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Automation Risk Analysis

Will “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%

“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%

“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

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

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

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

  • 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.

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

  • Defrost frozen valves, using steam hoses.

  • 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.

  • Repair or replace damaged equipment.

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

  • Calculate material requirements or yields according to formulas.

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

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

  • Gauge tank levels, using calibrated rods.

  • 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.

  • 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.

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

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

Technologies & Software

  • Mistral (Mistral AI)
  • Coordinated incident management system CIMS software
  • Qwen (Alibaba)
  • Grok (xAI)
  • Rockwell Automation AI
  • Interlock shutdown systems
  • DeepSeek
  • Gemini (Google)
  • Nova (Amazon)
  • Alarm management system software
  • Sight Machine AI
  • Microsoft Word
  • Siemens Industrial AI
  • ChatGPT (OpenAI)
  • Claude (Anthropic)
  • Kimi (Moonshot AI)
  • Microsoft Office software
  • Cognex Vision AI
  • Distributed control system DCS
  • Microsoft Excel
  • ABB AI Robotics
  • Llama (Meta)
  • Wet scrubbers
  • Steam hoses
  • Bourdon tubes
  • Rotary pumps
  • Reciprocating compressors
  • Screw conveyors
  • Air conditioning systems
  • Industrial liquid flowmeters
  • Industrial fans
  • Thermocouple temperature probes
  • Tensometers
  • Refrigeration systems
  • Cooling towers
  • Personal protective equipment
  • Gas analyzers
  • Agitator tanks
  • Blending vessels
  • Silencers
  • Effluent treatment systems
  • Belt conveyors
  • Display screens
  • Soap-spray storage tanks
  • Reciprocating pumps
  • Radiographic detecting instruments
  • Heating vessels
  • Neutralizer tanks
  • Control boards
  • Bucket elevators
  • Collectors
  • Digital surface thermometers
  • Desktop computers
  • Conveyor feeders
  • Chain conveyors
  • Centrifugal compressors
  • Positive displacement pumps
  • Steam turbines
  • Humidifiers
  • Viscometers
  • Axial flow fans
  • Centrifugal fans
  • Hydraulic accumulators
  • Barometers
  • Converter vessels
  • Recording calorimeters
  • Pressure gauges
  • Capacitance probes
  • Storage drums
  • Industrial dryers
  • Chemical reactor vessels
  • Calibrated rods
  • Fire extinguishers
  • Thermocouples
  • Panel lights
  • Boilers
  • Hoppers
  • Panelboards
  • Distillation columns
  • Mixing tanks
  • Centrifugal pumps
  • Manometers