Advanced CO2 Absorption Simulator for Real-Time Carbon Capture Optimization

Smart Simulator provides Smart Savings

PiControl Solutions LLC has developed CO₂ absorption simulator software.It is a state-of-the-art chemical process simulator using CO₂ absorption column model designed to meet a client’s unique requirement of predicting the real-time CO2 absorption rate, since carbon capture technologyis gaining momentum as industries pursue a lower carbon footprint. As industries pursue a lower carbon footprint, carbon capture, utilization, and storage (CCUS) technologies have become essential. Yet these systems are often complex to build, so experimental chemical simulationsare highly beneficial. CO₂ absorption columns are widely used in the coal gasification industry, natural gas processing plants, power generation facilities, and cement manufacturing. This simulator mimics the mass transfer mechanisms, fluid dynamics simulation, and process control strategies in gas-liquid separation systems and provides real-time pH calculations based on CO₂ absorption dynamics. It has an interactive display similar to a SCADA interfacewith dynamic flow control, real-time pH monitoring, titration process simulations, and graphical trend outputs.The following PID control is planned to be added: pH control to fight against flow rate disturbances, reflecting industrial process control principles. pH control will vary CO₂ flow rates or water injection flows.

The system continuously calculates the CO₂ mass balance and displays outlet CO₂ concentration (g/L) and capture efficiency in real time. This also demonstrates how increased flow rates or process flooding can negatively impact CO₂ absorption efficiency.

The model uses a simplified correlation between absorbed CO₂ and hydrogen ion concentration, applying a smoothing algorithm to ensure realistic pH behaviour. The simulator displays a dynamic pH value updated at each simulation cycle, alongside a pH trend curve tracking historical data.

To mimic post-absorption chemical testing, the simulator includes an automated titration feature. We can inject NaOH increments of 0.5 ml and observe the resulting pH adjustment curve.

Simulated results are logged and exportedin CSV, JSON, and XML formats for seamless ERP system integration and API connectivity.

Digital Twin compatible

The software includes essential mass balance algorithmsand chemical equilibrium equations, yet to be fully deployed as a Digital Twin, it requires real IO plug-ins connected to PLC hardware for real-time system monitoring, process optimization, and predictive maintenance.