Designed, Optimised, Delivered About Us Our Services Chemical plant Optimise your Plant Designed, Optimised, Delivered Optimisation Our Services About Us Applying advanced modelling techniques to help you overcome your most difficult processing challenges, improve efficiency and yields, and optimise your CAPEX, OPEX and energy costs and emissions Power plant Ensure the Safety of your Plant About us Our Services Designed, Optimised, Delivered Process Safety Cost-effective and efficient process safety that adds value to your operations. Designed, Optimised, Delivered About us Our Services Digitisation Digitally Transform your Process Bring your plants design, safety, and process design information up to date. Apply advanced simulation technology to create a digital twin to improve operational efficiency, minimise energy use and emissions, and maximise profitability.

What we do?

Primarily Process Engineering focussed, Flex Process applies a combination of real-world practical engineering experience together with expertise in advanced process simulation tools such as steady-state and dynamic modelling, to solve our client’s difficult problems. We offer a unique range of services including traditional process design and engineering, process safety, training, and simulation and optimisation. All our services are linked by a common theme, the application of advanced simulation tools to provide more accurate and cost-effective solutions to our clients, all in one place. Flex Process acts as an independent, all in one place supplier for these specialist technical services, that together will solve your problems.

Flex Process understands that your priority is getting results. Although our Engineers really enjoy developing challenging simulations, our simulation expertise is just a means to an end; we believe that our clients are looking for practical, cost effective solutions to their problems and this is what our unique combination of services provides.

We work in partnership with our clients as a long-term provider of independent technical and process engineering support usually involving simulations. When we work with new clients, we typically start with small projects which then lead to bigger projects and long-term support. As the relationship develops, we develop models of much of the clients’ plant that can eventually cover the entire site with an accurate and functional digital twin that can be used by the client in numerous ways to optimise their plant, reduce energy and emissions, improve safety, provide training simulations. and help them overcome many process challenges as they arise.

We are always finding new uses for our simulation techniques although our work is typically in three main overlapping service areas:

Flex Process has extensive experience with assisting our clients on their digital transformation journey using a staged or phased approach. This starts at the basic level where we help with capturing and digitalizing basic plant information, through reverse engineering where we use our simulation expertise to create or recreate basic plant information such as process flow diagrams, data sheets, and P&IDs etc. We then combine all of this together with our simulation expertise to develop a digital twin based on our advanced 3D models and simulations.

A digital twin developed in this way, has enormous potential benefits, opening up numerous opportunities to optimise and trouble-shoot the plant, reduce energy use and emissions, improve safety and reliability, and provide training simulations.

Flex Process apply advanced steady-state and dynamic modelling techniques to help our clients overcome their many process and project challenges. We specialise in difficult problems; whatever the challenge, we can help – design, new process development, optioneering, scale-up, troubleshooting, debottlenecking, optimization, energy efficiency, training, alarms and trips, process safety time, or operating too close to the safe operating envelope. Our Engineers regularly find additional ways to apply these modelling techniques too. We use many different modelling and simulation techniques to support our clients, depending on your needs we can perform steady-state or dynamic modelling, dispersion modelling, CFD or FEA etc.

Together with our extensive real-world engineering experience, our modelling expertise provides a risk-free way to solve your particular concern. It enables us to gain a thorough understanding of your process so that it can be optimised, and potential improvements can be tried timely and without real-world consequences, supporting design and operating decisions with accurate information and with easy consideration of alternatives and design sensitivities.  This can significantly improve operating plant performance and reduce engineering iterations in project development, reducing project lead times and significantly reducing project and financial risk.

Flex Process have experience with modelling relief devices and relief systems, and LNG. Our Relief Flow software and LNG Rollover prediction software have the potential to save our clients millions of dollars in reduced CAPEX and operating costs.

Our Process Safety consultants can work with both industry and regulators to ensure your plant meets all safety and risk management requirements. We believe that getting process safety right adds value, and ensures a cost-effective design and efficient operation. We offer process safety services such as facilitation of safety studies (HAZOP, HAZID, PHR, LOPA & SIL, Bowtie & ALARP, inherent safety, PSSR) and other support (Safety Case and ALARP demonstrations, consequence modelling, functional safety, barrier management, RCA, safety culture, due diligence). Ideally, we get involved early with preliminary hazard assessments and inherent safety reviews. We incorporate sustainable design principles into these reviews ensuring the right balance of capital and operating costs, environmental and safety performance. Our dynamic simulations allow us to understand what happens when things go wrong, during start-ups or non-steady state operations, allowing evidence-based decisions to be made. This avoids basing designs and procedures on risky assumptions, and many of our clients have benefited as a result.

Why choose us?

Most major plant challenges require a combination of different expertise to successfully resolve them. Flex Process can supply the right combination of engineering and technical disciplines, together with real-world practical engineering experience and our expertise in advanced process simulation to solve your problems. Flex Process acts as an independent, all in one place supplier for these specialist technical services, that together will solve your problems. Whether your focus is process engineering and design, operating improvements, process safety, energy and emissions reductions, or assistance with digital transformation and Industry 4.0, Flex Process can help.

Our people thrive on applying an innovative approach to problems. Although our engineers really enjoy developing challenging simulations, our simulation expertise is just a means to an end; we believe that our clients are looking for practical, well-engineered, and cost-effective solutions to their problems and this is what our unique combination of services provides. We can help you on your digital transformation journey by providing cost-effective digital twins of your plant that will open numerous opportunities for you; new build designs can be optimised to get the right balance of capital and operating costs, environmental and safety performance, and existing operating plant can be modified to squeeze out more capacity and optimise yields, emissions, and energy costs. Our advanced modelling techniques and innovative approach will ensure you get value for your money and a safe, efficient, and reliable plant.

Many digital transformation initiatives on manufacturing sites are hampered by their reliance on OEM support for their OT systems such as DCS, SCADA and safety instrumented systems. This is especially a problem for older and larger sites where these are from many different OEM suppliers who do not support each-others hardware and software. As an independent service provider, we can help bridge this gap by acting as an honest broker and providing support to all systems.

Our process safety engineers can assist you to meet all safety and risk management requirements. We believe that getting process safety right adds value and ensures cost-effective design and efficient operation; we also incorporate inherent safety and sustainable design principles into all our activities ensuring the right balance of capital and operating costs, environmental and safety performance. Our dynamic simulations complement our process safety and sustainability activities allowing us to thoroughly understand what happens when things go wrong and during abnormal conditions when your risks are highest. This substantially reduces your risk as we can model adverse events and base our decisions on accurate information rather than on risky assumptions, but without any real-world consequences.

Industries Served

Refinery

OIL AND GAS, REFINERY & LNG

Bulk

BULK & PETROCHEMICALS

Atom

NUCLEAR

pap-01

PAPER

Energy

POWER, ENERGY & UTILITIES

Steel

STEEL & HEAVY INDUSTRY

Pharma

PHARMACEUTICALS & FINE CHEMICALS

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Decarbonisation & Net Zero

The world has a major problem and changing the way industry goes about its business is a major part of the solution.  Many of our clients are transitioning to Net Zero, and Flex Process is with them. Flex Process is a leader in applying advanced process simulation tools to solve our clients’ difficult problems – and no problem is more challenging than the race to Net Zero. We understand the long-term approach required to make this transition and we work with our clients to provide innovative and efficient solutions and help them overcome challenges as they arise.

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