Modelling services for energy and process industry

Today’s industrial processes are becoming increasingly complex as new technologies are rolled out, old assets are used in new ways and new sectors are interconnected.

Present-day processes involve complicated geometry, chemical reactions, mass and heat transfer, multiphase flows, and complex rheology. All the while new, more efficient processes are needed to meet the growing demands in the energy and process industry to reduce emissions and utilise raw materials more economically.

Advanced modelling and simulation play a leading role in tackling these challenges. These tools allow us to get the most out of our systems by providing valuable insight before taking any actions or making major decisions. With modelling and simulation, we can, for instance, prototype different aspects of a system, test scenarios and optimise processes quickly and reliably. Technologies such as digital twins help us replicate behaviour and monitor and investigate processes.

As a result, you can gain new insights, eliminate errors, come up with novel solutions and build new services as well as achieve significant cost savings.

At VTT, we offer a unique combination of modelling, testing and piloting, all under one roof. Thanks to our multidisciplinary team of experts, we can also bring in expertise from hydrogen-related technologies, grid development and technology, district heating and much more. 

Our rich history in developing computational fluid dynamics (CFD) dates to the 1980s when we began developing our own models for different processes and applications. We have focused our development efforts especially on multiphase flow simulations. 

When it comes to source-code level expertise, VTT houses some of the bright minds behind industry-leading software such as Apros. 

We offer many simulation tools and services that help solve a variety of problems. The tools can be combined, allowing for co-simulating systems and processes. We develop models from lab scale to pilot scale and ultimately to industrial scale.

Our modelling services allow you to, for example: 

• Design processes to meet your goals 
• Improve the production process 
• Assist process operations 
• Design electrification of processes in a volatile energy grid 
• Design Carbon Capture and Usage processes 
• Test new fuels and their effects on boilers 
• Confirm the correct components and dimensions of equipment
• Simulate accidents in a nuclear reactor

All this with no risk to safety or the environment, or loss of production time.

Apros®

Apros is a dynamic analysis and simulation software product developed by VTT and Fortum. It is used to ensure the safety and efficiency of large-scale systems such as thermal and nuclear power plants or district heating and cooling networks. The bigger and more complex the system is, the more value Apros provides. 

In addition to a wide variety of easy-to-use process component unit models, Apros has comprehensive libraries for modelling automation and electrical systems, all in interconnection. The software is best suited to model processes with e.g. water and steam, molten salt, oils and gases. 

With Apros, you can:

• Reduce risks and conform with safety regulation with a safety analysis 
• Check controls and dimensioning well in advance with engineering support 
• Shorten commissioning time with automation testing 
• Transfer knowledge with operator training. 

Apros is a registered trademark of VTT and Fortum.

Aspen

Aspen is a steady-state simulation software for large-scale systems and processes. The established, industrial-standard modelling tool is particularly well-suited for modelling chemical reactions and carbon capture as well as distillation, conversion, and other complex processes. The captured data can be used for techno-economic or life-cycle analyses, for instance.

Computational fluid dynamics (CFD)

With CFD, we can model complex individual structures such as reactors in 3D. CFD can be used to design, optimise, trouble-shoot and redesign equipment.

OpenFOAM

OpenFOAM is a free, open source CFD software used to solve anything from complex single-phase, multiphase and reacting fluid flows. OpenFOAM enables massive parallel computing with up to thousands of processors operating concurrently. It’s the perfect R&D tool for the energy and process industry’s equipment and processes. 

VTT is an active collaborator of the OpenFOAM Foundation, and we work closely with the lead developers of the software.

Ansys Fluent 

Ansys Fluent is the industry-leading fluid simulation software that allows you to generate accurate and reliable fluid simulation results. With Ansys Fluent, we can model a large variety of industrial single- and multiphase flows. 

VTT has developed numerous submodels to Ansys Fluent and combined CFD simulations with thermodynamic equilibrium software or with Apros code.

Related projects, ecosystems:

• Apros

Related project cases:

• Apros