The Challenge

Market demands, technology, and regulations are constantly evolving, and your team's skills must adapt. Without a safe and effective training environment, plant management faces significant risks and missed opportunities.

Our Solution

Production system simulations provide input for the development of valuable solutions. That’s because they are the source of clear insights into complex systems. In the fertilizer industry, we provide high-fidelity technology training simulators (TTS) specifically developed to that end. 

Our process simulator software creates a dynamic environment to analyze computer models while they are running, harnessing world-class thermodynamics know-how. It has already proved its worth at various (urea, ammonia and nitric acid) fertilizer plants and in other chemical processes, such as hydrogen peroxide to propylene oxide (HPPO).

How does it work?

The Process Simulator runs various urea melt and granulation operating modes, including:

•  Normal operation
•  Cold start-up
•  Recovery mode
•  Blocking-in and restarting
•  Blocking-in and draining
•  Switching pumps
•  Recovering from pre-defined scenarios

The simulator is fully equipped, including control valves, interlocking system, clearly marked (field) manual valves, sample points, trending system. 

The process simulator can be configured to precisely mirror your plant process equipment, control and interlocking system, with corresponding DCS setup. 

Why use a process simulator?

•  Unlimited Opportunities for Experimenting and Learning:

Our technology training simulators (TTS) are real-time dynamic process simulators for fertilizer plants. They create a process simulation that behaves like a real plant. Each TTS has the look and feel of a real DCS system, with unlimited opportunities for experimenting and learning. This helps make your plant safer, more cost-effective and improve its technical performance.

•  More dynamic insights:

The simulation software delivers more insights into the technical ins and outs of operational processes. It’s a valuable training tool that enhances the know-how of plant operators, giving them a better understanding of plant dynamics.

•  Maximum risk reduction:

Safety first! By simulating the operation processes in a risk-free environment, plant operators learn how to keep their fertilizer plant running even when unforeseen issues occur. Simulation models can be animated in 2D/3D, allowing concepts and ideas to be more easily verified, communicated and understood. Analysts and engineers gain trust in a model by seeing it in action and can clearly demonstrate findings to management.

•  Lower operating costs: 

Training in standard operating procedures and unforeseen issues brings more efficient plant operations within reach and saves you valuable time and money down the line. Downtime, equipment damage, disruptions, training time and human error are reduced. You also benefit from trouble-free start-ups and faster recovery after disruptions. Your staff are trained to run your plant at maximum capacity while dealing with the boundary conditions, including minimizing steam consumption and ammonia losses, testing new modified operation procedures before implementation, and checking control and interlocking functions.

A Realistic Virtual Plant

Don't let a lack of hands-on experience become a risk to your plant's safety and efficiency. Empower your team with the knowledge and confidence they need to handle any situation.

The Stamicarbon Urea Process Simulator transforms training from a theoretical exercise into practical, ingrained expertise, leading to safer, more efficient, and more profitable plant operation.

Contact us to schedule a demo or discuss a customized training program tailored to your team's needs.