Detailed Engineering Solutions

Heat & Mass Balance Preparation

Rigorous heat and mass balance for FEED and detailed engineering

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Technical overview

Heat & Mass
Balance Preparation

Heat and mass balances are the quantitative foundation of every process engineering design — driving equipment sizing, energy integration, utility demand, and emission inventory. An inaccurate or incomplete balance propagates errors through every downstream discipline. Arborion Global delivers rigorous, validated balances using Aspen HYSYS, Aspen Plus, ProMax, and gPROMS across all operating cases, with full property-method validation and documented uncertainty bounds.

Heat & Mass Balance Preparation — Overview
Engineering process

Heat & Mass Balance Preparation workflow

Scope & Data Inputs

Define system boundary, operating cases, feed compositions, product specs, and utility availability limits.

Property Method Selection

Select and validate thermodynamic package against experimental, licensor, or literature data for each service fluid.

Steady-State Simulation Build

Construct and converge the process simulation model across all design, minimum, and maximum throughput cases.

Energy Targeting & Pinch

Run pinch analysis, optimise heat exchanger network, and generate utility loading summary for all cases.

Sensitivity & Turndown Analysis

Vary key process parameters to map the safe operating window, emission inventory, and utility band.

Deliverable Package

Issue stream tables, utility summary, simulation model files, and supporting environmental inventory data.

Heat & Mass Balance Preparation — Scope
Scope of work

Every deliverable — from basis to handover

Complete Heat & Mass Balance Preparation scope — every calculation, drawing, specification, and construction support activity.

Steady-state simulation across design, minimum, maximum, and turndown cases
Property method selection and validation against experimental or licensor data
Heat exchanger network synthesis and pinch analysis
Column, reactor, and separator performance across all operating cases
Utility loading summary: steam, cooling water, fuel gas, refrigeration, electricity
Energy targeting, integration opportunity identification, and retrofit options
Emission inventory generation for permit and environmental assessment
Sensitivity analysis to define safe operating window and parameter interactions
Engineering outcomes

Outcomes of Heat & Mass Balance Preparation

Operating Envelope & Stream Accuracy
  • Defines safe operating envelopes
  • Identifies high-energy streams for hazard analysis
  • Supports relief and vent sizing
  • Hardens HAZOP deviation analysis
Permit & Process Documentation Defence
  • Provides validated data for permit applications
  • Supports environmental inventory submissions
  • Documents design basis for regulator
  • Aligns with industry simulation best practice
Debottlenecking & DCS Optimisation
  • Identifies energy and utility optimisation
  • Strengthens operator process understanding
  • Supports DCS configuration and tuning
  • Improves debottlenecking analysis
Energy & Capital Efficiency
  • Slashes energy and utility consumption
  • Right-sizes equipment for true operating cases
  • Improves capital efficiency
  • Supports retrofit and revamp economics
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