Process Simulation

In today’s challenging world of O&G business, engineers are continuously being pushed to develop processing facilities at reduced costs whilst maintaining operational flexibility and not increasing the risk to people and the environment. Process simulation studies enable the asset owners and the system designers to gain a better insight into the design and operation of their facilities.

In downstream process, simulation studies are used to:

  • Design, Develop, Analyze and optimize various processes.
  • Analyze existing processes
  • Define the process parameters used in the design of future processes.

Process Simulation is often performed during the design phase or before a plant becomes fully operational to see how changes in equipment specifications, scheduling, downtime, and maintenance can affect a process throughout the duration of its life cycle. Although simulation techniques vary depending on the size and complexity of the process, along with the software being used to perform the modeling.

There are two main types of refining simulation

Steady state simulation

Steady state simulation analysis is used to analyze the processes when the system is in equilibrium. Typical applications of steady state simulation analysis are to:

  • Develop the heat and material balance for the process
  • Prepare process equipment data sheets
  • Analyze relief and flare systems

Application of steady state simulation comes majorly during the conceptual phase of a project with a motive to understand how a design can be altered to get the most out of a process from both a business standpoint and an engineering perspective.

Dynamic simulation

Dynamic simulation is an extension of steady state simulation that allows the user to predict the response of process parameters due to changes in operation with respect to time.

Some of the dynamic simulation analysis utilized in refinery and petrochemical processes to optimize the performance are:

  • Compressor dynamic simulation
  • Heat exchanger tube rupture analysis
  • Transient surge analysis of a fire water system
  • Optimization of Process control systems

We offer the following services in the area of Process Simulation:

Steady State Simulation

  • Process Synthesis
  • Process Design (FEED Stage)
  • Process Optimization
  • Process Revamp/Debottlenecking
  • Process Simulation Model building

Dynamic Simulation

  • Engineering Study of Process/Equipment/Pipelines
  • Control Scheme Design and Validation
  • Start-up/Shut down study
  • Online Optimization
  • Kinetic modeling
  • Simulation model tuning

Operator Training

  • Engineering studies and report generation.
  • Modification/maintenance of dynamic/steady state simulation models.
  • Platform independent services (capability on Hysys, Unisim, Dynsim, OLGA, Pipesim etc.)
  • Training services for Hysys and Unisim.
  • Collaborating on study projects with EPC’s.
  • Development of user defined modules on Hysys and Unisim platforms for proprietary calculations.
  • Development of automation application for Hysys and Unisim platform.

Simulation of Dynamic Behaviors of Process Equipment’s and process piping viz.

  • Compressor Loop Study, Anti-surge line/Valve design and its adequacy checking.
  • Depressurizing Study, Design and validation of relief valve/vent valve/Emergency depressurization system.
  • Control Scheme validation.
  • Start-up/ Shutdown/ Scenario testing.
  • Critical control loop tuning parameter estimation.
  • Validating Cause and Effect matrix for ESD system for critical equipment’s or plant-wide.
  • Plant performance checking
  • Debottlenecking/Revamp Study

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