Digital twin in the chemical industry: A review

Abstract

Adopting digital twin technology in the chemical industry is reshaping process optimisation, operational efficiency, and safety management. By leveraging data from sensors and control systems, the digital twins provide actionable insights, enabling more precise control over chemical reactions, improved quality assurance, and reduced environmental impact. Additionally, the ability to simulate “what‐if” scenarios accelerates the innovation cycle and supports compliance with stringent regulatory standards. This research article explores the implementation and impact of digital twins in chemical manufacturing environments. It examines how digital twins enable continuous monitoring and control by mirroring chemical processes, predicting equipment failures, and simulating complex reactions under various conditions. The study highlights the benefits of digital twins, including improved process efficiency, enhanced product quality, and reduced environmental and operational risks. The research also addresses challenges and limitations, such as data integration complexities and the need for high‐fidelity models. By providing a comprehensive analysis of current applications and future prospects, this paper aims to advance the understanding of digital twins' role in driving innovation and sustainability within the chemical industry.