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Process and flowsheet simulation

Modelling processes and flowsheets requires dedicated tools as well as a solid understanding of the underlying mechanisms, such as thermodynamics, inorganic chemistry, control instrumentation and equipment behaviour.

Thermodynamic calculations and models

Thermodynamic models are suitable tools to relieve some of the complexity of multi-component processes. Both for exploratory work as for process optimization, they can give a solid estimation of the expected equilibrium, phase compositions, metal yields, produced or required heat, and so on.

InsPyro has a strong background in thermodynamics and metallurgical theory. We are highly flexible and can provide phase diagrams, process models, or materials interaction studies, always keeping the application in mind, and assisting in the interpretation and in implementing the implications.

Flowsheet modelling

Mass and energy balances of connected processes or complex flowsheets are a crucial start for optimization or investment decisions. InsPyro uses specialized tools to find the most realistic balance based on known amounts, compositions, temperatures, and dimensions. The process entails finding missing data, and highlighting suboptimal performance.


These flowsheet models can become a tool for engineers and operators in the plant thanks to the ProOpt framework. In a first phase, InsPyro engineers will provide reports, graphs, and simulation results to study practical raw material mix scenarios, debottlenecking scenarios, or the effects of planned modifications, as required.

Spark software applications and worksheets

We can provide your R&D engineers with a standalone program or an Excel-based worksheet in which they only have to fill out the composition, and the result is calculated with one click. Process engineers will like our ability to provide process models integrated with Excel or with your production environment software. Read more on our software here.



Gas bubble injection in a lead refinery kettle

Computational fluid dynamics

With CFD, the flow and reaction patterns in a reactor can be studied in detail. The technique allows to investigate:

  • Temperature distribution, e.g. in the metal or on a refractory wall
  • Particle behaviour (e.g. flue dusts or fumed metals), including breakage, collision, and coagulation, and the effect on the particle size distribution function
  • Effect of reaction speed and process parameters on the throughput
  • Effect of design changes on operational performance

Read more and find several case studies on our CFD modelling page.

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