In the evolving energy landscape, digital innovation is reshaping how we design, operate, and optimise complex energy systems. At the forefront of this transformation is BPT, Billington Process Technology, a Norway-based company dedicated to accelerating the global green shift through cutting-edge lifecycle simulation technology. With its expertise acquired by executing over 400 projects, BPT has become a key player in de-risking investments in hydrogen, ammonia, e-methanol, CO₂ capture and utilization (CCU), and other sustainable energy systems.

Knut-Erik Spilling, CEO of BPT, underscores the company’s vision: “Our mission is to provide undisputed value by de-risking investments in complex energy plants. We aim to be the world leader in lifecycle simulator solutions, supporting projects from feasibility to full-scale operations.”

 

The Power of Digital Production Twins

BPT’s Digital Production Twins stand out in the market by integrating industry-standard process simulators with proprietary unit operations software developed by BPT’s domain experts. Unlike traditional digital twins, which often provide limited dynamic capabilities, BPT’s solutions offer high-fidelity simulation of both steady-state and fully dynamic behaviours.

“For hydrogen and its derivatives, high-fidelity modelling is critical,” Spilling explains. “The dynamics of both electrolysis and chemical reactions must be accurately represented to ensure optimal system design and operational efficiency.” By enabling precise modelling of renewable-powered production processes, BPT helps clients bridge the gap between fluctuating energy inputs and the steady-state requirements of industrial production.

 

Enhancing Green Energy Systems with Simulation

The shift towards green hydrogen, ammonia, and e-fuels presents unique challenges. Many new energy systems rely on intermittent renewable sources like wind and solar, while their production processes require stability. BPT’s simulation technology enables engineers to design plants that balance these conflicting demands from the outset.

“We work closely with owners and engineering houses to develop optimised solutions,” says Spilling. “By using advanced simulators combined with strong competence and experience, we can identify potential design and operational challenges early, saving our clients time and money.”

BPT’s contributions extend beyond just improving designs. By leveraging dynamic simulations, the company plays a crucial role in validating control strategies, optimising start-up and shutdown procedures, and preparing for real-world operational scenarios. This approach ensures that facilities are not just well-designed but also practical and efficient in operation.

 

Closing Technology Gaps with BPT SimApps

One of BPT’s key innovations is its suite of SimApps—custom-built software modules that enhance the capabilities of traditional process simulators. These applications address critical gaps in existing simulation tools, particularly for emerging green technologies.

“Industry-standard simulators were built for fossil fuel systems,” Spilling notes. “Applying them to green energy systems without modifications leads to inaccuracies. That’s where BPT SimApps come in—we’ve developed specialised unit operations for electrolysis, reactors, and other key processes.”

These tailored solutions allow for more reliable predictions of system performance, reducing uncertainties in large-scale green energy investments. By enabling accurate modelling of electrochemical and thermochemical processes, BPT ensures that projects are not only technically feasible but also financially viable.

 

De-Risking Investments with Lifecycle Simulations

Investing in green energy infrastructure comes with inherent risks, from uncertain performance metrics to evolving regulatory landscapes. BPT’s lifecycle simulation approach mitigates these risks by allowing stakeholders to test and refine designs before committing to large-scale deployment.

“A major advantage of our approach is that we can simulate a facility’s entire lifecycle—from design to operation,” Spilling explains. “We validate control system implementations, train operators, and monitor performance in real time, ensuring efficiency at every stage.”

A prime example of this is BPT’s involvement in a large-scale e-fuel project. By developing a full-scope dynamic process simulator, BPT helped optimise plant design, validate operational strategies, and support off-take agreement negotiations. The simulator’s ability to model complex interactions between hydrogen, synthesis gas, and Fischer-Tropsch reactors proved invaluable in securing project feasibility.

 

Sustainability and Efficiency Through Digitalisation

BPT’s digital solutions are not just about performance—they also drive sustainability. By identifying inefficiencies and optimising energy use, BPT contributes to lowering the carbon footprint of industrial processes. Additionally, simulation-based training reduces the need for physical testing, further minimising waste and resource consumption.

“The use of digital solutions is, in itself, a driver for sustainability,” says Spilling. “By integrating system engineering expertise with advanced simulations, we ensure that projects are both efficient and environmentally responsible.”

 

The Role of Partnerships in Driving Innovation

Collaboration is a cornerstone of BPT’s strategy. By working with industry leaders, research institutions, and technology providers, BPT continuously refines its solutions to meet the needs of a rapidly evolving sector.

“Partnerships are essential to our business model,” Spilling states. “Innovation, integrity, and agility define our company culture, and close collaboration with clients and industry peers enables us to deliver maximum value.”

This approach has led to successful engagements with key stakeholders across the energy spectrum. By aligning with strategic partners, BPT is accelerating the adoption of digital twin technology in green energy projects worldwide.

 

The Future of BPT and Digital Energy Solutions

As the demand for green hydrogen and sustainable fuels surges, BPT is poised for significant growth. With a strong foothold in the Nordics, the company is expanding throughout Europe and beyond. Supported by the EUROSTARS R&D funding program, BPT has been able to advance its R&D efforts while simultaneously executing multiple commercial projects.

“We’re experiencing a booming market for our expertise,” Spilling reveals. “Looking ahead, we plan to scale our business globally, leveraging digital innovation to drive the energy transition.”

With its unparalleled expertise in process simulation, commitment to innovation, and focus on sustainability, BPT is shaping the future of green energy. By providing high-fidelity digital twin solutions, the company is not only de-risking investments but also paving the way for more efficient, resilient, and cost-effective energy systems worldwide. •