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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

  • Gauge tank levels, using calibrated rods.

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

  • 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.

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

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

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

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

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

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

  • 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.

  • 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.

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

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

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

  • Repair or replace damaged equipment.

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

Technologies & Software

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