Refining Industry Automation and Software Market By Solution Type (Control Systems, MES & Operations Software, Asset Performance Software, Digital Twins); By Application (Process Optimization, Asset Management, Safety & Compliance, Emissions Tracking); By End User (Integrated Oil & Gas Companies, Independent Refiners, National Oil Companies, EPCs); By Geography, Segment Revenue Estimation, Forecast, 2024–2030

Introduction And Strategic Context

The Global Refining Industry Automation And Software Market will witness a steady CAGR Of 6.3%, valued at USD 18.6 Billion In 2024 and projected to reach USD 27.0 Billion By 2030, according to Strategic Market Research.

 

This market represents a foundational pillar in the modernization of downstream oil and gas operations. Refining is under mounting pressure — decarbonize, digitize, and still deliver consistent throughput. Against this backdrop, automation and software platforms are no longer auxiliary; they’re central to staying operational, safe, and profitable.

 

Automation systems in refineries now manage everything from process controls and real-time analytics to digital twins and emissions tracking. Over the next five years, adoption will accelerate, driven by a few clear forces. For one, many legacy plants are hitting a technical ceiling — operators simply can't run them efficiently without new digital infrastructure. On top of that, geopolitical supply risks are pushing refiners to sweat every unit of capacity. That’s where predictive control, digital asset management, and machine learning come in.

 

At the same time, environmental regulations are tightening. Many refiners are being mandated to monitor and report emissions more frequently and accurately. Automation tools now help operators not only meet compliance but optimize processes for energy use — a major cost lever.

 

There’s also a workforce dimension. Skilled refinery operators are retiring faster than they can be replaced. That’s created urgency around knowledge capture and systems that support semi-autonomous operations. The most forward-looking refiners are investing in cloud-integrated control systems and AI-based diagnostics not just to optimize uptime, but to build a knowledge layer that sustains performance long after experienced staff leave.

 

In terms of stakeholders, this market cuts across global OEMs, industrial software developers, energy conglomerates, independent refiners, EPCs, and investment firms. It also includes regulatory bodies that are increasingly involved in how automation systems are configured and validated.

 

What's changing fast is the role of software. Historically, automation in refining was hardware-heavy — think DCS panels, PLCs, and HMIs. Today, the growth is shifting to software — optimization engines, cloud-based analytics, digital twins, and AI/ML platforms. And the differentiator is no longer just control — it’s intelligence.

 

To be honest, the automation stack in refining hasn’t evolved this fast since the 1990s. What we’re seeing now is less about replacing analog systems and more about redefining how refineries operate altogether.

 

Market Segmentation And Forecast Scope

The refining industry automation and software market is layered, with segmentation spanning control systems, software types, deployment models, and end-use environments. Each segment plays a unique role in optimizing safety, throughput, and regulatory compliance. For stakeholders—from OEMs and EPC firms to refinery operators—understanding these segments is key to identifying investment-ready areas between 2024 and 2030.

By Solution Type

By Solution Type, the market breaks into three core buckets: control systems, operations software, and analytics platforms. Control systems—like distributed control systems (DCS) and programmable logic controllers (PLC)—remain the backbone of real-time plant operations and incident prevention. However, growth is tilting toward advanced analytics, manufacturing execution systems (MES), and digital twin software, as refineries pursue higher margins and faster decision cycles.

• Control Systems (DCS, PLC, SCADA, SIS): Still the largest market segment, supporting core plant reliability, operational stability, and safety controls. This segment is estimated to represent ~44% of market revenue in 2024, reflecting ongoing replacement cycles and safety modernization projects.

• Operations Software (MES, APC, Workflow Automation): Growing adoption as refiners seek tighter coordination between production planning, scheduling, and real-time execution. Cloud-enabled MES modules are increasingly deployed in phases to reduce implementation risk.

• Analytics Platforms (Predictive Maintenance, AI Optimization, Digital Twins): The fastest-growing bucket, driven by payback visibility and the ability to reduce margin leakage. Software-based tools are expected to grow nearly twice as fast as core control systems through 2030.

Many operators are now layering AI-enabled decision engines over traditional control stacks to unlock incremental gains in heat recovery, catalyst efficiency, and throughput balance. In parallel, a notable shift is the rising share of predictive maintenance platforms, which detect early signs of equipment degradation and are particularly valued in older refineries where unplanned downtime is costly and common.

 

By Application

By Application, usage clusters around process optimization, asset integrity, safety management, and emissions tracking. Process optimization dominates, especially in fuel refining and desulfurization units where margin leakage can occur within hours. Refiners continue to prioritize optimization software that improves yields, reduces energy intensity, and stabilizes unit performance under feedstock variability.

• Process Optimization: Includes advanced process control (APC), real-time optimization (RTO), and AI setpoint tuning. Dominant segment as refiners prioritize throughput stability, yield uplift, and energy efficiency.

• Asset Integrity: Predictive maintenance, condition monitoring, and reliability analytics aimed at compressors, rotating equipment, heat exchangers, and critical instrumentation.

• Safety Management: Safety instrumented systems (SIS), alarm management, incident prevention analytics, and digital permit-to-work systems to reduce operational risk.

• Emissions Tracking & Compliance: Continuous emissions monitoring, automated compliance reporting, flare minimization, and carbon accounting dashboards—rapidly expanding as regulations tighten.

That said, emissions monitoring is catching up due to tighter global carbon compliance rules and stakeholder pressure around ESG outcomes. Environmental dashboards, automated reporting systems, and flare minimization algorithms are becoming standard across facilities, especially in Europe and North America.

 

By End-User

By End User, the primary markets include integrated oil & gas companies, independent refiners, and national oil companies (NOCs). Each group differs in buying behavior, implementation cadence, and technology priorities.

• Integrated Oil & Gas Companies: Global majors (e.g., ExxonMobil, Shell) typically implement full-stack automation—from field instrumentation to enterprise analytics—with multi-year rollout plans and global vendor standardization. They often prioritize cybersecurity, interoperability, and enterprise-wide performance benchmarking.

• Independent Refiners: More narrowly focused on process efficiency and emissions compliance, often seeking modular software that layers onto existing infrastructure. They favor shorter payback cycles, quick wins, and low-disruption deployment.

• National Oil Companies (NOCs): Particularly in Asia and the Middle East, NOCs are investing heavily in automation as part of national energy transformation and capacity expansion plans. These projects often prioritize scalability, localization, workforce enablement, and long-term vendor support.

 

By Region

By Region, market segmentation reflects different paces of adoption driven by maturity of installed assets, regulatory intensity, and capital investment cycles. North America and Europe are focused on modernization and sustainability, while Asia-Pacific is building new capacity—often with automation designed in from day one. Latin America and parts of the Middle East are catching up fast, driven by cost savings, workforce constraints, and rising environmental expectations.

• North America: Modernization-heavy market focused on debottlenecking, energy efficiency, and emissions compliance. Strong demand for analytics, reliability platforms, and cybersecurity hardening.

• Europe: Sustainability and regulatory compliance shape investment priorities, accelerating emissions dashboards, automated reporting, and optimization to reduce energy intensity.

• Asia-Pacific: Capacity expansion and greenfield builds support rapid adoption of integrated automation platforms and digital twins, with a bias toward scalable architectures.

• Latin America & Middle East: Increasing automation adoption driven by cost control, aging infrastructure, and operational resilience initiatives; adoption often begins with modular analytics and reliability upgrades.

 

Deployment Model And Operating Environment

Across segments, deployment models are evolving from on-premise-only stacks toward hybrid architectures that combine edge processing with cloud analytics. While safety-critical controls remain predominantly on-premise, refineries are increasingly using cloud-connected layers for historian analytics, fleet-wide benchmarking, and enterprise reporting. This shift is especially visible in multi-site operators aiming to standardize KPIs and reduce engineering overhead.

• On-Premise: Preferred for real-time controls, high-availability requirements, and safety-critical workloads; remains standard for DCS/SIS environments.

• Hybrid: Most common trajectory through 2030—edge control with cloud-based analytics and reporting, balancing latency, security, and scalability.

• Cloud-Native: Growing adoption in MES modules, digital work management, and non-critical analytics, particularly where data governance and connectivity are mature.

 

Fastest-Growing Sub-Segments

Across all segmentation layers, the lines between hardware and software are blurring. Vendors increasingly offer integrated platforms where analytics, control, and optimization are bundled—not sold piecemeal. The fastest-growing sub-segments include:

• Digital Twins for Simulation-Based Optimization: Used for unit-level scenario testing, turnaround planning, and constraint-based optimization—often delivering short payback via throughput and energy improvements.

• Cloud-Integrated MES Platforms: Enable rapid deployment of scheduling, quality, and execution workflows with enterprise visibility, supporting both economic and ESG goals.

• Predictive Maintenance Platforms: High ROI in aging assets by reducing unplanned downtime, improving reliability, and optimizing spare parts strategies.

Expert Insight: The refining automation market’s growth engine is shifting toward software-defined value—where AI, digital twins, and cloud-connected execution systems deliver measurable margin uplift and compliance readiness. Between 2024 and 2030, vendors that bundle control + analytics into integrated platforms—and prove payback quickly—will be best positioned to win modernization and greenfield projects alike.

 

Market Trends And Innovation Landscape

Innovation in refining automation isn’t just incremental — it’s systemic. The traditional automation stack, once focused on control and visualization, is now giving way to integrated intelligence, predictive autonomy, and edge-to-cloud connectivity. Between 2024 and 2030, this shift will define competitive advantage in the refining industry automation and software market.

One of the most visible trends is the rise of digital twins. Initially adopted for simulation and training, these virtual replicas now serve as real-time performance engines. Refineries use them to model everything from crude blend impacts to flare system behavior. What’s changed is the fidelity — today’s twins are data-driven and dynamically updated through live sensor input. This isn’t just modeling; it’s operational forecasting.

 

Another major shift is the AI-ification of control systems. Traditional DCS setups relied on static control loops. Now, machine learning algorithms are sitting on top of these controls, dynamically adjusting process variables in real time. Early adopters are using AI for tasks like sulfur recovery optimization or hydrogen balancing — areas where process dynamics are too complex or volatile for static tuning.

 

Edge computing is also gaining momentum. Operators want lower latency, more autonomy, and less reliance on central servers — especially for safety-critical functions. Vendors are responding with edge-enabled PLCs and condition monitoring tools that can process vibration, pressure, or temperature data locally before triggering control responses or alerts.

 

There’s also a wave of innovation in energy management. Given refining’s role as one of the most energy-intensive industrial sectors, automation platforms are now embedding energy KPIs directly into operations dashboards. Real-time steam balance, heat exchanger efficiency, and furnace tuning are no longer side calculations — they’re core control metrics.

 

On the cybersecurity front, zero-trust architecture and OT-specific threat detection tools are emerging as non-negotiable features. With rising geopolitical tensions and cyberattacks on critical infrastructure, refinery operators are demanding automation software that comes hardened out of the box. This includes anomaly detection algorithms that track not just equipment behavior but operator access patterns.

 

Vendor strategies are also shifting. Several large automation providers are moving toward subscription models for software delivery. Instead of upfront licenses, they’re bundling software, analytics, and support into recurring OPEX contracts. This is helping refineries manage costs more predictably while ensuring systems stay updated.

 

In terms of partnerships, we’re seeing alliances between cloud hyperscalers and industrial automation firms. These tie-ups are enabling multi-site refinery operators to standardize data lakes, apply AI centrally, and benchmark performance across facilities — something that was nearly impossible with siloed legacy systems.

One refinery CTO recently noted that what used to be a DCS upgrade project is now a “data architecture decision.” The shift is cultural as much as technical — moving from automation as a system to automation as a strategy.

 

There’s no doubt the innovation curve here is steep. But it’s also practical. Most refiners aren’t chasing futuristic concepts — they want technologies that drive uptime, safety, and margin right now. The winners in this market are those who can deliver future-ready tools without disrupting today’s operations.

 

Competitive Intelligence And Benchmarking

The refining industry automation and software market isn’t overcrowded — but it is highly consolidated, with a few global players shaping most of the innovation and deployment patterns. What separates these companies isn’t just technical capability — it’s vertical domain expertise, integration flexibility, and the ability to deliver results across hybrid environments.

Emerson remains a dominant force, particularly with its deep presence in process control and asset management. Its edge lies in field instrumentation integration and predictive diagnostics, especially through its Plantweb digital ecosystem. Emerson continues to gain traction in downstream refining by offering packaged analytics and control that work seamlessly with existing legacy systems. Their ability to play across both greenfield and brownfield projects makes them a go-to partner for incremental modernization.

 

Honeywell Process Solutions holds strong in high-integrity control and advanced operations software. Their Experion platform is often the default for large refineries seeking integrated safety, control, and performance optimization. Honeywell’s recent focus has been on energy efficiency modules and carbon capture-ready automation blocks. They're also investing in workforce simulation platforms — helping clients train new operators using virtual plant environments tied directly to live control systems.

 

Schneider Electric, through its EcoStruxure platform, positions itself as a sustainability-focused automation partner. While traditionally strong in electrical distribution and energy monitoring, Schneider has scaled up its refining presence via acquisitions in industrial software. Its current push is toward decarbonization toolkits — integrating power quality management with process control to reduce overall energy draw per barrel refined.

 

ABB has built its competitive edge around high-speed data acquisition and modular digital twins. Known for scalable DCS systems and performance management software, ABB stands out in regions like the Middle East, where large national oil companies are retrofitting facilities for long-term resilience. Their emphasis on cybersecurity and electrical integration also appeals to refineries undergoing full-stack modernization.

 

Yokogawa Electric is a specialist in advanced process control and refinery-wide orchestration. Its OpreX suite focuses heavily on continuous process industries, and in refining, they’ve doubled down on model predictive control (MPC) and cloud-integrated historian systems. Yokogawa often wins contracts where precision and reliability are prioritized over flexibility — such as in catalytic reforming or alkylation units.

 

Rockwell Automation continues to carve out a presence in modular and discrete process units within refineries — especially in U.S. midstream-linked refining hubs. Their advantage is speed and scalability, often appealing to operators looking for plug-and-play automation within niche refining sections like blending or product dispatch.

 

A few other names are making targeted plays. AspenTech, for example, is influencing the high-end software stack — particularly around simulation, planning, and AI-based optimization. Their tools are often embedded into broader vendor ecosystems and are now essential in refinery scheduling and margin optimization workflows.

Across the board, the competitive narrative is shifting from “who provides the best control system” to “who delivers the most flexible and intelligent automation stack that can scale across assets and integrate into corporate data architectures.”

The next five years are likely to see more collaboration than direct competition. Many vendors are forming alliances — pairing control with cloud, or field data with AI — to deliver modular, future-ready platforms. And that’s exactly what the modern refinery needs: systems that can evolve, not just install.

 

Regional Landscape And Adoption Outlook

The adoption curve for automation and software in the refining sector isn’t uniform — it’s shaped by regional priorities, infrastructure maturity, and regulatory intensity. While some regions are focused on modernizing legacy assets, others are leapfrogging straight into next-gen automation with greenfield builds. Between 2024 and 2030, this uneven adoption will continue to define growth pockets and solution design choices across the refining industry automation and software market.

North America remains the most mature market, driven by a mix of aging infrastructure and high environmental scrutiny. Many U.S. and Canadian refineries are over 30 years old, and automation upgrades here are focused on extending asset life, minimizing emissions, and improving labor efficiency. Cloud-based analytics, edge computing, and emissions dashboards are being layered over existing DCS and PLC systems rather than fully replaced. There’s also growing investment in operator training simulators to compensate for the wave of retirements across control room staff.

In one Gulf Coast refinery, a full predictive analytics layer was deployed not to replace the DCS, but to flag early catalyst degradation. The ROI came in less than 9 months due to reduced unplanned outages.

 

Europe is adopting automation through a sustainability lens. With EU directives pushing for carbon neutrality, refiners here are investing in emissions tracking, energy optimization, and advanced process control tuned for low-carbon fuels. Plants in Germany, the Netherlands, and Scandinavia are implementing automation not just to improve yields, but to quantify Scope 1 and Scope 2 emissions in real time. There’s also strong uptake of automation around hydrogen integration, especially as refineries add electrolysis units and low-carbon fuel blending to meet regulatory thresholds.

 

Asia Pacific is where the real expansion is happening. New refinery projects in China, India, and Southeast Asia are being designed from the ground up with automation embedded. These greenfield sites are implementing cloud-native MES platforms, digital twins, and fully integrated asset management systems right from commissioning. State-backed refiners in China and India are investing in centralized analytics platforms to manage distributed asset networks and improve national refining productivity.

That said, the region is highly fragmented. While tier-1 facilities are going digital-first, many smaller plants still lack integration between field instruments and control systems. As a result, there’s strong demand for scalable, modular solutions that don’t require full stack replacements.

 

Middle East refineries, particularly in Saudi Arabia, the UAE, and Oman, are undergoing structured digital transformation. National oil companies are rolling out smart refinery programs that include advanced control systems, integrated cybersecurity, and real-time production optimization. These programs are often tied to broader economic diversification efforts and energy transition goals, making automation a political as well as operational priority.

 

Latin America presents a mixed picture. Brazil and Mexico are leading refinery automation efforts, with government-supported investments aimed at improving reliability and safety in older state-run facilities. Elsewhere, lack of capital and skilled labor has slowed adoption. However, international joint ventures and PPPs are starting to unlock software-led upgrades that can be deployed without full infrastructure overhauls.

 

Africa remains largely underpenetrated, though interest is rising. New refinery projects in Nigeria and Angola are considering automation as part of early-stage design. That said, basic infrastructure, power reliability, and skilled labor shortages continue to pose challenges. Portable control platforms and remote diagnostic systems are emerging as pragmatic solutions for these markets.

What’s consistent across all regions is a rising expectation that automation must deliver more than just control. It must support workforce efficiency, compliance reporting, and energy optimization — often within tight budgets and legacy constraints. As a result, vendors offering flexible deployment models, cloud-first solutions, and localized support networks are gaining traction.

 

End-User Dynamics And Use Case

In refining, automation isn’t a one-size-fits-all play. Each end user — whether it’s a global oil major, an independent refiner, or a state-owned company — approaches automation with different priorities. Some want long-term asset resilience, others want immediate cost reduction. Understanding these dynamics is critical to building scalable, relevant automation strategies.

Integrated oil & gas companies typically take the long view. Their refining operations are part of a broader value chain, so automation is used not just for process control, but to connect refining with upstream and downstream insights. These players invest in end-to-end optimization platforms that span planning, scheduling, maintenance, and emissions reporting. For them, the priority is standardization — rolling out unified automation architectures across multiple plants to drive enterprise-wide benchmarking and data analytics.

 

Independent refiners, especially in North America, operate under tighter margin pressure. Their automation investments focus on reducing downtime, cutting energy use, and meeting compliance. Unlike integrated firms, they favor modular software that can be deployed over existing infrastructure without disrupting operations. Many independents are also adopting cloud-based asset monitoring tools to compensate for leaner onsite technical teams.

 

National oil companies (NOCs) in regions like the Middle East and Asia are undergoing major digitalization. These firms are often building new refineries or modernizing existing ones as part of national transformation plans. Their goals are dual: improve domestic fuel security and position themselves as competitive exporters. Automation here is being bundled into full smart refinery programs — complete with AI, real-time emissions monitoring, and cybersecurity frameworks.

 

Engineering, procurement, and construction (EPC) firms also play a major role. While not end users in the traditional sense, they’re the ones integrating automation into new refinery builds. EPCs are increasingly partnering with automation vendors earlier in the project lifecycle — helping to ensure that systems are scalable and compliant before commissioning even begins.

 

Use Case: Smart Maintenance in a Middle Eastern Refinery

A major NOC-operated refinery in the Middle East faced chronic reliability issues in its hydrocracking unit — especially around heat exchanger fouling, which impacted throughput and energy consumption.

The refinery partnered with a global automation vendor to implement an AI-driven maintenance platform integrated with existing DCS and condition monitoring systems. Using machine learning models trained on five years of operations data, the system began identifying early fouling patterns days before they would normally be noticed.

At the same time, edge-based diagnostics were installed to monitor critical variables in real time. The result? A 23% reduction in unplanned shutdowns within 12 months, a 12% cut in steam consumption, and a measurable reduction in maintenance-related safety incidents. What stood out wasn’t just the performance gains — it was the fact that the system was deployed without needing to replace existing infrastructure.

This kind of result shows the new reality: automation isn’t just about better control — it’s about enabling smarter, safer, and more predictable operations in a high-risk, high-cost environment.

Bottom line — the best automation tools are those that meet end users where they are. For global majors, that means data integration and scalability. For independents, it’s modularity and ROI. And for NOCs, it’s about future-proofing national infrastructure.

 

Recent Developments + Opportunities & Restraints

Recent Developments (Past 2 Years)

• Emerson partnered with a major Middle East NOC in 2024 to deploy its next-gen Plantweb Optics platform across five national refineries. The rollout included AI-driven analytics, predictive maintenance, and emissions tracking modules.

• In 2023, Honeywell introduced a cloud-native version of its Experion PKS system tailored for hybrid refinery environments. This allows remote operations centers to manage multiple refineries under one integrated platform.

• ABB launched its Ability Genix Industrial Analytics platform with a focus on energy optimization in high-emissions units such as FCCs and reformers. Initial pilots in Europe showed over 8% energy savings.

• Schneider Electric announced a strategic collaboration with Microsoft Azure in 2024 to deliver refinery-wide digital twins that integrate power systems, control logic, and asset performance data into a unified cloud architecture.

• Yokogawa expanded its OpreX suite in 2023 with a new emissions intelligence module, which uses real-time process data to adjust operating conditions for better carbon control — a key feature in EU-based refineries.

 

Opportunities

• AI-Driven Optimization: AI tools for yield forecasting, emissions reduction, and anomaly detection are becoming refinery essentials. Adoption is rising particularly in regions where skilled operators are retiring and margin compression is severe.

• Smart Retrofitting: Demand is growing for modular software and edge devices that can be installed on aging DCS/PLC systems without full replacement. This “retrofit-friendly” automation is opening up growth in cost-sensitive markets.

• Greenfield Digitalization: New refining projects in Asia and the Middle East are specifying automation from day one — including digital twins, predictive control, and emissions tracking. Vendors who can bundle hardware, software, and services are winning large multi-year deals.

 

Restraints

• High Capital Intensity: Comprehensive automation systems — especially those with predictive layers or real-time emissions modeling — require large upfront investment. Smaller operators struggle to justify the spend without guaranteed ROI.

• Workforce and Skill Gaps: Many refineries still lack in-house expertise to manage or scale modern automation systems. This limits the impact of advanced software platforms unless supported by long-term vendor partnerships or training programs.

 

7.1. Report Coverage Table

Report Attribute	Details
Forecast Period	2024 – 2030
Market Size Value in 2024	USD 18.6 Billion
Revenue Forecast in 2030	USD 27.0 Billion
Overall Growth Rate	CAGR of 6.3% (2024 – 2030)
Base Year for Estimation	2024
Historical Data	2019 – 2023
Unit	USD Million, CAGR (2024 – 2030)
Segmentation	By Solution Type, Application, End User, Region
By Solution Type	Control Systems, MES & Operations Software, Asset Performance Software, Digital Twins
By Application	Process Optimization, Asset Management, Safety & Compliance, Emissions Tracking
By End User	Integrated Oil & Gas Companies, Independent Refiners, National Oil Companies, EPCs
By Region	North America, Europe, Asia-Pacific, Latin America, Middle East & Africa
Country Scope	U.S., Canada, Germany, UK, China, India, Japan, Brazil, Saudi Arabia, etc.
Market Drivers	- Surge in energy efficiency mandates - Aging infrastructure pushing retrofit demand - Labor shortages fueling AI-based automation
Customization Option	Available upon request