AspenTech Blog | 2D Flowsheets To 3D Models | Accelerate FEED, Integrate Process Simulation

Going From 2D Flowsheets To 3D Models Is Just One Jump Ahead

October 07, 2025

 

In today’s fast-paced environment, companies across all industries are under pressure to deliver cost-effective greenfield and brownfield projects, while meeting their respective sustainability goals. Speed and accuracy during early-stage design are critical to achieving these objectives.

Traditionally, process simulation and 3D modeling have been separate steps. Process simulations often evolve during early design, while 3D models come later. This disconnect can slow down projects during later stages and increase the risk of costly redesigns.

But what if we could bridge that gap?

Aspen HYSYS® and Aspen Plus® allow process engineers to simulate complex processes with precision, leveraging advanced thermodynamics and rigorous heat and material balances to accurately define optimal operating conditions. However, these simulations don’t capture spatial realities like safety spacing, accessibility or site constraints.

That’s where Aspen OptiPlant3D Layout comes in.

As part of AspenTech’s Concurrent Engineering solution, Aspen OptiPlant 3D Layout enables a collaborative workflow with Aspen HYSYS and Aspen Plus. This enables the import of simulation data, including preliminary equipment sizes, operating conditions and equipment connectivity as well as the use of AI-driven auto layout to generate feasible 3D layout options reflecting real-world constraints and design rules.

This workflow transforms how teams approach Front-End Engineering Design (FEED) and integrates process engineering with layout design, enabling faster, more informed decisions.

With this approach, teams can create 3D layouts faster using simulation data as the foundation, share visual models with stakeholders earlier to improve cross-disciplinary alignment, evaluate multiple layout options to minimize capital costs and physical footprint, identify potential design issues early and avoid unnecessary redesign costs later.

Combining Aspen HYSYS or Aspen Plus with Aspen OptiPlant 3D Layout empowers teams to move from simulation to 3D seamlessly. It’s not just about faster design – it’s about making better-informed decisions earlier. 

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