When teams at one of the largest refinery complexes in the United States needed to inspect a storage tank component after it went back into service, they didn't send anyone out to the site.
They opened a browser, pulled up a digital replica of the tank, confirmed the component was correctly installed, and took the measurements they needed - all without leaving the office. This is a ZynQ visual twin in practice.
ZynQ is a visual twin platform that creates interactive, true-to-life digital replicas of industrial assets. Teams can navigate, inspect, and collaborate on a digital version of their asset remotely, accessible via the cloud, from anywhere in the world.
The Baytown Complex is one of the largest integrated refining and petrochemical facilities in the United States. Founded in 1919, it sits on approximately 3,400 acres along the Houston Ship Channel, about 25 miles east of Houston, encompassing a refinery, chemical plant, and olefins plant. The refinery can process up to 588,000 barrels of crude oil per day, and with a workforce of approximately 7,000 people, the complex produces fuels, chemicals, and materials supplying industries across transportation, construction, packaging, and beyond.
Since 2022, ZynQ 360 has been working with the teams at Baytown Refinery, digitally capturing and replicating their storage tank infrastructure across crude, intermediate, and chemical feedstock tanks. What began as a historical documentation project has grown into something broader, and that expansion has largely been driven by the teams themselves, finding new applications as they became more familiar with the platform.
Those use cases now include planning equipment layouts before execution, preparing for management conversations by showing real tank conditions rather than describing them, and remotely verifying work after a tank returns to service without requiring an additional site visit.
Eight organisations across operations, engineering, and contractors are all working from one shared view.
The cumulative value is straightforward: less time in the field. In refinery environments, every unnecessary site visit carries preparation time, safety protocols, PPE requirements, and travel. Reducing those visits improves both productivity and safety simultaneously.
Over 65,000 interactions were recorded on the ZynQ platform from the site in 2025 alone, a figure that reflects genuine day-to-day use, not just occasional access.
There is also a less visible benefit worth noting. In a refinery environment, having complete visual documentation of every asset, accessible immediately, from anywhere, matters when something unexpected happens. Emergency response and incident investigation become significantly more straightforward when the full asset history is already there.
For anyone facing similar challenges around tank integrity, maintenance planning, or emergency preparedness, ZynQ 360 has published a short case study on the Baytown project.
Download the case study here: https://zynq360.com/zynq-software/case-studies/
Trusted by Industry Leaders
ZynQ 360 works with major industry clients including ExxonMobil, Shell, Apache, Boskalis, Syngenta, Equinor, Beach Energy and nexos, establishing itself as a trusted partner in asset visualisation across the energy and industrial sectors.
About ZynQ 360
ZynQ 360 is a leader in transforming asset management through its comprehensive data acquisition services and secure, sustainable ZynQ visual twin platform. It’s services minimise the need for travel, facilitate remote working, and make crucial asset data readily accessible for various industries worldwide.
Learn More:
Visit www.zynq360.com to explore their data capture services and the ZynQ visual twin platform in more detail.
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