Industrial modelling · Engineering · Audits

Process and Energy Engineering. Industrial Process Modelling

Engineering consultancy for medium and large industrial and utility clients since 1990: process analysis, power systems modelling, energy efficiency and 3D models of machinery, plants and whole factories.

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Established: 1990
Industries: Chemical, petrochemical, fertilizers
Utilities: Gas and power
Transport: Aviation and aerodromes

About us

Decades of plant know-how, demonstrated with models.

HMJ was established in 1990. Based on many years of experience in industry (chemical, petrochemical, fertilizers), utilities (gas, power) and transport (aviation and aerodromes), we offer engineering consultancy for medium and large industrial and utility clients in the areas of process analysis, process modelling, power systems modelling, energy efficiency analysis, and the selection and delivery of process machinery.

We use the best industrial software from renowned suppliers for the modelling of process, energy and media flows, and we make 3D models of machinery, plants and whole factories. For years we have cooperated with leading European manufacturers of industrial process machinery: compressors, turbines, mixers, tanks and motors.

We hold references from top Polish and European industrial clients.

Services

From the process model to the virtual factory.

Process model

The process model is the starting point of every industrial plant or utility. It describes, quantitatively and qualitatively, the transformation of raw materials, input media and energy through successive stages of semi-products to the output product. For chemical processes it covers reactions, change of physical state, and thermal and energy balances.

The approach is not limited to process industry: this way of thinking can and should be used in any industrial or public installation. We use advanced CAPE software for process flows and balance calculations and offer:

analysis of the existing process
proposals for optimisation and changes
proposals for new machinery and apparatus

Process flow diagrams of ammonia, nitric acid, saltpetre and urea plants

Energy model

A linear electric energy model allows fast and accurate assessment of an existing factory power grid: switching stations, generators, power lines, consumers, motor start-up, cable loads, protections, overloads, transients and harmonics, and it identifies hot spots and development needs.

After a detailed inventory of the grid we use specialist software to model it under normal conditions and in transient states. Besides balance sheets of electric energy consumption, the model shows critical points, overloads and the harmonic components passed back to the supply lines.

The electric balance, together with thermal and media balances, is the main input for assessing the efficiency of a plant or a whole factory.

Single-line diagram of a factory power grid

3D modelling

Professional 3D software such as Bentley OpenPlant or SolidWorks makes it possible to build models of arbitrary accuracy, from single components and machines to plants and whole factories. Despite the manhours involved, virtual twins of entire factories, with machinery, material flows, material data and process data, are the future of industry.

On request, we submit a detailed offer for a model of an industrial plant of any size.

3D model of a process compressor on its foundation

Machinery

Depending on the accuracy required, we model casings of process machines and apparatus (compressors, turbines, pumps, motors, reactors, boilers, tanks) with main internals: rotors, bearings, seals and gears, plus material flows and animation of working movements.

3D model of a process installation with piping and vessel

Plant

We model installations in 3D with foundations, piping, machines, apparatus, valves and support structures, from a schematic level with overall dimensions and weights, down to a level of detail matching virtual reality.

3D model of turbine halls on a steel structure

Factory

Combining models of partial installations with internal transport, roads, walkways, terrain shaping, geodetic heights, pipelines, cable routes, buildings and structures gives a model of a whole factory or utility, open to animation, virtual walk-through, multiple cameras and positioning on geodetic maps, GPS points and GIS models.

Energy audit

A full energy audit of a whole factory covers the media balance, thermal balance, electric energy balance and effluents released to the environment. The fastest route to an accurate, credible audit is to build the process model and energy model first, from analysis of the existing state, using specialist engineering software (CAPE, CAD, energy).

For process industry in particular, the balances must include media beyond water, air, steam and electricity. A comprehensive process model validated on current parameters lets us calculate available savings precisely and propose modernisation options.

HMJ is among a limited number of engineering houses able to carry out a complete energy audit of a whole industrial factory using full-scale process and energy modelling. The audit is made in line with Polish and EU regulations (Dz.U. 2012 poz. 962 and Dz.U. 2016 poz. 831) and best engineering practice. We also recommend an Energy Efficiency Assessment for newly planned investments.

A detailed technical and commercial offer follows a written inquiry from the client, based on a manhour estimate at fixed hourly rates. Depending on plant size and profile and the level of detail, the workload runs from a few hundred to several thousand manhours (if 3D modelling is requested).

Current project

A technical standard for underground siting of Gen IV nuclear reactors.

In view of studies and planning now under way in Polish public institutions on the development of nuclear power in the country, HMJ has prepared a proposal for a Technical Standard on underground siting of Generation IV nuclear reactors.

The proposal, in the form of a draft Polish/European Technical Standard, has been presented to CEN/CENELEC, the Polish Committee for Standardization (PKN) and the IAEA, and to major European manufacturers of nuclear power plant equipment, and has been submitted for presentation at an IAEA symposium.

The draft takes an engineering-sense approach to ecology, prioritising long-term protection of surface resources and the population.

Read the draft standard (PDF)

First page of the draft standard: Minimum technical requirements for siting of nuclear power plants with Generation IV nuclear reactors

Configuration 1: reactor and steam generators in the primary heat transport system — Configuration 1: reactor and steam generators below ground

Configuration 2: reactor, steam generators and turbogenerators below ground

Configuration 3: reactor and heat exchangers below ground, turbogenerators on the surface

Architecture portfolio

Design work beyond the plant.

Airport terminal

Complete design of a large airport, with an X-ray view of the terminal building. Design study.

Watch the video Watch the terminal video

Opera

Opera building with an ellipsoidal auditorium, with excellent acoustics.

Watch the video

Visualisation of a brick hotel tower with museum

Hotel with museum

Design proposal for a public investor.

Watch the video

Visualisation of a suburban manor residence

Suburban residence

A manor-style suburban residence for a private investor.

Skyscraper

Conceptual skyscraper after Kazimierz Malewicz's "Architekton", for the K. Malewicz Foundation.

Watch the video

Airport layout showing phase 1 in 2025 and phase 2 in 2050, with runway usage diagram — Airport layout study: phase 1 and phase 2

Aerodromes are a long-running theme.

HMJ's aerodrome research, including runway configuration, aircraft docking and turnaround, is published in the articles listed below, and has its own site.

Visit HMJ Aviation

References

Trusted by Polish and European industry.

Select a name to read the reference letter.

Publications

Articles

Newsletters

Intellectual property

Trademarks and proprietary designs.

Registered trademark

HMJ

UPRP No. R.316078

Registered design

Docking in Place

EUIPO No. 015005233-0001

Bentley Going Digital Awards 2022, Certificate of Excellence, nominee

Recognition

Going Digital Awards 2022 nominee

Central Communication Hub in Poland · Forbes 30 under 30 Poland

Contact

Tell us about your plant.

Detailed technical and commercial offers are prepared on a written inquiry.

Write to secretary@hmj.com.pl

Registered office: HMJ Sp. z o.o.
Gilarska 76
03-589 Warszawa, PL
NIP 524-267-63-47
Office: ul. Skowronków 11
05-504 Złotokłos
Phone: +48 22 826 89 09
+48 504 079 919
Web: www.hmj.com.pl

Data protection: we do not store your personal data, except the e-mail address on the newsletter recipient list. We do not include cookies in our e-mails, do not pass on or sell your e-mail address to any third party, and use it only to send the newsletter. We do not profile or otherwise process address data beyond sending automated newsletter e-mails, from which you can unsubscribe at any time.