Supervisory Monitoring and Control Using Chemical Process Simulators and SCADA Systems

A digital twin (DT) is an automation strategy that integrates a physical plant with an adaptive, real-time simulation environment, with bidirectional communication between them. In process engineering, DTs promise real-time monitoring, prediction of future conditions, predictive maintenance, process optimization, and control. Dashboards for process monitoring are becoming increasingly relevant for tracking key metrics and supervising industrial units in real time. Supervisory Control and Data Acquisition (SCADA) systems are widely used for process automation, with ScadaBR, an open-source, freely licensed platform. This work presents the development of a computational tool that integrates the Aspen HYSYS/Python with the ScadaBR system for real-time monitoring and supervision of dynamic models. The virtual plant, which replicates the system’s physical behavior, was connected to the SCADA platform via the Modbus protocol, enabling bidirectional data exchange between the simulated model and the supervisory interface. The system supports operational analysis and control strategy validation. Two case studies were analyzed: (i) a simplified catalytic hydrocracking process, implemented in the Python environment, and (ii) a heat exchanger networks process, simulated using the HYSYS simulator. In the second case, the process was dynamically simulated, with real-time monitoring of a simple dynamic indicator that correlates the feed methane concentration with heat transfer fluids. The results demonstrate the feasibility and applicability of the proposed approach for educational purposes, operator training, and process engineering validation, fostering a more realistic and interactive simulation environment. Furthermore, the results show that the tool is promising for dynamic monitoring of environmental and energy indices, demonstrating that methane consumption relative to process feed can be evaluated and controlled over time.