Process Simulation in Oil & Energy

Hyper-automation for Refineries, Petrochemical & Chemical Industries

Application of Industrial Internet of Things (IIOT) for process improvements and profit maximization

  • Modeling

    Artificial Neural Network (ANN) Modeling Process Simulation Modeling (Steady State and Dynamic) Mathematical modeling

  • Basic Design (Optimized)

    Development of Process Flow Diagram (PFD) Equipment Sizing

  • Special Studies

    Pressure Excursion / Surge Analysis Temperature Transient Analysis Control Strategies Sensitivity study

Modeling Services include:

Artificial Neural Network (ANN) modeling
– Fault Detection With Shell & Tube Heat Exchanger
– Desalter Unit Of Refinery
– Carbonation Tower Of Soda Ash Plant

Integrated Dynamic Process Simulation Modeling
– Liquified Natural Gas (LNG) Boil-Off Gas Re-Condensation
– Liquified Natural Gas (LNG) Re-Gasification Facility

Mathematical Modeling
– Crude Distillation Unit (CDU)
– Gas Sweetening Unit (GSU)
– Liquified Natural Gas (LNG) Unloading
– Membrane Separation Process
– Coal Fired Thermal Power Plant

Integrated Steady State Process Simulation Modeling
– Vacuum Distillation Unit And Saturated Gas Unit (CDU, VDU And SGU)
– Continuous Catalytic Reformer (CCR)
– Fluidized Catalytic Cracker (FCC)
– Diesel Hydro De-Sulfurization (DHDS)
– Coker & Gas Plant Light Cycle Oil (LCO)
– Hydrocracker Hydrogen Generation Unit (HGU)
– Sulphur Recovery Unit (SRU)
– Sour Water Stripping System (SWS)
– Ethylene Plant (Cracker) With Enhanced Binary Refrigeration (EBR)
– Butadiene Extraction Unit (BEU)
– Ammonia Plant Including Reforming Exchanger System (RES) And Purifier Feed Effluent Exchanger
– Carbon Monoxide Plant
– Cryogenic Air Separation Plant
– Iso Propyl Alcohol (IPA) Plant
– Iso-Butyl Acetate / N-Butyl Acetate – Acetic Acid – Water Distillation Column
– Iso-Butyl Acetate, Acetic Acid, Xylene, Water Distillation Column
– Membrane Separation Process To Separate Carbon Monoxide & Hydrogen From Their Mixture

Use Cases and Success Stories:

Harmony Organics Pvt. Ltd.
Designed, developed, and implemented data driven models using AI/ML (ANN, Hybrid Modeling)
• Styrene Chlorohydrin Rectors
• Hydrogenation Reactors
• Optimization of Phenyl Ethyl Alcohol (PEA) Plant
• Improved conversion rate by recommending process for manufacturing of Styrene Chlorohydrin that is completely safe for human life
• Improved solvent for Hydrogenation of Styrene oxide to increase throughput / conversion

Equinox Software and Services Pvt. Ltd.
Designed, Developed, and tested Data Science Models (ANN, Hybrid)
• Fault Detection in Shell & Tube Heat Exchanger
• Desalter Unit of Refinery (Bharat Petroleum Corporation Limited (BPCL), Mahul, India)
• Carbonation Tower (GHCL, India)
• Designed, Developed, and tested process simulation and optimization software for Crude Distillation Unit (CDU)
• Designed, Developed and Used Steady state process simulation model using Aspen HYSYS (Refsys)
• Diesel Hydro Desulphurization (DHDS) Reactor and downstream units for Bharat Petroleum Corporation Limited (BPCL) Mumbai Refinery.
• Crude Distillation Unit (CDU), Vacuum Distillation Unit (VDU) and Naphtha Stabilizer along with Pre-Heat Train (PHT) for Bharat Petroleum Corporation Limited (BPCL) Mumbai Refinery
• Atmospheric and Vacuum Units (AVU) for Indian Oil Corporation Limited (IOCL) Paradip Refinery
• Fluidized Catalytic Cracker (FCC) downstream of reactor for Indian Oil Corporation Limited (IOCL) Paradip Refinery

Toyo Engineering India Private Limited
Designed, developed, and implemented integrated process simulation models
• Dynamic modeling using Aspen HYSYS
• Mathematical modeling and process simulation study of temperature transient in vapor return line during LNG unloading, used for detailed engineering of GSPC LNG Limited plant in Mundra, Gujarat
• LNG re-gasification facility model using Aspen HYSYS, used for studying pressure excursion in NG send out header during emergency shutdown (for Petronet LNG Limited, Dahej, Gujarat, and GSPC LNG Limited, Mundra, Gujarat)
• Model for Re-condensing of boil-off gas at LNG Re-gasification facility using Aspen HYSYS, used for adequacy check of flare header and Knock Out drum sizes, and checking process control strategies for Hazira LNG Limited (Shell), Hazira, Gujarat
• Steady state modeling using PRO/II
• Iso Propyl Alcohol (IPA) plant - includes three phase azeotropic distillation for Deepak Fertilizers Plant, India
• Ethylene plant (Process: ABB Lummus, Plant: Sidi Kerir Petrochemicals Company, Egypt)
• Enhanced Binary Refrigeration (EBR), (Process: ABB Lummus, Plant: Haldia Petrochemicals Limited)
• Ammonia plant including KBR Reforming Exchanger System (KRES) and Purifier Feed Effluent Exchanger
• Sulphur Recovery unit (SRU) using Aspen HYSYS (SulSim Module) and ProTreat, (Plant: Hindustan Petroleum Corporation Limited (HPCL), Visakh, India)


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