Inprocess' OTS supports startup of AirPlant One
Process simulation consulting company Inprocess has successfully completed a project supporting the startup and operational readiness of AirPlant™ One, a facility producing power-to-liquid sustainable aviation fuel (SAF) and E-Naphtha™ from captured carbon dioxide, water, and renewable electricity. The facility operated by Twelve has recently begun producing representing a major milestone in the fuel industry.
As part of the project, Inprocess developed a comprehensive Dynamic Simulation and Operator Training Simulator (OTS). The simulator was designed to support control system validation, operator training, and commissioning activities before startup, helping reduce operational risks.
The OTS provided a safe and realistic environment where operators could train using the future plant configuration, despite the facility not yet being in operation. During simulator testing, major control strategies with significant improvement opportunities were identified and addressed before startup. Following commissioning, the facility operated continuously for approximately 24 days before a planned shutdown, with no unplanned shutdowns saving approximately $50k per avoided shutdown.
The project has now reached completion, with the facility successfully online producing E-Jet® SAF and E-Naphtha™.
By enabling the identification and resolution of control challenges prior to startup, the simulation environment helped Twelve reduce commissioning uncertainty and contributed to a smoother transition into commercial operation. The project also established a digital foundation that will benefit schedule risk reduction at future scale where cost avoidances are exponentially higher.
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