Process Dynamics Simulation
Process dynamics simulation for startup, shutdown, transients and control
jimmylea helps clients analyse and predict the behaviour of chemical processes over time. Unlike steady-state models, dynamic modelling accounts for changing feed conditions, pressure, temperature and equipment operation. This capability is essential for projects involving start-up, shutdown and transient behaviour, where safety and operability depend on reliable predictions.
Our engineers bring over 50 years of combined experience and advanced degrees in chemical engineering to every project. Using specialised software, we model plant behaviour, optimise control strategies and evaluate safety-critical events. Whether assessing system response, troubleshooting control logic or evaluating energy usage under varying loads, we deliver accurate and practical engineering insight.
What is process dynamics simulation?
Process dynamics simulation uses computational models to predict how chemical processes respond to changing operating conditions. It combines thermodynamics, transport phenomena, reaction kinetics and mass and energy balances to evaluate transient operating scenarios, including feed fluctuations, equipment failures and process upsets.
Beyond control optimisation, these models are used to evaluate equipment such as heat exchangers, reactors and distillation columns under changing operating conditions. Engineers use the results to refine control parameters, identify operational risks and improve system resilience. The models also provide a virtual training environment without the cost or risk of physical testing.
Why Engage Us to Conduct Process Dynamics Simulation ?
Dynamic modelling supports better design, safer operations and more informed engineering decisions. It enables faster troubleshooting, reduces downtime and helps identify operational risks before implementation. Virtual testing of control strategies improves plant readiness under a wide range of operating scenarios.
By improving efficiency and stability, these engineering tools help reduce energy costs, improve product quality and support environmental compliance. For projects involving scale-up, process safety or advanced control design, jimmylea delivers practical, cost-effective engineering solutions that improve operational performance.
Process dynamics simulation is widely used throughout the chemical and process industries to improve safety, operability and control system performance. Industry guidance from the Institution of Chemical Engineers (IChemE) recognises the importance of dynamic modelling for process safety, operator training and control system design.
Thermal Analysis of Process Cooling Water (PCW) Systems
At jimmylea, we help businesses ensure their cooling systems work reliably under real-world conditions. Using advanced process dynamics simulation, we analyse how process cooling water (PCW) networks perform when equipment loads increase.
In one recent project, our thermal analysis revealed that the site’s existing heat exchanger no longer had enough capacity to handle the expanded load. This shortfall led to higher water return temperatures and uneven cooling across equipment.
By modelling the system in detail, we identified the cause of the performance gap and recommended upgrades to restore reliable operation. Our work gave the client a clear plan for maintaining stable production and avoiding costly downtime.
Process Dynamics Simulation of Methanol Transesterification
At jimmylea, we use advanced process dynamics simulation to model and optimise chemical reaction systems. A key example is the transesterification of methanol, a widely used process in biodiesel and specialty chemical production.
Our simulations capture the full reaction dynamics, accounting for kinetics, heat transfer, and phase interactions between methanol, triglycerides, and catalysts. By integrating these variables into a dynamic model, we can predict conversion rates, product yields, and the thermal behaviour of the reactor under different operating scenarios.
This approach provides engineers and operators with a detailed understanding of how the process responds to changes in feed composition, temperature, and mixing conditions. It also allows us to identify the conditions that maximise conversion efficiency while minimising energy demand and side-product formation.
Through this work, jimmylea helps clients design safer, more efficient, and more reliable chemical processes, supporting innovation in renewable fuels and industrial chemistry.
Process Dynamics Simulation of Turbine Power Recovery
This process dynamics simulation illustrates a turbine system where material and energy balances are tracked across the process. The material streams are characterised by vapour fraction, temperature, pressure, mass flow, liquid volume flow, heat flow, actual gas flow, and standard gas flow, allowing a detailed assessment of thermodynamic and flow conditions at each stage. The energy streams report heat flow across exchangers and pump power demand, enabling precise evaluation of power recovery and overall system efficiency.
As part of a larger process development project, we delivered a dynamic simulation that integrates these variables to quantify turbine performance and optimise energy recovery within the system.
Process System Simulation
As part of a hydrogen production study, we delivered process system simulation of a Pressure Swing Adsorption (PSA) unit, a widely used technology for gas separation and hydrogen purification. The simulation modelled the adsorption and desorption cycles, demonstrating how impurities such as nitrogen and carbon dioxide are selectively captured on adsorbent beds under varying pressures, while hydrogen is recovered as a high-purity product stream.
The work captured each step of the PSA cycle, adsorption, pressurisation, depressurisation, purification, and hydrogen recovery, and quantified hydrogen yield, purity, and recovery efficiency. This analysis provided a robust basis for evaluating system performance and optimising PSA operation within hydrogen fuel production schemes.
