Shape Digital Launches New Technology to Reduce Emissions on FPSOs

Shape Lumen, the company's new solution, identifies the root causes of unplanned gas flaring, anticipates risks, and accelerates GHG analyses.

HOUSTON--(BUSINESS WIRE)--Shape Digital, an industrial AI company that develops digital decision-making platforms for asset-heavy industries, today announced its new domain intelligence technology focused on decarbonization and operational efficiency in the oil and gas sector. Shape Lumen is a real-time flare intelligence agent that connects root-cause signals that may otherwise be invisible across the process plant (gas, water and oil), improving flare management and enabling teams to build use cases with concrete actions that directly support emissions reduction and regulatory compliance.

In one specific case, the solution demonstrated an average reduction of more than 12% in daily unplanned flaring emissions. Applied to onshore and offshore assets such as Floating Production Storage and Offloading (FPSO) units, this reduction has already represented an estimated savings of US $200,000 per year for an FPSO producing 200,000 barrels per day, using gas price in USD/MMBtu and carbon price in USD/tCO2e as the basis.

The tool takes a horizontal approach, analyzing the entire production system (gas, water, and oil), monitoring flow limits, and, when violations occur, assessing engineering variations captured by sensors in the period preceding the event. The algorithm automatically classifies the root cause of unwanted flaring on an hourly basis, reducing the time engineers spend manually tracing anomalies in raw data from as many as 10 days to real-time visibility.

“Flare monitoring and analysis have traditionally been chronic pain points for the oil and gas industry due to fuel waste, the impact of emissions, and the severe risk of regulatory fines,” says Leonardo Machado, VP of Growth at Shape Digital. “Lumen transforms complex process engineering data into direct, mitigating actions so that bottlenecks can be anticipated and non-routine flaring events do not recur frequently.”

Shape Lumen was presented at GASTECH 2025 in Fiera Milano (Italy) and comes at a time of growing pressure on the industry for greater operational efficiency, emissions reduction, and regulatory compliance, especially regarding unplanned flaring, which can be caused by equipment failures and other situations. Following a successful pilot, MODEC has expanded the solution to ten FPSOs of its fleet in Brazil this year, demonstrating its application at scale in real-world operations.

In addition to mapping the history of root causes, Shape Lumen incorporates an artificial intelligence-based predictive model that projects the cumulative flaring trend for the current month, alerting managers if the asset is on track to exceed regulatory limits set by oversight agencies. With implementation taking approximately one month per offshore unit once basic instrumentation requirements are met, Shape Digital is focused on expanding the solution in Brazil while pursuing opportunities in additional markets globally.

For more information, please visit: https://www.shapedigital.com/.

About Shape Digital

Shape Digital combines deep industrial expertise with agentic AI to serve as an intelligence layer for capital-intensive industries, helping teams move from operational data to precise action. Shape connects data from virtually any online or offline source or system, turning existing operational data into automated analysis, prognosis, recommendations and calls to action that help operators optimize performance, maintenance, safety and efficiency. Rather than replacing existing systems or adding another dashboard, Shape layers intelligence onto the systems and data companies already use. Born out of MODEC, a global leader in solutions to the floating offshore oil and gas market for more than 50 years, Shape brings decades of real-world industrial and heavy-asset expertise to its technology, helping operators, engineers and business leaders make smarter, faster decisions without adding unnecessary complexity. For more information, please visit: https://www.shapedigital.com/.