Process Design & Modeling
Design & Modeling Consulting
At Ghost Solutions, we specialize in advanced process modeling to help our clients unlock greater efficiency and performance in their operations. Using industry-leading tools like OLI and METSIM, we’re able to simulate complex chemical systems and full-process flows with precision.
OLI: Hydrometallurgy, aqueous and electrolyte chemistry, providing insight into:
Reaction dynamics
Scaling and corrosion
Asset longevity
METSIM: Analysis for chemical and metallurgical processes:
Mass and energy balance modeling
Analyze raw input to product output.
A high-fidelity process model ensures equipment is sized correctly and utilities are balanced before startup.
Our models reduce risk during design and prevent costly rework during commissioning.
What We Deliver
PCT-01 → PCT-05 Modeling Tiers Including:
Mass and energy balances
Block flow and process flow diagrams (BFDs & PFDs)
Thermodynamic and reaction modeling for key chemical and phase interactions
Equipment sizing and specification to validate process capacity and design basis
Utility and heat integration analysis for efficient steam, power, and water usage
Recycle and control loop closure to ensure realistic steady-state and operating conditions
Economic evaluation — CAPEX, OPEX, and ROI metrics tied to model results
Dynamic simulations of start-up, shutdown, and transient behavior for operations and training
Integration with PI data for real-time reconciliation, performance monitoring, and digital twin functionality
Validated process documentation — design basis reports, P&IDs, and simulation files ready for scale-up or handover
Clarity Before Commitment
Validate mass & energy balance
Optimized design parameters
Process flexibility
Right sized equipment
Fewer change orders
Improved safety and compliance
Predictive troubleshooting
Faster startups
Informed economics