For the ever-evolving world of industrial processes and engineering, the importance of accurate and efficient simulations cannot be overstated. And, with the increasingly complex nature of interconnected industries, the need for reliable and versatile simulation tools has never been more critical. Modern advanced software empowers engineers to explore, analyze, and optimize complex processes across diverse disciplines, seamlessly bridging the gap between chemical, mechanical, electrical, and other engineering domains. You agree that they open the door to boundless possibilities, empowering engineers to model, analyze, and optimize various systems with unparalleled accuracy and efficiency. One such company that is making significant strides in the process modeling and simulation software industry is AspenTech Software. They are today synonymous with innovation, precision, and reliability.
With this blog, we’ll explore the benefits of process simulation & modeling software in multidisciplinary engineering & how Rishabh Engineering is leveraging AspenTech software tools for modeling, optimization, and design.
So, let’s get started!
Benefits of Process Simulation Modeling Software
Process simulation software acts as a visual aid, enabling users to view entire plants or facilities, even in cases where physical visits are impractical.
Increased collaboration is facilitated through digital representation, as simulations can be easily shared across the organization, allowing for remote work and real-time collaboration.
The software enables the analysis of assets without making physical changes, making it invaluable for refinery optimization, value chain optimization, and production optimization.
It empowers companies to maximize margins, reduce asset failure, and achieve environmental compliance by testing process adjustments directly within the simulation software.
Real-life examples, like the Baytown Refinery in Texas, demonstrate the software’s ability to provide an intuitive sense of complex processes in industrial settings.
Production optimization specialists can make recommendations based on Remote Monitoring & Operational Optimization using “real-time data” and the process simulation software to demonstrate proposed changes.
Companies can explore various options within the simulation to find the best parameters that align with their goals and objectives.
Aspen Technology, Inc is a prominent industrial software partner for Rishabh Engineering. They offer remarkable solutions that cater to intricate environments, where optimizing asset design, operation, and maintenance lifecycle plays a pivotal role. Further, Aspen Hysys and Aspen Plus are two highly sought-after software solutions in process flow simulation utilized by our designers & engineers. Renowned for their manufacturing simulation capabilities, these tools present engineers with many advantages, enabling them to streamline the design process, optimize operations, and elevate overall efficiency to new heights.
How Does Our Team Utilize Aspentech Software?
As an award-winning multi-discipline engineering services company, we cater to various industries, including oil and gas, chemical, petrochemical, and power. We provide engineering & design solutions using process simulation software tools for process industries, including modeling, optimization, and design. Here are some common ways how we utilize Aspen Hysys and Aspen Plus for manufacturing process simulation:
Process Simulation Using Aspen Hysys & Aspen Plus: It helps our engineers to create a digital representation of a chemical or industrial process. They input process data, such as feed composition, operating conditions, and equipment specifications, to analyze and optimize the process performance.
Process Optimization: It allows our engineers to optimize process parameters to achieve specific objectives, such as maximizing production, minimizing energy consumption, or reducing emissions.
Process Design: Enables our engineers to design or modify new processes by creating efficient & cost-effective designs by simulating different scenarios and configurations.
Feasibility Studies: We conduct feasibility studies for new projects or process modifications by assessing a project’s technical & economic viability before actual implementation.
Equipment Sizing and Selection: Our engineering team uses simulation tools to determine the appropriate sizing & selection of equipment like heat exchangers, distillation columns, and reactors, including line hydraulics by performing complex loop hydraulics, etc.
Heat and Material Balance: Both these tools help us to perform heat & material balance calculations to understand the energy requirements and material flow in a process.
Safety Analysis: Few of our teams utilize these tools for safety studies, including hazard analysis, relief valve sizing, and emergency scenarios simulations.
Use Case: Adequacy Check For Pressure Safety Values (PSV)
One of our customers was facing the complexity of checking the adequacy of the existing PSVs after considering various scenarios.
Data Points For Natural Gas Project
Data Points For HydroCarbons Project
Based on the PSV sizing summary report, the following recommendations were presented to client;
To select a smaller orifice size since the relieving capacity is less than 30% of the rated valve capacity
Defining stream composition range to get the minimum amount of aqueous phase from the bottom of the separator to accommodate existing PSV size
Here are a few simulation snapshots captured using AspenTech products.
Scenario 1: Natural Gas Project
i) Piping Operation Simulation for Pipeline Cleaning Operation
ii) Line Size Optimization
Scenario 2: HydroCarbons Project
i) Hydrogen Compression
It’s important to note that the specific applications and utilization of Aspen HYSYS and Aspen Plus by Rishabh Engineering may vary depending on the project specifications.
Why Use AspenTech Software for Process Simulation Modeling?
Precise Process Simulation: Both these software help with detailed process simulations, offering engineers a powerful platform to model and analyze diverse chemical processes. Engineers can predict performance, identify potential bottlenecks, and optimize designs before real-world implementation. This capability significantly mitigates risks associated with process design and empowers engineers to make well-informed decisions.
Extensive Component Libraries: Their vast component libraries encompass an extensive array of pre-built models and data for various chemical compounds. They contain thermodynamic data, physical properties, and process models for different substances, accurately representing complex mixtures and chemical reactions. It saves valuable time and effort for engineers, who can conveniently select desired components from the library and integrate them into their process models, streamlining the design phase.
Robust Optimization Capabilities: Efficiency is paramount in process design, and both Aspen Hysys and Aspen Plus enable engineers to define optimization objectives such as maximizing product yield, minimizing energy consumption, or reducing waste generation. It allows engineers to find cost-effective & sustainable solutions while meeting process requirements and regulatory standards.
Seamless Integration with Complementary Tools: Both these tools offer interoperability for engineers to harness the strengths of different software packages & create comprehensive workflows for process design.
New sustainability modules such as Green Hydrogen synthesis and Green Ammonia synthesis are an addition too.
In conclusion, AspenTech Software is crucial in optimizing industrial problems by offering improved efficiency, sustainability practices, a user-friendly interface, and enhanced collaboration among professionals. Its advanced capabilities make it an indispensable tool for industries seeking to maximize operational performance while minimizing environmental impact. Aspen Hysys and Aspen Plus software offers numerous advantages in the chemical industry’s process design field. Their accurate process simulation capabilities, extensive component libraries, robust optimization features, and seamless integration with other engineering tools make them indispensable for engineers. While Aspen Hysys focuses on steady-state simulations and conceptual design, you can conduct process modeling using Aspen Plus. Despite their complexities and high learning curve, these software solutions provide valuable insights and cost-effective solutions for process design. Other notable software options are also available for process design, each with unique features and advantages. By harnessing the power of these software solutions, our engineers can optimize processes, reduce costs, ensure regulatory compliance, and contribute to sustainable manufacturing practices.
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