Engineering Consultant


PFB is a process simulation specialist company with experience in oil, gas and petrochemical processes with a focus on “steady state” and “dynamic” simulation and control, energy optimization PFB offers engineering services in the field of conceptual design, basic design and detailed design. Part of the work of which is shown here:

Engineering Consultant
Engineering Consultant

Our Projects

Simulation, design, construction and implementation of acetic acid esterification reactive distillation process
  • Employer: Kavian industrial city, Iran

One of the processes for producing high purity methyl acetate and passing through the azeotrope point is the use of reactive distillation tower. In this project, a pilot unit was designed to develop an industrial unit at first. Serious control related problems are encountered in a reactive distillation column due to its very complex process dynamics. In this project Aspen Plus simulation software has been used to principle design a reactive distillation column for maintaining the product purity at the desired level. System nonlinearity and interactions make direct control of product purity for the high-purity design quite difficult. Introduction of tray temperature control helps in preventing the nonlinearity problem. Aspen Plus dynamics extends Aspen Plus steady-state models into dynamic process models, enabling design and verification of process control schemes. A tight and robust control scheme with two levels and one each of pressure, temperature, flow, composition and reflux controllers have been used to maintain the product purity at the desired levels and safely operate the plant at the desired operating conditions. Other works done in this project include the creation of technical documents such as PFD, P&ID, Process Data Sheet, Equipment Data Sheet, Instrument Data Sheet et.


Preparation of Simulator. For U-101,104-111-105 Ph.20&21, SPGC (by focused on rigorous dynamic model)
  • Employer: NIGC, Iran

This simulator name is VIRAMINE and its applications are Operator Training (OTS), Control System Checkout, Controls Analysis, Configuration, and Tuning Test Bed, Engineering and Operational Analysis Test Bed. This Simulator is developed at Petro Farayand Baarssava (PFB) Company. PFB's engineering team can offer plant’s facility a complete site specific operator training simulator (OTS) which emulates process plant and DCS control screens. PFB has a reputation for generating dynamically accurate simulations that represent actual plant systems for Operator Training. PFB has provided SPGC (South Pars Gas Complex) with many of its site specific control room operator training simulations worldwide, especially for some of its major facilities like Amine sweetening, Gas Dehydration, Ethane recovery and Refrigeration cycle in 3th and 8th refineries over the past 3 years. PFB has provided JBTC (Jam Beheshti Training Center) with all its site specific control room operator training simulators on its giant virtual training project. PFB specializes in the emulation of the control screen graphics which is done through OPC-UA development. Emulated systems from PFB include Yokogawa, DeltaV, Kerman Tablo, Honeywell and others.

IMS implementation at Natural Gas distribution Network using adaptive simulator (soft sensor)
  • Employer: NIGC, Iran

To obtain the accurate transient states of the big scale natural gas pipeline networks (4th zone Iranian Gas Transmission Company) under the bad and lack of data and non-zero mean noises conditions, a robust Kalman filter-based dynamic state estimation method is proposed using the linearized gas pipeline transient flow equations in this project. Firstly, the dynamic state estimation model is built. Since the gas pipeline transient flow equations are less than the states, the boundary conditions are used as supplementary constraints to predict the transient states. To increase the measurement redundancy, the zero mass flow rate constraints at the sink nodes are taken as virtual measurements. Secondly, to ensure the stability under bad data condition, the robust Kalman filter algorithm is proposed by introducing a time-varying scalar matrix to regulate the measurement error variances correctly according to the innovation vector at every time step. At last, the proposed method is applied to a 30-node gas pipeline network in several kinds of measurement conditions. The simulation shows that the proposed robust dynamic state estimation can decrease the effects of bad data and achieve better estimating results. For testing the soft sensor, a rigorous dynamic simulation of pipeline was developed by Aspen HYSYS Gas Pipe firstly and then the soft sensor (Kalman filter based on python code) was connected to dispatching units (few real pressure measurements).

Finding a practical method for flow gas metering under Qmin
  • Employer: NIGC, Iran

The minimum rated capacity (Qmin) for a gas turbine flow meter is generally considered to be the lowest flow rate at which the meter can still maintain an accuracy of 1.0%. A decrease in kinetic energy, attributed to low flow velocities, will allow frictional forces to act upon the turbine causing it to run slow or under-register. However, this loss of flow rate is partially compensated for by an increase in line pressure. Therefore, at elevated pressures the minimum capacity in Standard cfh increases directly as does the square root of Boyle’s Law pressure multiplier. For this reason, the term Qmin, when expressed in Actual cfh, becomes noticeably improved at elevated operating pressures. However, the measurement error of gas consumption of many consumers is very high at many times and will cause financial losses for gas producers.

Investigation on capacity increasing of the Methyl Acetate production process (acetic acid Esterification)
  • Employer: Fariman industrial park, Choubineh CO.,
Heat Exchangers detailed design
  • Employer: Shiraz refinery, Iran (sub-contractor: Kara San’at)
Investigation on efficiency increasing of Sarkhoon-Qeshm Sabilizatin unit (by focused on rigorous Aspen Plussimulation / proMAX)
  • Employer: Sarkhoon-Qeshm, Iran
Preparation of OTS Pkgs. For U-101, Ph.4&5, SPGC (by focused on rigorous dynamic model)
  • Employer:4&5, SPGC, Iran
Feasibility studies for increasing of Shourijeh’s gas storage capacity by reducing of compressors compression ratio
  • Employer: SGPC, Iran
Operational steering software development for U-101, Ph.4&5, SPGC
  • Employer: Ferdowsi UM, Iran
Feasibility studies for gas condensate Mini-Refinery (3000 BPD)
  • Employer: Mahshahr Industrial park, Anzani refinery, Iran
Investigation on capacity increasing of the Ethyl Acetate production process (acetic acid Esterification)
  • Employer: Fariman industrial park, Hallal Sazan,
FEED and Detail design of a gas condensate mini refinery (3000 BPD)
  • Employer: Kardan refinery, Iran
Technical check list preparation for Gas pressure reducing regulators (High pressure)
  • Employer: NIGC, Iran
Debottlenecking studies for BIDBOLAND gas plant.
  • Employer: BIDBOLAND Gas Refinery Company, Iran.

This project was carried out within the Research stream on optimization studies of BIDBOLAND gas refinery. This study evaluates the effect of Structural modifications on energy consumption of gas treatment units of BIDBOLAND refinery (Iran’s first gas refinery). To this aim, Aspen HYSYS (V.8.3) software was employed for the unit simulation in rate based method. The results show that where CO2 content in sour feed gas is less than 2 percent and MDEA solution is used as solvent, using multiple feeds to the absorption column, static mixers and absorption column side stream cannot reduce energy consumption level; while using desorption column side stream and a flash unit can reduce the unit energy consumption up to 10 percent.

Flare damages analysis
  • Employer: KHANGIRAN Gas Refinery Company, Iran