Process Simulation

Process simulations can quickly evaluate existing operations in refineries and industrial facilities to pinpoint operational bottlenecks, unit shortcomings, design limitations, and adequacy of relief systems.

Industry Renowned

Our trained and industry-renowned process simulation experts conduct an average of 50 highly complex process simulations a year, an equivalent of 8,000 labor hours, on hundreds to thousands of industrial units. Our team simulates everything associated with refinery or industrial facilities, whether pump to piping, tankage to exchanger trains, or reactors to reformers using state of the art HTRI software.

What sets our team apart from others is the knowledge, experience, and training in the latest simulation concepts, techniques, and cutting-edge technologies. They are industry experts in both static simulations where a unit performs in a low-stress, steady state, and dynamic simulations where a unit performs in a “what if” scenario at high-stress levels to better mimic real-world operations. Clients also often reach out to our team to dynamically simulate and update their models. They know that dynamically simulating relief systems, for example, to identify peak loads during relief events mitigate risk and saves them time and money.

Integration Strategies

Whether designing and validating alkalization units, reformers, or fluid catalytic cracking units, our clients know that revamping one unit in a large capital expansion project can impact numerous pieces of equipment or the feed of another unit in a refinery or facility. This is why clients often ask our team to integrate their existing models into our process simulations.

Process Simulation Procedures:

Evaluate: Review client data and designs to ensure that unit physical properties, flow temperatures, and historical information is captured in the model.
Simulate: Run the model through process simulation programs such as PRO/II and HYSYS, Petro-SIM, and UniSim.
Extrapolate: Leverage our team’s technical expertise to interpret the data and validate the model.
Validate: Perform third-party evaluation to validate our process, requirements, information, and model.

Simulation Expertise

Our team uses our simulation expertise to model everything from individual to complex refinery unit operations, relief valve sizing cases, and troubleshooting of existing systems. We have the ability to dynamically model the cascading effects of a global plant failure using industry leading software packages. Trained in both static and dynamic modeling, we can also customize our modeling services to provide quick and easy solutions to our client’s problems. Whether validating line sizing, debottlenecking a refinery unit for a revamp project, or changing feed for an existing facility, our experts can provide the best modeling solution using the latest simulation software technology.

Process Simulation Benefits

• Reduced cost
• Compressed schedule
• More efficient processes
• Shorter engineering change cycles
• Reduced rework and design changes
• Ability to model proposed changes in a controlled laboratory environment versus out in the
field where operations could be impacted
• Accurate and higher quality designs
• Rapid response

Related projects

Wharf Upgrade
Sulfur Treatment/Relief Reduction (STARR)
Utility Trestle Design
Cooling Water Infrastructure