Simulation in process engineering: increasing efficiency and reducing costs
- dsarikamis
- 23 hours ago
- 4 min read
Why simulation is the key to process understanding and optimisation?
Process engineering is all about efficiency and cost-effectiveness. But what can be done if processes do not run optimally, energy is lost or the desired quality is not achieved in the process? The solutions is a simulation.
Imagine you could digitally map your entire process - before the first plant is built or the first test run is carried out. A simulation makes exactly that possible: it shows where bottlenecks occur, how flows are organised and which adjustments have the greatest effect. In this way, problems are recognised even before the prototype phase. But that's not all: simulation also helps to analyse the situation when problems arise with existing systems and opens up new opportunities for innovation that would be difficult to implement using conventional methods.
But what exactly is a simulation? And how can it help your company move forward?
What is simulation?
“Simulation” means mapping real processes virtually in order to analyse and improve them. Instead of laboriously finding out what works through trial and error, simulation can be used to test different scenarios quickly and cost-effectively. There are three important simulation methods in process engineering:
CFD (Computational Fluid Dynamics): How is heat distributed in a heat exchanger? Where does turbulence occur in a pipe? CFD shows how solid particles, liquids and gases flow and helps to optimise designs for maximum efficiency.
FEM (Finite Element Method): When does a component give way under load? Where does material fatigue occur? FEM calculates stresses, deformations and stability in order to recognise weak points at an early stage.
DEM (Discrete Element Method): How do bulk materials behave in silos? Why does a powder pipe clog? DEM simulates the movement of individual particles in order to optimise flow properties. This method is essential for the simulation of bulk solids and granular media.
A major advantage lies in the combination of these methods. For complex problems, the combinations yields a comprehensive understanding - just as cross-ING develops innovative solutions through interdisciplinary collaboration. For example, CFD and DEM are combined for a fluidised bed reactor in order to map both the flow and the behaviour of the particles.
The landscape of simulation tools is very broad. Problems can differ greatly in terms of complexity, so the choice of tools is an essential factor in achieving results-orientated and cost-efficient simulation. Here, too, cross-ING helps with its expertise and network to first understand the physics, chemistry and biology and complexity of the problem and then identify the appropriate tools.
Why should you use simulations?
The biggest advantages at a glance:
Cost savings & less prototyping: Simulations replace many physical prototypes and expensive test series.
Fast design iterations & optimisations: Virtual prototypes allow for quick adjustments and optimised designs in the shortest possible time.
Better process understanding: Bottlenecks and potential for improvement become visible before they become a problem in the process design. For existing systems, a simulation helps to identify the causes of faults and inefficient processes and to develop targeted improvements.
Sustainability & energy efficiency: Simulation helps to recognise energy losses and make processes more resource-efficient, which contributes to a reduction in CO₂ emissions and more sustainable production.
Simulation @ cross-ING - Your partner for solution-orientated analysis
At cross-ING, we use state-of-the-art simulation techniques to make processes more efficient and economical or to identify problems. Our experts develop customised simulation solutions that are precisely tailored to your requirements. If required, we work with the existing simulation software.
Our simulation services:
Modelling and optimisation of processes for better scalability and efficiency.
Holistic simulation creation: Consideration of all relevant physical effects for precise modelling of the process.
Parameter determination: Definition and experimental validation of the required input variables to ensure realistic simulation results.
Energy analysis & excess heat utilisation: Simulation-based analysis to identify potential energy savings and recovery. Optimisation of waste heat utilisation through targeted technology selection.
Process monitoring & maintenance strategy: Development of digital twins for real-time monitoring of processes. Simulation to identify critical process parameters and predictive maintenance (LINK CC Artificial Intelligence - Predictive Maintenance?).
Conclusion: Simulation as a success factor for process engineering
Simulation is far more than just an analysis method - it is a driver of innovation and a problem solver. Companies that make targeted use of simulation not only save costs and time, but also open up completely new possibilities for more efficient, more sustainable and more powerful processes.
Would you like to take your processes to the next level? Contact us - we will show you how simulation can take your company can make it happen!
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