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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

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

  • 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.

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

  • Gauge tank levels, using calibrated rods.

  • 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.

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

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

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

  • Repair or replace damaged equipment.

  • 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.

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

  • 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.

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

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

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

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

Technologies & Software

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