Process Safety and Automation for
Process Safety and Automation for
Process Safety and Automation for
Chemical Industry
Chemical Industry
Chemical Industry
AI-enabled hazard detection, real-time process monitoring, and IEC 61508 functional safety systems designed for high-risk chemical environments.
Real-time
Process deviation detection and alerts
IEC 61508
Functional safety system compliance
ISO 14001
Environmental management certification
Trusted by Leading Enterprises Globally
Trusted by Leading Enterprises Globally
Industry Hazards
Most Common Challenges in
Chemical Industry
Each one has a measurable impact in downtime, safety, energy costs, or compliance readiness. Without continuous monitoring, they persist across shifts.
Chemical PPE Non-Compliance
Chemical PPE Non-Compliance
Chemical PPE Non-Compliance
Fire & Hazardous Material Incidents
Fire & Hazardous Material Incidents
Fire & Hazardous Material Incidents
Fire & Hazardous Material Incidents
Fire & Hazardous Material Incidents
Fire & Hazardous Material Incidents
Chemical PPE Non-Compliance
Chemical PPE Non-Compliance
Chemical PPE Non-Compliance
Limited Plant Visibility
Limited Plant Visibility
Limited Plant Visibility
Process Deviation Detection
Process Deviation Detection
Process Deviation Detection
Unauthorized Hazard Area Access
Unauthorized Hazard Area Access
Unauthorized Hazard Area Access
Environmental Compliance Gaps
Environmental Compliance Gaps
Environmental Compliance Gaps
Our Solutions
Scalable Capabilities for
Every Challenge
Connects to your existing DCS, Safety PLCs, and SIS over Modbus, HART, FOUNDATION Fieldbus, and OPC-UA. IEC 61508 functional safety architecture maintained.
Safety Monitoring
AI-powered monitoring that detects chemical PPE non-compliance, fire hazards, process anomalies, and safety violations in high-risk environments where manual oversight is limited by exposure risk.
Security & Access Control
Automated perimeter surveillance, identity verification, and vehicle management protecting reactor areas, hazardous material stores, and restricted process zones.
Operations Intelligence
Real-time monitoring of process conditions, vehicle movement, material handling activity, and environmental data across the chemical plant.
01
Safety
Chemical PPE Non-Compliance
Monitors compliance for chemical-resistant gloves, face shields, protective suits, and respiratory equipment across reactor areas, mixing zones, and hazardous material handling areas. Violations flagged instantly.
02
Safety
Safety Harness Detection
Monitors harness compliance for workers on elevated structures, storage tanks, and maintenance platforms in areas where fall protection is mandatory under process safety requirements.
03
Safety
Fire & Smoke Detection
Detects fire and smoke across solvent storage, reactor areas, and chemical handling zones. Integrated with plant DCS and emergency systems for automated alarm escalation — effective in environments where hazardous vapours accelerate fire development.
04
Safety
Person Under Suspended Load
Detects workers positioned beneath crane loads or suspended equipment during maintenance operations in reactor areas and storage yards. Real-time alerts allow intervention before an incident occurs.
05
Safety
Crowd & Occupancy Monitoring
Tracks the number of personnel in reactor areas, hazardous zones, and confined spaces. Alerts when occupancy exceeds safe limits for the area — particularly critical during maintenance shutdowns.
06
Safety
Object Detection in Pathways
Detects equipment, hoses, or materials left in plant walkways and access routes. Flags obstructions in areas where clear pathways are critical for emergency evacuation and hazmat vehicle access.
07
Safety
Safety Gloves Detection
Monitors glove compliance in areas where contact with chemicals, solvents, and hazardous materials creates daily hand exposure risk. Violations flagged in real time without manual supervision.
08
Safety
Vehicle Safety Monitoring
Checks vehicle headlights and safety compliance on internal plant roads — particularly relevant for tanker operations at night and during shift changes when visibility and fatigue risk increase.
Safety Monitoring
AI-powered monitoring that detects chemical PPE non-compliance, fire hazards, process anomalies, and safety violations in high-risk environments where manual oversight is limited by exposure risk.
Security & Access Control
Automated perimeter surveillance, identity verification, and vehicle management protecting reactor areas, hazardous material stores, and restricted process zones.
Operations Intelligence
Real-time monitoring of process conditions, vehicle movement, material handling activity, and environmental data across the chemical plant.
01
Safety
Chemical PPE Non-Compliance
Monitors compliance for chemical-resistant gloves, face shields, protective suits, and respiratory equipment across reactor areas, mixing zones, and hazardous material handling areas. Violations flagged instantly.
02
Safety
Safety Harness Detection
Monitors harness compliance for workers on elevated structures, storage tanks, and maintenance platforms in areas where fall protection is mandatory under process safety requirements.
03
Safety
Fire & Smoke Detection
Detects fire and smoke across solvent storage, reactor areas, and chemical handling zones. Integrated with plant DCS and emergency systems for automated alarm escalation — effective in environments where hazardous vapours accelerate fire development.
04
Safety
Person Under Suspended Load
Detects workers positioned beneath crane loads or suspended equipment during maintenance operations in reactor areas and storage yards. Real-time alerts allow intervention before an incident occurs.
05
Safety
Crowd & Occupancy Monitoring
Tracks the number of personnel in reactor areas, hazardous zones, and confined spaces. Alerts when occupancy exceeds safe limits for the area — particularly critical during maintenance shutdowns.
06
Safety
Object Detection in Pathways
Detects equipment, hoses, or materials left in plant walkways and access routes. Flags obstructions in areas where clear pathways are critical for emergency evacuation and hazmat vehicle access.
07
Safety
Safety Gloves Detection
Monitors glove compliance in areas where contact with chemicals, solvents, and hazardous materials creates daily hand exposure risk. Violations flagged in real time without manual supervision.
08
Safety
Vehicle Safety Monitoring
Checks vehicle headlights and safety compliance on internal plant roads — particularly relevant for tanker operations at night and during shift changes when visibility and fatigue risk increase.
Safety Monitoring
AI-powered monitoring that detects chemical PPE non-compliance, fire hazards, process anomalies, and safety violations in high-risk environments where manual oversight is limited by exposure risk.
Security & Access Control
Automated perimeter surveillance, identity verification, and vehicle management protecting reactor areas, hazardous material stores, and restricted process zones.
Operations Intelligence
Real-time monitoring of process conditions, vehicle movement, material handling activity, and environmental data across the chemical plant.
01
Operations
Vehicle Turnaround Time Tracking
Tracks every tanker and chemical transport vehicle from plant entry to exit. Identifies delays at loading and unloading points and creates a complete hazardous material movement log for compliance purposes.
02
Operations
Worker Productivity Analysis
Monitors operator workstation activity and control room occupancy across shifts. Tracks active periods and response times to support process safety performance reviews.
03
Operations
Tarpaulin Detection
Checks that tankers and chemical transport vehicles have covers and seals in place before leaving the plant — preventing spillage and meeting hazardous goods transport regulations.
04
Operations
Liquid Colour Change Detection
Monitors liquid colour changes, turbidity, and visual process indicators in real time. Detects deviations in liquid processes that indicate contamination, incorrect reagent addition, or process failure.
05
Operations
Liquid Colour Change Detection
Monitors liquid processes for unexpected colour changes that indicate contamination, process failure, or incorrect reagent addition — enabling intervention before off-specification product advances to the next stage.
06
Operations
Process & Operations Dashboard
Tracks energy and utility consumption across reactor operations, distillation, and utility systems. Identifies inefficiencies and provides the structured data required for ISO 50001 energy management compliance.
Our Capabilities
Our Capabilities
Complete Operational Technology Stack for
Chemical Industry
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Standards
Built to Meet the Standards
Your Industry Requires
Every system KGT deploys for steel and metal operations is designed to meet or exceed the compliance standards that govern your industry.
If your plant has gaps in any of the areas listed below, whether in safety documentation, environmental monitoring, traceability, or cybersecurity - our team will assess what is missing and build the infrastructure needed to support certification.
ISO 9001
- Quality Management Systems
ISO 45001
- Occupational Health and Safety Management
ISO 14001
- Environmental Management Systems
IEC 62443
- Industrial Automation and Control Systems Security
ISA-95
- Enterprise-Control System Integration
ISA-88
- Batch Control Standards
ISO 9001
- Quality Management Systems
ISO 45001
- Occupational Health and Safety Management
ISO 14001
- Environmental Management Systems
IEC 62443
- Automation and Control Systems Security
ISA-95
- Enterprise-Control System Integration
ISA-88
- Batch Control Standards
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
Connect to Content
Add layers or components to swipe between.
Vizibelt is an Ai-powered monitoring system designed for conveyor operations - detecting foreign objects in real time and preventing belt failures before they disrupt production.
Detected Foreign Object Incidents
1+
1+
Reduction in Downtime
1%
1%
Increase in Productivity
1%
1%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
We built Vizibelt
An AI-powered monitoring system that detects foreign objects in real time and stops the belt before damage occurs.
Detected Foreign Object Incidents
1+
1+
Reduction in Downtime
1%
1%
Increase in Productivity
1%
1%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC
Ready to discuss your
plant operations?
Ready to discuss your
plant operations?
Ready to discuss your
plant operations?
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
Connect to Content
Add layers or components to swipe between.
We built Vizibelt
An AI-powered monitoring system that detects foreign objects in real time and stops the belt before damage occurs.
Detected Foreign Object Incidents
0+
0+
Reduction in Downtime
0%
0%
Increase in Productivity
0%
0%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC