Process simulation and scale-up modelling

Thermodynamics first

Most bad simulations are bad because the property package was chosen by habit. Polar systems, electrolytes, supercritical operation and anything involving a solid phase all need deliberate choices, and where the literature is thin we regress against your own lab data rather than trusting a default binary interaction parameter.

What we model

• Steady-state flowsheets with closed recycles — where impurity accumulation shows up
• Distillation, extraction, crystallisation, drying and membrane trains
• Reactor models from your kinetic data, not from a conversion assumption
• Heat integration and pinch analysis
• Dynamic simulation for start-up, upset and control studies where the process warrants it

Sensitivity is the deliverable

The single number a model produces matters far less than how it moves. We run sensitivity across the variables you cannot control precisely — feed composition, ambient temperature, catalyst decay, utility availability — so the design has margin where it needs it and none where it does not.

Tools

Aspen Plus and HYSYS for the main flowsheet, HTRI or Aspen EDR for rated exchanger design, and DWSIM where you want an open model you can keep, run and modify yourself without a licence. Whichever we use, you receive the model file.