Modelling and Simulation for Process Industry

Modelling and simulation is a present-day way to understand and improve processes to meet the increasing efficiency, safety and environmental demands. Simulation has become an important enabling technology in decision-making, engineering and operation, covering the whole life span of a production system.

VTT has extensive experience (over 25 years of experience) in modelling and simulation for many industries. VTT offers a comprehensive set of tools and expertise for modelling and simulation of process and automation concepts: powerful dynamic simulation with Apros (together with Fortum), conceptual process design with BALAS, process chemistry with ChemSheet, and rotary kiln simulation with KilnSimu. These tools are ideal and useful for a wide variety of applications from steel mills to pulp and paper production, from energy production to biorefineries. Simulation aided engineering, as well as online and predictive simulation models can make you a forerunner in your business.

Benefits of process simulation
Using simulation-based methods to improve manufacturing has significant benefits. The benefits are achieved in terms of cost savings and intangible assets such as a deeper understanding of the process. The payback time of a typical improvement project is shorter than two years - in some cases only a few months. Benefits of applying simulation are:

  • Reduction of capital cost by better design
  • Reduction of time for design, commissioning, and start-up
  • Reduction of pilot plant cost, size, and complexity
  • Improved productivity and efficiency by material and energy optimisation
  • Increased process knowledge and confidence in big decisions
  • Training aid for new personnel
  • Extension of equipment life
  • Improved safety and environmental management

Tools for process simulation
VTT offers a comprehensive set of tools and expertise for modelling and simulation of process and automation concepts:

  • Apros - Powerful dynamic simulation
  • BALAS - Conceptual process design
  • ChemSheet - Process chemistry
  • KilnSimu – Rotary kiln simulator

The use of modelling and simulation ranges through the plant life-cycle from off-line virtual unit operation and process concept design to the testing and setup of controls and binary automation, training simulators and process development. VTT offers modelling and simulation services related to the above mentioned simulation tools, and beyond. The simulation services include modelling and simulation studies for customer applications, unit operation model development, other software development (e.g. interfaces between engineering tools), support, and training. In addition to simulation software and computational engineering expertise, VTT offers experimental facilities to complement demanding simulation studies.

Success stories can be found at: Modelling_and_simulation_brochure_updated_02032015.pdf