Dynamic simulation in enhancing industrial processes

Dynamic simulation can be efficiently applied to various industries. This article from AFRY's industry experts explains what dynamic simulation is, how it can be used, and the resources needed to implement it effectively.

Dynamic simulation provides a higher level of process analysis, allowing responses to difficult questions that may be complex or impossible to address with traditional steady-state simulation. The development in computing sciences and the improvement of computer processor speeds have overcome previous limitations, enabling the incorporation of a high level of detail in modeling and the development of large-scale models.

Dynamic simulation is a technique used to model complex systems in industries such as oil and gas, green industry, plastics, food, and nuclear. By simulating these systems on a virtual machine, engineers can test and predict how different variables and conditions might affect the system before making operational or design decisions. This technology is instrumental in process design, safety analysis, and control system optimisation, making it a valuable tool for industries facing increasing complexity and the need for efficiency. This approach offers numerous benefits, including startup and shutdown optimisation, process design optimisation, safety valve calculations, emergency depressurisation scenarios, and control topology testing.

One notable application of dynamic simulation is in startup and shutdown optimisation. Engineers can test startup procedures on a dynamic simulation before implementing them in the actual plant, allowing for a more efficient and safe process. This preemptive testing helps identify potential issues and refine procedures, ensuring a smoother and more reliable startup and shutdown process.

Dynamic simulation also plays a crucial role in process design optimisation. By evaluating the performance of equipment like separators and distillation columns under varying conditions, engineers can identify the most efficient and effective designs. This optimisation leads to improved performance, reduced energy consumption, and lower operational costs.

Safety Valve Calculations

Safety valve calculations benefit significantly from dynamic simulation. Traditional methods often rely on conservative estimates, which can result in oversized valves and increased costs. Dynamic simulation provides more realistic valve sizes by accurately modeling the system's behavior under various scenarios. This precision helps industrial operators to save money while ensuring safety and compliance with industry standards.

Emergency Depressurisation Scenarios

Emergency depressurisation scenarios, such as fire or equipment failure, can be simulated using dynamic simulation. This capability allows engineers to design effective emergency shutdown systems that protect both personnel and equipment. By simulating various emergency scenarios, engineers can develop robust and reliable systems that respond appropriately to different types of incidents.

Control Topology Testing

Dynamic simulation aids in testing and tuning control topologies, ensuring that proposed control systems can effectively manage the process parameters. By simulating the control system's behavior under different conditions, engineers can identify potential issues and make necessary adjustments before implementation. This testing helps optimise control strategies, leading to improved process stability and performance.

Transformative Applications Across Industries

Dynamic simulation has proven valuable across a diverse array of industries, including oil and gas, renewable fuels, food processing, pharmaceuticals, and emerging green technologies. AFRY's experienced team applies this tool to drive efficiency, safety, and innovation for clients worldwide. Here’s how it works in key sectors:

• Oil & Gas: AFRY’s simulations help optimise plant efficiency by minimising flaring and reducing carbon footprints, enabling clients to meet stringent environmental standards.
• Renewable Diesel and Sustainable Aviation Fuel: With a focus on sustainability, dynamic simulation supports biorefineries in optimising processes for renewable fuel production, aligning with global decarbonisation goals.
• E-Fuels: AFRY’s dynamic simulation expertise is essential in the production of e-fuels, including E-SAF, E-Methanol, E-Methane, and E-Ammonia, where precise control systems are critical for achieving high efficiency and sustainability. Using advanced modeling, AFRY enables clients to verify and optimise control topologies, ensuring robust, resource-efficient performance across diverse e-fuel production processes. This approach proactively addresses operational challenges, enhancing system reliability and reinforcing AFRY’s commitment to pioneering innovative, sustainable solutions in renewable energy.
• Food and Pharmaceutical Industries: Dynamic simulation adds a layer of safety and precision, addressing specific challenges like reactor implosion prevention and control strategy optimisation. This ensures process stability and regulatory compliance in highly sensitive environments.

Real-World Success Stories

The impact of AFRY's dynamic simulation services is evident through real-world applications. Here are a few success stories:

• Reactor Safety in Food Processing: AFRY identified a potential implosion risk in a client’s reactor system during cleaning procedures. By simulating the scenario, our team pinpointed pressure imbalances that could lead to failure. Based on our findings, the client implemented preventive measures, avoiding costly repairs and downtime.
• Marine LNG Fuel System Optimisation: Our team applied dynamic simulation to marine LNG systems, optimising fuel flow and pressure management. This project helped the client achieve stable and efficient operations under varying marine conditions.
• Pipeline Pressure analysis: AFRY’s dynamic simulation enhanced compressor efficiency and enabled accurate pressure analysis for pipeline operations. This work ensured reliable, safe, and cost-effective processes, meeting both regulatory and client standards.
• Carbon Capture and Power Plant Enhancement: In carbon capture projects, dynamic simulation enabled higher capture rates and lower energy consumption, advancing clients’ environmental objectives. Similarly, power plant simulations led to optimised designs that reduce emissions and improve performance

Sustainability and Innovation

Dynamic simulation is not only about optimising processes and reducing costs; it also plays a vital role in sustainability and innovation. By leveraging this technology, engineers can create more sustainable solutions that minimise environmental impact. For example, dynamic simulation can be used to optimise processes for producing sustainable aviation fuel and renewable diesel, contributing to the reduction of greenhouse gas emissions.

In conclusion, dynamic simulation is a powerful tool that enhances the efficiency and innovation of industrial processes. By leveraging this technology, engineers can create more sustainable solutions, optimise operations, and reduce costs, ultimately contributing to a healthier planet for future generations.