Detailed Engineering Solutions

Process Simulation & Modelling

Steady-state and dynamic simulation for design, troubleshooting, and OTS

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Technical overview

Process Simulation
& Modelling

Process simulation spans a wider brief than steady-state design. Dynamic models validate ESD response times, prove control-loop stability under upset conditions, and power Operator Training Simulators that build competency before first startup. Arborion Global delivers validated steady-state and dynamic models in HYSYS, Aspen Plus, gPROMS, and UniSim — from FEED basis-of-design through post-startup troubleshooting — with full documentation of model assumptions and validation evidence.

Engineering process

Process Simulation & Modelling workflow

Scope & Tool Selection

Define steady-state vs dynamic simulation need; select HYSYS, Aspen Plus, gPROMS, UniSim, or ProMax.

Model Build & Validation

Construct simulation topology; validate against plant data, licensor performance curves, or experimental results.

Steady-State Case Studies

Run design, turndown, and upset cases; document deviations from design intent and resolve reconciliation.

Dynamic Simulation

Build dynamic model for ESD validation, control-loop tuning, startup/shutdown procedure support, or OTS.

Control & ESD Tuning

Tune PID parameters, safety-function response times, and override logic against performance acceptance criteria.

Deliverable Package

Issue validated simulation files, steady-state and dynamic case reports, and OTS scenario library.

Scope of work

Every deliverable — from basis to handover

Complete Process Simulation & Modelling scope — every calculation, drawing, specification, and construction support activity.

Steady-state design simulation across all operating cases and turndown

Property method selection and experimental/licensor data validation

Dynamic simulation for ESD response validation and control-loop tuning

Operator Training Simulator (OTS) build and scenario library development

Distillation column and reactor performance characterisation

Compressor and pump performance curve integration and validation

Heat integration and pinch analysis to target energy recovery

Simulation-supported HAZOP deviation analysis and consequence bounds

Engineering outcomes

Outcomes of Process Simulation & Modelling

Operating Envelope & Transient Safety

Validates ESD response under transient conditions
Supports startup and shutdown procedure design
Strengthens HAZOP deviation analysis
Reduces commissioning risk

Process Data & Permit Defence

Maintains alignment with industry best practice
Documents design basis for regulator
Supports permit and consent applications
Withstands client and licensor audit

Control Strategy & Optimisation Quality

Elevates DCS tuning and response
Supports operator training and competency
Identifies debottlenecking opportunities
Builds out revamp planning

Energy & Yield Improvement Value

Reduces commissioning time and cost
Optimises energy and utility consumption
Avoids costly design rework
Supports OTS-led operator competency

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