Demand-based aeration for wastewater treatment
Aerate to demand.
Not the worst case.
AIPLC turns the data your plant already collects into near real-time estimates of oxygen demand, then recommends aeration adjustments that cut energy use without new sensors or hardware.
Fig. 1 · The Aeration gap
Full-scale data
Power spent on aeration
120 kW
POWER REQUIRED FOR BOD REMOVAL
52 kW
Over-aeration · ~68 kW
~57%
of aeration power goes to over-aeration due to fixed setpoints
AIPLC analysis of aeration efficiency within a full-scale wastewater utility in California. Demand reflects carbonaceous (BOD) oxidation.
01 · The Aeration gap PROBLEM
Plants pay to deliver oxygen that their process doesn't need.
Aeration is typically the largest energy cost in conventional wastewater treatment. Yet conventional aeration systems don't know how much oxygen is actually needed. Instead, they rely on dissolved oxygen sensors, which measure oxygen remaining in the water, not the actual demand.
To manage this uncertainty, operators use fixed setpoints with conservative safety margins.
And that uncertainty is paid for in electricity, every hour of every day.
02 · Our solution
The AIPLC value proposition
We provide
02 items
01
A customized model for real-time demand estimation
02
Recommended adjustments to optimize process performance
Utilities receive
03 items
01
Soft-sensor capabilities for determining real-time loading rates
02
Optimized performance for operational cost reduction
03
An integrated, real-time digital consultant
03 · How it works
Two processors, one operator with final control.
Input
Existing SCADA Data
Flowrates, power outputs, and other PLC signals your plant already archives go in. No new instruments, no extra sampling.
Processor 1
The Interpreter
Mechanistic models incorporating microbial kinetics and mass balance turn existing data into estimates of biochemical demand tailored to your process stream.
Processor 2
The Optimizer
Models considering permit limits, equipment constraints, and electricity tariffs determine aeration adjustments to reduce operational cost.
In development
Output
Operator Approval
Recommendations appear on an operator-facing screen. AIPLC runs outside the PLC control network, and nothing changes without human approval.
04 · Built for utilities
What Makes AIPLC Different
A.
No New Hardware
Works with the PLC and SCADA systems you already run. No capital project, no new analyzers to maintain.
B.
First Principles, Not a Black Box
Built on process-engineering models that engineers and regulators can follow, not an opaque AI model.
C.
Operators Stay in Control
Recommendations, not autonomous control. AIPLC sits outside the control network to protect critical infrastructure.
D.
Compliance is Non-Negotiable
Effluent quality is a hard constraint. Savings never come at the expense of compliance to treatment standards.
05 · Pricing
One setup fee, then you pay when you save.
01 · One time
Implementation
A one-time fee to customize, validate and integrate AIPLC with your plant’s existing automation, scaled to plant size and complexity.
02 · First Year
Performance
A fraction of the energy savings we verify against an agreed baseline. No verified savings, no performance fee.
03 · Monthly (after First Year)
Preservation
A small monthly subscription that begins after your first year of use, covering continuous monitoring, model updates and support.
Every engagement is scoped to the plant. Contact us for a site-specific estimate.
06 · Progress
Where we are, and what comes next.
Complete
July 2026
AIPLC founded; Interpreter development begins.
Complete
Fall 2026
Interpreter validated against multiple years of full-scale operating data.
In progress
Now
Optimizer development and deployment planning with a California partner utility.
Target
Fall 2027
First full-scale deployment of the Interpreter and Optimizer.
Planned
Spring 2028
Publish verified savings and expand to more utilities.
Near-term goal: substantially reduce aeration energy while maintaining treatment performance, verified in full-scale operation.
Long-term vision
Make Every PLC Intelligent
Though we are starting with wastewater treatment, we believe the same approach applies wherever PLCs run processes on fixed, conservative setpoints, from water distribution and energy to food and beverage, pharmaceuticals and semiconductor manufacturing.
07 · Pilot program
Be one of our first demonstration partners.
For our first partner facilities, we’re waiving the implementation fee. Tell us a little about your plant and its SCADA setup, and we’ll follow up to see whether AIPLC is a good fit.
Same data. Same Hardware. Lower costs.
© 2026 AIPLC