Equation Oriented · Self-Learning · Closed-Loop Digital Twins

Your partner in production optimization and digital twins.

Anukoolan developed the first live HYSYS-based LNG Real-Time Optimization system — and delivers digital twins and process simulation for refineries, LNG plants, and gas processing facilities worldwide.

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◆ AspenTech Independent Solution Provider (ISP) · Presented at AspenTech Optimize 2026

Years cumulative experience

Live digital twins

Countries

Our Solutions · The Process Map

From the wellhead to finished product

Follow the hydrocarbon through the plant — and see the digital-twin solution that plugs in at every stage.

Anukoolan · Process Map Refinery and Gas · 6 stages

Not sure where to start? We scope a single-unit pilot anywhere along the chain.

Global Footprint

Live installations, worldwide

The full network on one map — every site placed by its true coordinates, connected back to our Pune HQ. Filter by fleet.

Anukoolan · Global Ops 18 projects · 7 countries Global · Software: Electrolyzers (Fuel Cell) — AspenTech ← Swipe the map to explore →

Regional Focus

India Region

8 sites · incl. HQ

Regional Focus

Middle East Region

4 client sites

Track Record

Selected projects

Named projects across LNG & gas, refining, petrochemicals, and clean energy.

01Oil and Gas Optimization at CairnBarmer & Surat · IndiaGas Processing Digital TwinOptimises unit operating parameters via column and compressor pressures, whose set points are typically adjusted manually to maximise gas/oil production and minimise wastage such as flaring.—

02IOCL R&D CentreFaridabad · IndiaFCC Riser Model (INDMAX)Developed and validated a high-fidelity 27-lump FCC riser model against commercial plant data to accurately predict INDMAX olefin yields while accounting for hydrocarbon partial-pressure effects and secondary cracking.—

03Electrolyzers - Fuel CellsGlobal · SoftwareFuel Cell & Electrolyser SimulationACM-based dynamic model library covering PEM, Alkaline, and Solid Oxide fuel cells and electrolyzers — from single-cell electrochemistry to fully wired stacks — enabling modelling of sustainable energy supply and demand.—

04Cumene and Phenol production at Deepak PhenolicsDahej · IndiaCumene / Benzene UnitsProcess modelling and optimization for the cumene and benzene units, including optimization of azeotropic and non-azeotropic distillation columns.—

05Flare and Relief Assessment at a Middle Eastern CompanyJubail · Saudi ArabiaFlare & Relief System Design StudySizing and analysis of a flare and relief system to ensure the safe handling of hydrocarbon releases across design and operational scenarios.—

06Lube Oil Recovery at IF Petro LtdGhaziabad · IndiaProcess Unit ModelDesign of a vacuum distillation column and supporting unit operations to separate lube oils into Diesel, SN70, SN150, SN300, and SN500.—

07Real-Time Closed-Loop Optimization at BPCL Kochi Refinery CDU-3 UnitKochi · IndiaBPCL Digital TwinImplemented Real-Time Optimization (RTO) for the Crude Distillation Unit (CDU) to maximize CDU/VDU product yields while minimizing utility consumption.—

08Dynamic Simulation Study in ThailandMap Ta Phut · ThailandGas Processing Dynamic SimulationDynamic simulation study that verified control philosophies and control loop performance, and assessed critical operating scenarios, including product slate changes, compressor trips, refrigeration interactions, and recovery/rejection mode transitions.—

09Steam Methane ReformerUSASteam Methane ReformerOur steam methane reformer modeling platform combines rigorous 2D reactor and furnace simulations — from pseudo-homogeneous to fully heterogeneous, pellet-resolved formulations — to predict conversion, tube metal temperature, and fuel efficiency with a precision that supports real operating and revamp decisions. The same framework extends to ammonia cracking, and paired with our hydrogen electrolyzer modeling capability, we can analyze hybrid SMR-electrolysis configurations — helping producers optimize the balance between conventional, carbon-capture-ready hydrogen and renewable electrolytic hydrogen as part of a comprehensive sustainable hydrogen strategy.—

10Ethylene CrackerHazira · IndiaRigorous Reactor ModellingDeveloped rigorous hydrogenation reactor models for various refinery processes, including C3, C4, and GHU units, using RPLUG reactors. The models were calibrated and fine-tuned against actual plant operating data to accurately replicate process performance, enabling reliable simulation, optimization, and operational decision-making.—

11BPCL HydrocrackerDelhi · IndiaHydrocracker Digital TwinDevelopment of a high-fidelity hydrocracker model in Aspen Custom Modeler (ACM) for crude field and vegetable oil.—

12L&T Dynamic SimulationMumbai · IndiaDynamic SimulationExamined the compressors to determine which are feasible with an anti-surge valve under different operating scenarios.—

13MEG Salt Reclamation Asian CompanyKiyanly · TurkmenistanMEG Salt ReclamationDeveloped a rigorous, integrated Aspen Plus model — combining offline steady-state and transient simulation — for the MEG Reclamation and Salt Management unit, accurately representing the thermodynamic and hydraulic behaviour of all process streams (including salt formation) and equipment. The model supports several use cases: the effect of feed flowrate, composition, and temperature on salt produced, utility requirements (power, hot oil), and column hydraulics (flooding, pressure drop); and salt accumulation in the circulation loop resulting from variation in flow to the centrifuges. These studies help identify operating bottlenecks, evaluate optimal operating windows, and assess trade-offs between product quality, salt formation, and energy consumption — supporting client engineers in process improvement, what-if analysis, troubleshooting, and equipment performance monitoring.—

14Hyundai Oil BankSeoul · South KoreaDigital Twin for Hyundai Oil BankImplementing a digital twin across the entire refinery unit—including the CDU, MHC, RDS, FCC, and SDA—to monitor real-time equipment performance.—

15Australian LNG FacilityDarwin · AustraliaLNG and Gas Processing Real-Time OptimizationA real-time optimization (RTO) system for a two-train LNG plant, integrated with the plant’s APC layer. The system maximizes profitability by pushing the feed rate to increase LNG production while minimizing utility usage. At times, LNG output reaches its limit; the system shifts product yield based on relative market value to maximize overall economic return.—

16Energy Optimization and Green Energy Study - 1Saudi ArabiaGas Processing PlantAn energy optimization and green energy study of a gas processing plant, evaluating power, heating, and cooling demand across the full facility to maximize total return on investment. Energy conservation opportunities were identified across inlet facilities, sour water stripping, acid gas recovery, sulphur recovery and tail gas treating, MEG and TEG units, cooling water, and the steam/condensate/power plant — evaluating measures such as optimized column feed temperatures, variable-frequency drive pumps, waste heat recovery, hydraulic turbines, and optimized boiler/gas turbine sizing and configuration. Each measure was assessed economically through CAPEX and OPEX estimation and NPV analysis to rank options by value, with the complete package structured to meet FEL-1 engineering phase deliverable and approval requirements.—

17Energy Optimization and Green Energy Study - 2Saudi ArabiaGas Processing PlantAn energy optimization and green energy study of a gas processing plant, evaluating power, heating, and cooling demand across the full facility to maximize total return on investment. Energy conservation opportunities were identified across inlet facilities, sour water stripping, acid gas recovery, sulphur recovery and tail gas treating, MEG and TEG units, cooling water, and the steam/condensate/power plant — evaluating measures such as optimized column feed temperatures, variable-frequency drive pumps, waste heat recovery, hydraulic turbines, and optimized boiler/gas turbine sizing and configuration. Each measure was assessed economically through CAPEX and OPEX estimation and NPV analysis to rank options by value, with the complete package structured to meet FEL-1 engineering phase deliverable and approval requirements.—

18Compressor and Pump Optimization and Green Energy StudySaudi ArabiaOil and Gas Processing PlantsAn energy optimization and green energy study that evaluates pump and compressor energy optimization opportunities to maximize total return on investment (ROI). The analysis compares driver options — fixed-speed, variable-frequency drive, steam turbine, and gas turbine — alongside capacity variation over the production forecast horizon for the plant lifetime. It also assesses configuration trade-offs, such as single-stage versus two-stage compression, to identify the most economical setup across the plant's operating life. Each measure was assessed economically through CAPEX and OPEX estimation and NPV analysis to rank options by value, with the complete package structured to meet FEL-1 engineering phase deliverable and approval requirements.—

Self-Learning Digital Twin

One model. Three jobs. Zero decay.

Built on equation-oriented Aspen HYSYS — the modelling approach that makes plant-wide optimization tractable. The twin runs an automated 20–30 minute cycle: reconcile, calibrate, optimize, publish — continuously.

Ingest — historian data (IP.21 / PI) validated and reconciled automatically.
Calibrate — self-learning reconciliation model configured with an innovative method that re-tunes parameters to the current plant state.
Optimize — the EO model finds the most profitable operating point within constraints.
Publish — targets and KPIs delivered to dashboards and APC every cycle.
What-if case studies — run scenario studies on the calibrated twin to evaluate feed, operating, or design changes before applying them in the plant.

Technology stack: Aspen HYSYS EO · Aspen Online · Hysys · AOL
Model acceptance: Material balance: as good as client plant data · Uptime ≥90% · Temperature, Flow: as per RWMSD
Data & visualize: Data Historian · Dashboard technology of client’s choice

Industries

Industries we serve

Oil & Gas

LNG

Refining

Petrochemicals

Gas Processing

Clean Energy

Our Team

150+ years of cumulative experience

Dr. Hiren Shethna

Founder & Optimization Lead

M.Tech IIT Bombay · PhD University of Manchester
26 years at AspenTech and Saudi Aramco
Implemented 25+ digital twin models worldwide

Dr. Karuna Potdar

Simulation & Modelling Lead

B.Chem.Eng + PhD, ICT Mumbai
32 years at Reliance Industries
Led RIL's simulation & modelling team
15+ plant models deployed across RIL

Shailesh Sakarkar

Training & Simulation Lead

B.Tech, Laxmi Narayan Institute, Nagpur
30 years in the process industry
80+ simulation training programs delivered globally

AspenTech Optimize · Conference Paper

CDU Digital Twin Built with Equation-Oriented Modelling in Aspen HYSYS and Custom Modeling Technology Helps Refinery Improve Margins

Co-authored with AspenTech.

AspenTech Optimize 2026 · Conference Paper

Development of a High-Fidelity FCC Riser Model Through ACM Integration for INDMAX Technology

Co-authored with IOCL R&D Centre Faridabad and AspenTech — a proprietary 27-lump kinetic model validated against commercial plant data.

FAQs

Common questions

Contact

Talk to us

Unit type, the problem, and whether plant data or a model already exists — three lines are enough to start.

Reply within one business dayNDA-ready, no obligation

Direct

Email

info@anukoolan.com

Anukoolan Solutions Private Limited · Pune, India

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Pilot

Start small

We can scope a single-unit pilot of the digital twin to demonstrate value before any wider rollout — with defined acceptance criteria from day one.