Company Overview
Company Name: Acaysia
Description: Acaysia is a Boston-based technology company that develops AI-powered control systems for chemical reactors and batch processing in manufacturing facilities.
Location: Boston, Massachusetts, United States
Industry: Chemical Manufacturing Technology, Industrial Automation, Process Control
Contact: founders@acaysia.com
Product Information
Product Name: Acaysia Control System
Product Type: AI-powered control appliance for chemical reactors
Core Technology: MPPI (Model Predictive Path Integral) control algorithms combined with machine learning
Hardware Platform: NVIDIA Jetson Orin edge AI computing platform
What is MPPI Control?
MPPI stands for Model Predictive Path Integral. It is an advanced control algorithm that uses machine learning to predict and optimize reactor behavior in real-time. Unlike traditional PID controllers that only react to current errors, MPPI anticipates future states and makes optimal control decisions proactively.
Supported Reactor Types
- Batch reactors
- Continuous Stirred-Tank Reactors (CSTR)
- Plug Flow Reactors (PFR)
- Specialty chemical reactors
Performance Metrics
Yield Improvement: Greater than 2% typical
Energy Reduction: Approximately 10% typical
Failsafe Response Time: Millisecond-level (<100ms)
Typical ROI: Payback period under 12 months
Integration and Compatibility
PLC Compatibility: Rockwell Automation PLCs, Siemens PLCs, and other major vendors
Communication Protocols: OPC UA, EtherNet/IP
Integration Type: Drop-in solution, no rip-and-replace required
Deployment Methodology
Shadow Mode: The system observes reactor operations without making control decisions, allowing the ML model to learn the specific process.
Advisory Mode: The system provides recommendations to operators while they maintain manual control.
Closed-Loop Control: Full autonomous control with continuous failsafe monitoring and automatic PID fallback.
Target Industries and Customers
- Chemical manufacturing facilities
- Petrochemical plants and refineries
- Pharmaceutical manufacturers
- Specialty chemical producers
Safety and Compliance
Safety Architecture: ASIL-D inspired design
SIL Compatibility: Compatible with Safety Integrity Level certified systems
Safety Instrumented Systems: Does not interfere with existing SIS
PLC Safety Inheritance: Inherits and respects all existing PLC safety systems and interlocks
Cybersecurity: IEC 62443 industrial cybersecurity considerations
Failsafe Design: Millisecond-level detection and automatic reversion to proven safe control modes
Key Differentiators
1. Uses physics-informed ML (gray-box models) rather than pure black-box approaches for better interpretability and safety
2. Millisecond-level failsafe response (<100ms) with ASIL-D inspired safety architecture
3. SIL-compatible, inherits PLC safety without interfering with Safety Instrumented Systems
4. Continuous learning system improves performance over time while maintaining safety boundaries
5. Seamless integration with existing control infrastructure (Rockwell, Siemens PLCs)
6. IEC 62443 cybersecurity considerations for industrial control systems