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Automation Risk Analysis

Will “Chemical Process Operator” be Automated?

Historical Context: Oxford Study (2013)

Ranked #487 of 702. Estimated risk: 85.0%

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AI Exposure Risk

51%

“Chemical Process Operator” will maybe be replaced by AI.

Based on the cognitive demands, communication requirements, and logical reasoning intrinsic to this occupation according to O*NET data, we project a 51% probability of disruption by generative AI and Large Language Models.

Automation & Robot Risk

59%

“Chemical Process Operator” will maybe be replaced by robots.

Evaluating the physical dexterity, repetitive motion tasks, and manual labor associated with this role, our analysis indicates a 59% likelihood of substitution by advanced robotics systems.

Personal & Financial Insights

Every occupation has a unique profile. For Chemical Plant and System Operators, the Bureau of Labor Statistics and O*NET classify the day-to-day work broadly as: Control or operate entire chemical processes or system of machines.

Avg. Annual Salary $76,290
Avg. Hourly Wage $36.68
Available Jobs (US) 17,840
Job Title & Hierarchy Code (SOC) Chemical Plant and System Operators #51-8091
Wage vs. National Median
ℹ️

Data is based on the reference occupation: “Chemical Plant and System Operators”

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Core Skills & Abilities

  • Gauge tank levels, using calibrated rods.

  • Regulate or shut down equipment during emergency situations, as directed by supervisory personnel.

  • Notify maintenance, stationary engineering, or other auxiliary personnel to correct equipment malfunctions or to adjust power, steam, water, or air supplies.

  • Monitor recording instruments, flowmeters, panel lights, or other indicators and listen for warning signals to verify conformity of process conditions.

  • Supervise the cleaning of towers, strainers, or spray tips.

  • Defrost frozen valves, using steam hoses.

  • Turn valves to regulate flow of products or byproducts through agitator tanks, storage drums, or neutralizer tanks.

  • Control or operate chemical processes or systems of machines, using panelboards, control boards, or semi-automatic equipment.

  • Record operating data, such as process conditions, test results, or instrument readings.

  • Repair or replace damaged equipment.

  • Interpret chemical reactions visible through sight glasses or on television monitors and review laboratory test reports for process adjustments.

  • Move control settings to make necessary adjustments on equipment units affecting speeds of chemical reactions, quality, or yields.

  • Inspect operating units, such as towers, soap-spray storage tanks, scrubbers, collectors, or driers to ensure that all are functioning and to maintain maximum efficiency.

  • Patrol work areas to ensure that solutions in tanks or troughs are not in danger of overflowing.

  • Calculate material requirements or yields according to formulas.

  • Direct workers engaged in operating machinery that regulates the flow of materials and products.

  • Confer with technical and supervisory personnel to report or resolve conditions affecting safety, efficiency, or product quality.

  • Draw samples of products and conduct quality control tests to monitor processing and to ensure that standards are met.

  • Start pumps to wash and rinse reactor vessels, to exhaust gases or vapors, to regulate the flow of oil, steam, air, or perfume to towers, or to add products to converter or blending vessels.

Technologies & Software

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  • Siemens Industrial AI
  • Microsoft Excel
  • DeepSeek
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  • Nova (Amazon)
  • Belt conveyors
  • Blending vessels
  • Axial flow fans
  • Fire extinguishers
  • Screw conveyors
  • Desktop computers
  • Calibrated rods
  • Viscometers
  • Boilers
  • Neutralizer tanks
  • Distillation columns
  • Humidifiers
  • Bucket elevators
  • Mixing tanks
  • Thermocouple temperature probes
  • Storage drums
  • Effluent treatment systems
  • Steam turbines
  • Industrial fans
  • Chemical reactor vessels
  • Refrigeration systems
  • Panel lights
  • Thermocouples
  • Industrial liquid flowmeters
  • Steam hoses
  • Agitator tanks
  • Centrifugal fans
  • Pressure gauges
  • Centrifugal compressors
  • Capacitance probes
  • Tensometers
  • Positive displacement pumps
  • Industrial dryers
  • Radiographic detecting instruments
  • Cooling towers
  • Centrifugal pumps
  • Barometers
  • Reciprocating pumps
  • Silencers
  • Conveyor feeders
  • Collectors
  • Rotary pumps
  • Control boards
  • Chain conveyors
  • Hydraulic accumulators
  • Panelboards
  • Converter vessels
  • Air conditioning systems
  • Bourdon tubes
  • Digital surface thermometers
  • Personal protective equipment
  • Soap-spray storage tanks
  • Wet scrubbers
  • Recording calorimeters
  • Manometers
  • Hoppers
  • Gas analyzers
  • Display screens
  • Heating vessels
  • Reciprocating compressors