Case Studies

Challenge

Optimize CO₂ capture efficiency and reduce energy consumption without costly physical testing.

Solution

Developed and calibrated a high-fidelity steady-state digital twin of the absorption column using real plant operational data.

Projected Results

• Significant reduction in specific energy consumption
• Substantial improvement in capture rate compared to baseline performance
• Rapid return on investment expected within months of deployment

Challenge

Understand interactions between absorber, stripper, heat exchangers, and compression to maximize plant-wide efficiency.

Solution

Built a comprehensive steady-state digital twin of the entire CCU process train, validated against 6 months of operational data.

Projected Results

• Notable improvement in overall plant efficiency
• Substantial annual operational savings
• Significant reduction in unplanned downtime

Challenge

Predict transient behavior during startups, shutdowns, and load changes to improve operational safety and stability.

Solution

Developed a dynamic digital twin capable of simulating time-dependent phenomena, calibrated using real plant startup and upset condition data.

Projected Results

• Dramatic reduction in startup time
• Enhanced safety record during commissioning phases
• Substantial increase in operator training effectiveness

Challenge

Coordinate operations across multiple process trains while maintaining product quality and minimizing energy use.

Solution

Implemented a multi-train dynamic digital twin with real-time integration, validated using 12 months of historical plant data across all units.

Projected Results

• Significant energy savings across all production trains
• Notable increase in production capacity
• Major annual reduction in operational costs