SIMCET
Real-time PID tuning simulator with 20+ pre-built process simulations covering flow, temperature, pressure, level and composition loops, plus a testing-and-grading module used for PID tuning certification.
Process control simulation software is a category of real-time simulator software that replicates the dynamic behavior of industrial process equipment and control loops, without tying up a real plant unit. PiControl Solutions builds this category around a family of 13 simulators: SIMCET for general PID tuning practice, and a set of unit-operation simulators, PiDistill, PiDistill-B, PiDistill-B Lite, PiLevel, PiTemp, PiFlow, PiAgitator, PiReact-T, PiHEx, PiDeltaP, and PiPump, plus STYROSIM, a full plant-scale DCS simulator, that each model a specific piece of process equipment in depth.
The first time an engineer tunes a loop, runs a distillation column, or responds to an alarm should not be on a live production unit. Process control simulation software reduces training risk by letting engineers and students practice on realistic process dynamics first, closed-loop response, column behavior, reactor dynamics, pump curves, before they touch real plant equipment.
Each simulator in the family models a specific loop or piece of process equipment in depth, from general PID tuning practice through distillation, reaction, heat exchange, pumping, and a full plant-scale DCS. Start with SIMCET for general tuning practice, then add the unit-operation simulators that match your plant or curriculum.
Real-time PID tuning simulator with 20+ pre-built process simulations covering flow, temperature, pressure, level and composition loops, plus a testing-and-grading module used for PID tuning certification.
Continuous distillation column dynamic simulator capturing tray hydraulics, reboiler and condenser response, and feed composition disturbances.
Batch distillation column simulator modelling reflux drum behaviour, cut transitions, and end-point determination for specialty and pharma plants.
Azeotropic batch distillation simulator — a lighter-footprint version focused on azeotropic separations and entrainer-based distillation.
Level controller in vertical tank simulator modelling integrating-process behaviour and cascade level-flow control.
Temperature controller for heat exchangers simulator capturing dead-time-dominated thermal dynamics.
Flow controller in heat exchanger simulator capturing flow-loop dynamics with realistic valve characteristics and pump curves.
Agitation effect simulator modelling mixing time, blend uniformity, and impeller-driven flow patterns in stirred vessels.
Tubular reactor simulator modelling plug-flow dynamics for cracking, polymerization, and other tubular reaction systems.
Heat exchanger network simulator modelling multi-unit networks with cross-coupling between hot and cold streams.
Pressure drop simulator capturing dynamics across piping, control valves, and process equipment.
Pump system simulator modelling centrifugal and positive-displacement pump dynamics with realistic curves and cavitation behaviour.
Styrene monomer plant DCS simulator — a full plant-scale dynamic simulator with PCS 7 control-room interface for operator training, alarm-response practice, and APC strategy validation.
Industrial plants use PiControl's process control simulation software to train new process engineers, recertify experienced operators, and build a safety-conscious culture without risking real plant equipment. SIMCET alone includes 100+ real-world process control examples grouped by industry, and the unit-operation simulators add depth on distillation, reaction, heat exchange, and pumping.
Engineering colleges and universities use PiControl's simulators as virtual laboratories that help students bridge the gap between control theory and practice. Students gain a deep understanding of control principles, distillation columns, reactors, heat exchangers, and other core chemical engineering concepts before they ever set foot on a real plant floor.
Process control simulation software is a principal subfield within industrial process optimization, and it delivers value on four fronts.
Young engineers and students practice tuning PID loops and gain confidence without the risk of affecting real processes. SIMCET alone comprises 100+ real-world process control examples, separated into groups by industry type.
PiDistill, PiDistill-B, PiLevel, PiTemp, PiFlow, PiAgitator, PiReact-T, and PiHEx serve as virtual laboratories that help students bridge the gap between theory and practice, preparing them for future roles in chemical engineering.
Students and professionals experiment with different scenarios, explore how process conditions impact outputs, and manipulate control parameters in real time across distillation, reactor, heat-exchange, level, and flow loops.
Training and experimentation within a simulated environment let engineers learn to control processes without the risk of plant problems or shutdowns, across every simulator in the family, from SIMCET to STYROSIM.
SIMCET, the flagship of PiControl's process control simulation software family, is deployed in industrial plants and engineering colleges across 40+ countries. The unit-operation simulators extend that same real-time approach to distillation, reaction, heat exchange, and other unit operations, including PiDistill, built by PiControl in cooperation with the Louisiana Tech University Department of Chemical Engineering. Read more in our customer success stories.
Tell us which loops, columns, or processes you want to simulate, and we'll recommend the right simulators from the family for your plant or curriculum.
See PiControl's simulators run in real time, from PID tuning on SIMCET to distillation, reaction, and heat exchange on the unit-operation simulators. A PiControl engineer will demonstrate the products relevant to your plant or curriculum and map out a training path for your team.