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Automation Risk Analysis

Will “Process Technician” be Automated?

Historical Context: Oxford Study (2013)

Ranked #487 of 702. Estimated risk: 85.0%

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AI Exposure Risk

51%

“Process Technician” 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 Technician” 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

  • 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.

  • Calculate material requirements or yields according to formulas.

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

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

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

  • Repair or replace damaged 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.

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

  • 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.

  • Defrost frozen valves, using steam hoses.

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

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

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

  • 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.

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

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

Technologies & Software

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