is a future goal, not a current reality.

Expansion beyond Nigeria

Dangote’s collaboration with Honeywell extends beyond Nigeria. The American company has been selected to help develop a new mega-refinery in Lamu county, Kenya. This reflects Dangote’s broader strategy to expand its refining capacity across Africa.