SK Inno "Introducing AI-Based Smart Plant 2.0... Saving 10 Billion KRW Annually"

First in the Industry to Introduce Smart Plant in 2016
Strengthening Execution by Utilizing Know-how Including Proprietary Solutions

SK Innovation announced on the 26th that it has introduced "Smart Plant 2.0," which integrates artificial intelligence (AI) and digital transformation (DT) technologies, and expects to achieve cost improvements exceeding 10 billion KRW annually.

Unlike smart factories applied in general manufacturing industries, Smart Plants are implemented in large-scale process industries such as petrochemicals, refining, and steelmaking. Smart Plants focus on maximizing efficiency, whereas smart factories emphasize optimizing manufacturing processes. Since SK Ulsan Complex (CLX) first introduced Smart Plant in the industry in 2016, it has developed most of its core systems for data and work management, including production management (OASIS) and equipment management (OCEAN-H), in-house.

Using an AR program to estimate scaffolding quantities.
[Photo by SK Innovation]

The upgraded Smart Plant 2.0, introduced last year, centers on enhancing cost competitiveness through energy savings and productivity improvements by adopting automation and intelligent technologies, while also ensuring safety by preventing accidents and equipment failures.

SK Innovation is applying over 40 Smart Plant 2.0 projects within SK Ulsan CLX in areas such as process operation, equipment management, and safety, health, and environment (SHE). Key projects include process automatic operation programs, advanced process automatic control, equipment failure prediction solutions, and the establishment of an integrated safety monitoring system at Ulsan CLX.

In the process operation field, repetitive tasks and process start-up/shutdown have been automated, and AI has been introduced into advanced process control (APC) technology to enhance control levels. Robot dogs have also been deployed on the production floor. These robot dogs patrol the site to monitor gas leaks and measure gauges.

An intelligent robotic dog is inspecting the SK Ulsan CLX site.
[Photo by SK Innovation]

In equipment management, a failure prediction solution based on equipment data such as vibration and temperature has been established to prevent accidents. The use of drones for inspecting high-altitude equipment and robots to replace hazardous tasks is expanding the application of robotic replacements for dangerous work. The scope is also broadening to various fields such as AI-based automatic inspection point selection and result analysis, and AR-based on-site scaffolding work simulation and task verification.

In the safety, health, and environment (SHE) sector, efforts are underway to establish an integrated safety monitoring system covering the 2.5 million pyeong area of SK Ulsan CLX. Major components include ▲mobile-based work permit issuance system ▲location management system for subcontractor workers ▲real-time gas detection system in confined spaces ▲XR safety training, among others.

SK Innovation is training about 90 Citizen Data Scientists (CDS) specializing in data analysis and around 10 AI/DT experts at SK Ulsan CLX. New engineers are required to complete the CDS course. SK Innovation is developing an engineer technology chatbot based on large language model (LLM) technology and plans to utilize it across all engineering tasks starting in the second half of this year.

Pre-learning the inside of a heat exchanger using VR equipment.
[Photo by SK Innovation]

An SK Innovation official stated, "SK Ulsan CLX has the highest level of technology based on its expertise in building and operating Korea’s first Smart Plant," adding, "Through the enhanced execution capability of Smart Plant 2.0, we will secure world-class competitiveness and further build an 'Autonomous Plant.'"