Industrial Process Simulation Software

Introduction

In the past, various chemical, biological, manufacturing and laboratory processes were carried out in laboratories or factories. In the modern world, the advancement of technology has provided a means. through which these processes can be practically carried out in a risk-free environment. This is achieved by using process simulation software solutions and services. Process simulation is used for design development, analysis and optimization in technical processes including: chemical units, chemical processes, environmental systems, power stations complex production operations, biological processes and similar technical works.

Simulation is sometimes used instead of modeling, but actually is the result of running a model. First, a model is produced. Then it is used for studies and running a simulation.

Process Simulation

Process simulation is a computer representation of a real-world system or process. Its main purpose is to act as a substitute (from a behavioral point of view) for a process. Studying a real process can be very expensive and disruptive. Also, can help to better understand a real system and improve that system.

Main Objectives

1. Increase product yield

2. decrease production time

3. Reduction of possible errors during production and sometimes after production

4. Reduce costs

Why Should Processes be Simulated?

It is clear that in the competitive world of manufacturing and process engineering, the use of  software is widespread and this is an essential tool for simplifying and analyzing complex processes. This tool not only simulates real-world processes, but also performs repetitive calculations with greater speed and efficiency. This saves time, money and increases the safety and chances of success in different stages.

Types of Simulation

1. Static 

This model of process simulation is based on steady state processes. If the variables that define the behavior of the process. If they do not change in time, this process is in a steady state. Process simulation software performs mass and energy balance of a process in constant time to obtain a steady state model of the process. Steady state models require less time and computing power to produce. Hence, they are easier to develop. These processes are common in chemical engineering, mechanical engineering and electrical engineering.

2. Dynamic 

This model is an advanced form of static process simulation. It also explains the dependence of time on the accumulation of mass and energy Dynamic simulations are more powerful than static simulations.

Because they include the description, prediction and control of the impact of time on real processes. The dynamic simulation makes possible the practice and extensibility of the production process. In general, dynamic simulations are more complex and require more calculation time and computing power to run.

The Importance of Simulation in Chemical Engineering

Simulation in chemical engineering, like all other fields, is very practical and useful. Mathematical models can be used as a basis for analyzing, predicting and discovering existing process behaviors in real conditions. In general, simulation helps us a lot to increase information about a specific process.

In fact, chemical engineering tells us how to do a process. Simulation also helps us to have better options to improve the performance of a process. Chemical engineers can use simulation to check all the design options of a process and implement the best option.

Suitable Simulation Software

There are various software for simulating industrial processes in chemical engineering, among the most important of which the following software can be mentioned:

Aspen Plus

ASpen Plus is one of the most famous chemical engineering software. which is used to simulate and design mineral systems, refinery and petrochemical systems. Among the applications of aspen plus software in the industry, we can mention the design, development, improvement of operating conditions and optimization of petrochemical and refinery processes.

The strength of this software compared to other database software is really strong, this software is about solids, liquids and gases. One of the most important advantages of this software is the ability to simulate polymer systems with it.

Aspen Hysys

Hysys is used to simulate refinery and petrochemical systems and electrolytic and solid systems. Hysis software is one of the powerful chemical engineering software.

Due to its powerful processor, Hysys software solves difficult and complex engineering problems in the shortest time and provides the most accurate analysis. The results of the simulation of the process by Haysis software are highly accurate according to the assumptions of the software.

These results are comparable to the real results and with correct assumptions, the error becomes negligible. Also, with the help of Hysys software, a chemical process can be modeled and the behavior of the system can be predicted in different operating conditions.

Comsol

Comsol Multiphysics software is a complete simulation suite that can solve the differential equations of nonlinear systems by partial derivatives using the finite element method (FEM) in one, two, and three-dimensional spaces.

This software enables modeling and then simulation with extremely high accuracy. A long time to perform a test, not repeating the test with different conditions, and more importantly, the test may be expensive, which can be greatly reduced with the help of software.

ACM

Aspen Custom Modeler (ACM) software is one of the advanced tools in the field of simulation and modeling of industrial processes. This software is developed by Aspen Technology. This software is specially designed for engineers and professionals of chemical, petrochemical, oil and gas, and other similar industries.

Aspen Plus Dynamics

It is one of the most powerful simulation software. It is necessary to control and accurately simulate the process in dynamic mode (considering changes with time). To simulate the dynamics of the process, the process must first be simulated in a static state (ignoring time changes). This software has the ability to simulate chemical processes in dynamic mode.

Promax

ProMax simulation software is currently one of the most powerful software available for simulating refinery and chemical processes. Among the special features of this software, we can mention its rich material bank and its thermodynamic packages.

ProMax software has a unique feature in the field of thermodynamic equations for sweetening and refinery processes. The special features of this software for gas sweetening processes have made it distinct and unique.

HTRI

One of the important tools in heat transfer are heat exchangers. HTRI software is the best option for simulating heat exchangers, with this software you will have a better view of how heat exchangers work and you can use it to evaluate and design all types of heat exchangers.

PRO II

This software has a really good ability to design refinery distillation towers and also to simulate distillation towers. In addition to the mentioned cases, it can also simulate non-polymeric refinery and petrochemical systems.

This software is useful and works in many chemical industries by accurately calculating the amount of heat and materials in a project, as well as providing different thermodynamic models.

Aspen Adsim

Among the important and practical software in chemical engineering, chemical and petrochemical industries. This software belongs to ASPEN Tech company. The features of this software are modeling and simulation of processes, accurate understanding of the process and analysis of process behavior in dynamic mode, performing calculation operations and energy and mass balances accurately and many other applications.

ASPEN-EDR

This software deals with the design and construction, simulation and evaluation of heat exchangers in the form of different modules (shell and tube exchangers, plate exchangers, air cooler, etc.). The use of heat exchangers is widely found in various refinery, chemical and petrochemical industries, and in fact, heat exchangers are very key and important equipment for the heart of the process, i.e. reactors, distillation towers, etc.

ASPEN Energy Analyzer

Aspen Pinch software is a tool that helps design engineers to optimize the balance of total value and energy to reduce costs. Also, this software is used to minimize design costs in chemical units, refineries and power plants. Today, due to the ever-increasing reduction of energy and the high cost of process equipment in refineries and power plants, pinch technology is a suitable tool for optimizing industrial units.

Aspen flare net

This software allows process engineers to accurately simulate the performance of their burners and predict various parameters such as flame temperature, exhaust gas velocity, pollutant emissions, etc. It also helps engineers improve the performance of their processes by providing advanced and accurate capabilities.

Petro-SIM

Petro-SIM software is a product that is used to design and simulate refinery processes such as: upstream industries, intermediate industries and downstream industries. Although it can be used for other processes as well, its main feature and distinction is the complete sets included in this software for simulating refinery processes such as Alkylation, Reforming, Visbreaking, etc.

ANSYS Fluent

Ansys Fluent is the world’s most powerful software in the field of computational fluid dynamics (CFD) analysis. This software provides the user with the possibility to use it to analyze the desired models and increase their efficiency.

The ability of Fluent software to accurately solve the widest and most complex problems has made it the best fluid simulation software in the market. From simulating air flow on an electric vehicle to combustion in a gas turbine, this software is done.

Applications of Simulation

In today world, simulation is widely used in industry. some of which are as follows:

Types of production lines (such as automobile manufacturing, steel production, etc.)

In factories, transportation systems

Airports and airlines

Supply Chain Management (SCM) and Distribution Systems (DS)

Petrochemical, oil and gas industries

Conclusion

In general, in today’s life, simulation is one of the necessary tools to check every scientific and industrial project before it starts. In fact, it is clear that in the competitive world of manufacturing and process engineering, the use of simulation software is widespread and it is an essential tool for simplifying and analyzing complex processes.

As mentioned, in chemical engineering, slope making is very practical and necessary, and carrying out processes without previous simulation is completely meaningless and only wastes time and money. In other words, simulation saves time, money and increases safety.