Digital process design involves far more than just the process simulation typically used to design and optimize processes.

It comprises an integrated set of techniques and methodologies that deploy validated digital twins of processes – embodying detailed physics and chemistry knowledge – to explore the decision rapidly and effectively, optimize process and product designs and quantify and manage technology risk.

What is digital design?

Digital process design involves capturing all relevant information in a validated predictive model of the process, then using this model to explore the decision space using advanced analytical and optimization techniques.


PSE has worked with some of the largest organisations in the process industries to evolve a definitive model-based approach to digital process design that can be applied across all process industry sectors.

PSE’s gPROMS ProcessBuilder and gPROMS FormulatedProducts environments offer true digital design capabilities, from concept or formulation to online operation.

What are the benefits?

Systematic digital process design brings many benefits:

Accelerated innovation

The ability to explore the decision space systematically, reduce experimentation time and integrate experimentation and design means faster time-to-market.

Better processes

Full, rigorous optimization means better-designed, better-performing and more flexible processes able to produce the right quality product in the face of variability.

Better products

Digital design makes possible the integrated design of formulated products and their manufacturing processes, and enables screening of formulations for viability early in the cycle.

Reduced risk

With global system analysis you can quantify technology risk systematically and manage the effects of uncertainty, to make sure you can produce profitably come what may.

Reduced experimentation

Experimentation is used to support the validation of the model, rather than to perfect the design. This means that experimentation time and cost can be kept to a minimum, enhancing R&D effectiveness.


Who uses digital design and why?

PSE’s digital design tools and methodologies are used across the spectrum of process industries.

…better drugs to market, faster

The Systems-based Pharmaceutics Alliance promotes digital design for simultaneous formulation of drug products and design of their manufacturing processes.

…better catalysts and reactors

New catalyst formulations are tested in high-fidelity virtual reactors, removing the need for expensive field trials.

…optimal process designs

Reactor and separation sections can be optimized simultaneously to take into account all interactions.

…accelerated fuel cell development

Digital design is used to design complex fuel cell systems and test how they perform during realistic drive cycles.