M. TAJJIOU, ABB, The Randstad, Netherlands
The energy sector is at a crossroads. As the world accelerates toward net-zero targets, the demand for sustainable fuels has never been greater—e.g., liquid biofuel demand increased by 0.2 exajoules in 2024.1 Biofuels are increasingly positioned as a critical element in the low-carbon energy transition, offering a pathway to reduce greenhouse gas emissions while maintaining energy security. However, producing biofuels at scale remains a complex process, as market competitiveness, process intricacies and safety requirements demand operational excellence.
In this context, digitalization is not merely an operational enhancement—it is a transformative necessity. Digitalization encompasses advanced process control, safe and efficient maintenance, onsite and cloud-based instrument monitoring, turning raw sensor data into actionable insights for optimization and predictive maintenance.
Central to this transformation is instrumentation. Advanced sensors and analyzers form the foundation for process control and safe, efficient biofuel production. By capturing real-time data across every stage of production, instrumentation enables operators to understand exactly what is happening in their plants at any given moment. This visibility allows for precise control, rapid response to deviations and optimization of resources, all of which directly contribute to higher efficiency, reduced emissions and improved sustainability.
Real-time instrumentation: The backbone of operational excellence. In modern biofuels plants, flowmeters and pressure sensors—standards in fermentation tanks and distillation columns—provide operators with continuous visibility into critical process parameters. These devices allow plant operators to monitor mass flow, pressure and temperature in real time, facilitating precise control over a range of applications.
Similarly, pressure relief valves and temperature sensors, interlocked with emergency shutdown systems, are fundamental for ensuring operational safety. They act as both sentinels and safeguards, preventing incidents before they escalate and maintaining reliability across complex production systems.
Instrumentation also plays a pivotal role in integrating production processes into a cohesive, digitally enabled system. When measurements from multiple sensors are combined, they provide a holistic view of plant performance, allowing operators to identify inefficiencies, optimize energy use and increase safety. This integration transforms plants from reactive environments into proactive, data-driven operations and maintenance. Together, these systems ensure that operations are both efficient and sustainable, reducing waste and energy use while maintaining product quality.
Data-driven sustainability. Digitalization enables biofuels plants to achieve extraordinary environmental performance. By integrating advanced sensors with analytics, operators can accurately monitor energy consumption, material usage and emissions. This high-quality process data supports informed decision-making to reduce carbon intensity. Additionally, a data-driven approach also ensures compliance with regulatory frameworks and sustainability certifications. Precise monitoring can ultimately improve fuel yield by 5%–10% while reducing energy costs by up to 15%,2 demonstrating a measurable impact.
By implementing and leveraging data acquisition and handling systems, companies and operators can ensure full compliance with global emissions reporting standards (including EN17255), helping producers demonstrate a measurable environmental impact.
Instrumentation across the production cycle. Instrumentation is essential at every stage of biofuels production. During feedstock intake, flowmeters and level instruments ensure accurate measurement and tracking of raw materials. During distillation and refining, instruments continuously monitor temperature, pressure and flow to maintain process stability and fuel quality.
Gas analyzers measure composition and purity, enabling operators to verify that outputs meet regulatory and performance standards. These precise measurements are critical not only for quality control but also for reducing waste and energy consumption.
Electromagnetic flow measurement in action. In refinery water networks, accurate flow measurement plays a critical role in optimizing pump performance, reducing energy consumption and improving overall system efficiency. By precisely measuring flowrates in cooling loops or distribution networks, electromagnetic flowmeters enable operators to balance flow according to actual demand. This prevents overpumping, which not only wastes energy but also increases mechanical wear and maintenance frequency. In boiler systems, precise flow control ensures proper steam generation while avoiding unnecessary heating or water loss—both of which can otherwise lead to reduced efficiency or pose operational risk.
Modern flow measurement solutions commonly feature modular designs that simplify commissioning and maintenance. Advanced diagnostics allow continuous condition monitoring of both the instrument and the process, enabling maintenance teams to detect and identify issues such as electrode fouling, empty pipe conditions or irregular flow patterns before they lead to costly disruptions.
Instrumentation also plays a crucial role in operational safety. Pressure relief valves, temperature sensors and gas detectors, when integrated with emergency shutdown systems, protect equipment and personnel while preventing unplanned downtime.
Optimizing efficiency through data. Advanced measurement tools provide the real-time data needed to optimize energy and resource use. Flowmeters, pressure transmitters and analyzers generate precise metrics that feed into process control systems. Operators can then fine-tune operations, reducing energy consumption, improving yields and maximizing resource efficiency.
For example, in fermentation, precise flow and pressure measurements allow for adjustments to nutrient dosing and temperature control, optimizing microbial performance. In distillation, accurate temperature and pressure readings ensure minimal energy use while achieving desired fuel purity. Across all stages, the combination of measurement, monitoring and control allows biofuels plants to operate as finely tuned systems.
The future: Connected and intelligent. Looking ahead, the role of instrumentation in biofuels production will only expand. Integrated sensor networks, real-time analytics and predictive algorithms will allow plants to respond dynamically to variations in feedstock quality, process conditions or energy availability. Emerging technologies such as optical gas sensors, Internet of Things (IoT)-enabled meters and artificial intelligence (AI)-driven process simulators will enable real-time self-optimization and predictive interventions, further increasing efficiency and reliability.
Predictive maintenance represents the most advanced and efficient form of maintenance. It relies on real-time diagnostics and performance data from smart instrumentation to predict potential failures before they occur. Instruments equipped with built-in sensors and diagnostic software continuously monitor their own health and send alerts when abnormalities are detected, such as sensor drift, fouling, excessive vibration or communication issues.
By addressing issues only when necessary and before they escalate, predictive maintenance optimizes resources, extends equipment life and minimizes unplanned downtime. It supports risk-based maintenance planning and is a key enabler of modern asset management strategies.
As biofuels production becomes more complex—incorporating advanced biofuels, sustainable aviation fuels and integrated biorefineries—robust and intelligent instrumentation will be essential. Connected sensors and control systems will enable automated optimization, proactive safety management and continuous performance improvement. In this way, instrumentation becomes not just a monitoring tool but a driver of operational intelligence.
Instrumentation is no longer a background element in biofuels production. It is central to performance, safety and sustainability. Flowmeters, pressure sensors, temperature monitors and gas analyzers—when integrated into intelligent systems—empower operators to make data-driven decisions that optimize efficiency, reduce emissions and ensure reliability.
By embedding measurement and analytics throughout production, biofuel plants become smarter, safer and more sustainable. In an era of environmental urgency and industrial complexity, the ability to measure, monitor and act on precise process data is the key to unlocking the full potential of biofuels and accelerating the transition to low-carbon energy. HP
LITERATURE CITED
International Energy Agency, Global energy review 2025, March 2025, online: https://iea.blob.core.windows.net/assets/5b169aa1-bc88-4c96-b828-aaa50406ba80/GlobalEnergyReview2025.pdf
Hauser, E., “From insight to impact: Why real-time energy monitoring is a game-changer for your bottom line,” Gauge Systems, May 2025, online: https://www.egauge.net/blog/2025/05/real-time-energy-monitoring/#:~:text=10%E2%80%9320%25%20reductions%20in%20overall,Benefits%20extend%20across%20departments
Mohamed Tajjiou has been with ABB for several years and currently serves as Global Chemical Manager for Business Line Instrumentation within ABB’s Measurement & Analytics division. He is passionate about driving digitalization and sustainability in the chemical industry, supporting operators in optimizing plant performance and improving energy efficiency. Tajjiou earned a degree in chemical engineering and began his career as a chemical engineer, gaining hands-on experience in industrial operations before transitioning into leadership roles. With a global perspective and inclusive leadership style, Tajjiou’s expertise spans digital transformation, advanced analytics, predictive maintenance and smart instrumentation technologies.