Process Simulation & Modeling

Process Simulation and Mathematical Modeling Services are among our core technical consulting and design offerings. Ingenero is a leader in simulation and modeling for the energy (upstream and downstream) and petrochemical industries. Our modeling and simulation services maximize throughout, efficiency, and yield for clients throughout the world.

Images Ingenero’s Process Simulation - Steady State and Dynamic

Ingenero delivers robust simulation models that are extensively used by clientele as predictive indicators to enhance critical decision making and greatly contribute to de-bottlenecking. We provide both rigorous thermodynamic models, statistical and empirical models, depending on the process. We use simulation models to provide services including troubleshooting, corrosion studies using ionic modeling, thermal pinch analysis, pressure relief and flare systems rating and design, dynamic simulation, customized reactor modeling, Operator Training Simulators (OTS) and process simulation software testing.

Training is a component of many of Ingenero's offerings. With dynamic simulation, for instance, we conduct offline training of board operators and field operators to produce long-term plant performance improvements. Dynamic simulation is also utilized for the development and tuning of APC control systems.

Ingenero is also actively engaged in providing training courses on Process Modeling and Simulation software like ASPEN, HYSYS, PRO II etc. at our facility and at customers place on their authorized license. In today’s competitive environment, we understand there is a constant need to upgrade and apply advance technologies in process engineering. Ingenero provides platform for chemical engineering by exposing them to new generation simulation tools which will give them competitive professional edge.

Training on HYSYS Technology will consist of topics as follows:

  • Basic simulation concepts.
  • Fundamentals on thermodynamics & selection criteria.
  • What-if analysis to improve plant capacity.
  • Separation systems in process engineering application.
  • Batch distillation and reaction simulation.
  • Basic concept of handling of refinery systems.
  • Plant connectivity with steady state simulator.
  • Guidelines on practical problems in process industries.

Courses are available for Three & Five days on continuous and week end basis. Course fees and details will be provided on request.

Images Linear and Non-Linear Programming

Ingenero helps clients optimize inventory, production, blending, and supply chain issues to maximize profits. Planning, scheduling and other operations are mathematically modeled per client constraints to maximize profits.

Images Heat Exchangers

Ingenero provides design and rating services for shell and tube exchangers, as well as specialty designs (e.g. twisted tube etc.). We can also monitor heat exchangers to optimize ongoing performance in addition to setting cleaning schedules.

Images Furnaces

Our furnace modeling services have consistently maximized productivity and minimized downtime for clients. In a recent project, we were tasked with determining the maximum capacity of a cracking furnace for olefins production and found that the furnace could operate at 118% of the current throughput, all while meeting the capacity constraints of the associated equipment. We model furnaces using empirical and specialized furnace software models. This includes furnace modeling for refinery units and crackers, as well as detailed thermal and hydraulic analysis.

1. Oil & Gas/Petroleum Refining

  • Sour gas treatment.
  • Gas Plant/LPG plant.
  • CDU/VDU modeling.
  • Dynamic modeling of FCC column.
  • Liquid-liquid extraction
  • Integrated model of pre heat train, pre-flash and atm. Column.

2. Chemicals & Petrochemicals

  • Acetic acid recovery system
  • Sections of ethylene plant
  • Alcohol drying using benzene/cyclohexane
  • Methanol plant
  • Phenol plant

3. Fertilizers

  • Steady state model of the ammonia plant
  • CO2 absorber column design
  • Urea hydrolyser simulation