Advancing Fertiliser Production Through Intelligent Process Simulation


Development of the Emulated OTSs – Ammonia and Urea plants (Instructor Book)

Safe and efficient fertiliser production depends on highly skilled operators capable of managing complex chemical processes and control systems. For Profertil, an Argentinian fertiliser producer specialising in granular urea and natural gas-based ammonia, Inprocess, a Quadrante Group company, developed emulated Operator Training Simulators (OTS) to support operator training and strengthen operational preparedness.

The project combined advanced dynamic process simulation with dedicated training resources, creating a virtual environment for developing technical expertise across both production units.

Two interconnected production processes, ammonia and urea, formed the basis of the simulation solution. Inprocess was responsible for the design, engineering and testing of dynamic process models developed in Aspen HYSYS Dynamics, including the associated control logic and emulation of the existing Schneider Distributed Control System (DCS).

The scope also included configuring dedicated Instructor and Operator Stations to support structured training activities.

To extend the simulator’s educational value, Inprocess developed a customised Inprocess Instructor Book (IIB), providing instructors with detailed technical guidance and a deeper understanding of the OTS solution beyond the standard operating manual.

Market

SP+LATAM

Sector

Digital Twin | Energy

Location

Argentina, South America

Client

Ammonia Plant | Urea Plant

By combining realistic process simulation with enhanced instructor resources, the project supports a more structured and comprehensive approach to operator training in complex fertiliser production environments.

The emulated OTS solutions enable operational teams to develop a deeper understanding of ammonia and urea processes and their associated control systems. The dedicated Instructor Book further strengthens knowledge transfer, helping instructors make more effective use of the simulators and supporting long-term training capabilities.