Honeywell deploys AI to Nigeria's largest refinery to boost output

AI meets heavy industry

Honeywell Technologies has officially launched its Forge Plant Cognition AI platform at the Dangote refinery in Lekki, Lagos. This move represents a major step in bringing industrial artificial intelligence to one of Africa's largest oil-processing facilities. The goal is to optimize complex operations and increase the refinery's overall productivity.

The new platform is not a standalone software solution but rather a sophisticated integration of multiple technologies. It combines Honeywell's industrial expertise with the high-performance capabilities of NVIDIA and Dell Technologies. By merging these tools, the refinery can better manage the variables involved in large-scale oil processing.

According to a company statement, the primary objective of this integration is to enhance both profitability and efficiency. The refinery operates in a complex environment where small improvements in process flow can lead to significant gains. By using AI to monitor and adjust these processes, the facility seeks to maximize its output while minimizing waste.

Projected financial gains

The deployment of Forge Plant Cognition comes with specific economic targets for the Dangote refinery. Preliminary estimates from the company suggest the AI system might provide operational advantages exceeding 29 cents for every barrel processed. While these figures are not guaranteed, they provide a clear benchmark for the expected return on investment.

At full-capacity throughput, these small per-barrel gains are expected to scale into substantial sums. Honeywell estimates that the platform could bring over $60 million in gross annual operational benefits to the facility. These savings are intended to help the refinery maintain a competitive edge in the global oil market.

The refinery has already shown strong financial momentum leading up to this technology launch. As reported by Reuters, Dangote Petroleum Refinery posted a net profit of $4.725 billion during the nine-month period concluding September 30. This is a notable turnaround from the corresponding period last year, where the facility recorded a loss.

Scaling African refining

This AI launch is part of a broader strategy to support Dangote’s ambitious expansion plans. The refinery currently has a nameplate capacity of 650,000 barrels per day, but it aims to more than double that figure. The target is to reach 1.4 million barrels per day by the year 2028.

Increasing the capacity of the Lekki facility will strengthen the refinery's position as a major supplier of refined petroleum products. These products are intended for distribution across Africa and into other international markets. Honeywell is providing the necessary technology and support to ensure this expansion meets its goals.

The refinery's revenue has already seen a massive jump as it processes up to 700,000 barrels of crude oil per day. Revenue more than doubled to $22.5 billion during the last nine-month period. The addition of AI technology is meant to sustain this growth as the facility moves toward its 2028 targets.

Expanding into Kenya

Honeywell is not limiting its involvement in the African refining sector to Nigeria alone. The company was recently selected to provide engineering services, technology, and equipment for a new refinery in Kenya. This project is estimated to cost $16 billion and will produce petrol, diesel, and jet fuel.

A key part of this expansion strategy involves reusing existing intellectual property and designs. Honeywell plans to use engineering designs developed for the Nigerian project to build the Kenyan facility. This approach is intended to streamline the construction process and reduce the overall timeline.

By reusing these designs, Honeywell expects to shorten the Kenyan refinery's development timeline by nearly two years. The new facility will serve domestic consumption in Kenya while also exporting supplies to East Africa. This demonstrates how the technology and methods used in Nigeria are becoming a blueprint for the rest of the continent.