RTsim is a Dubai (UAE)-based technology company with nearly 30 years of experience in mathematical modeling and digital simulator development for the Energy Industry.
While developing industrial operator training simulators for refineries and gas processing plants, a clear industry challenge emerged: companies require specialists who not only possess theoretical knowledge but are also capable of operating real technological processes from day one.
This demand led to the development of RTsim.Career — a dedicated educational platform designed to bridge the gap between engineering theory and industrial practice.
This article focuses on the RTsim.Career platform, its technical foundation, and its role in preparing future process engineers through simulation-based training.
1. Introduction
Modern industry faces the challenge of improving safety and operational efficiency, particularly through more effective training approaches. A digital twin is a virtual model of real equipment or processes used to simulate behavior under various operating conditions.
In the energy and chemical industries, digital twins are widely used to train operators, simulate emergency scenarios, and optimize technological processes without risks to real production.
However, despite the availability of advanced industrial simulation tools, a significant gap remains between academic education and real industrial practice. Graduates often possess strong theoretical knowledge but lack the practical skills required for process operation and decision-making in real environments.
During the development and implementation of industrial operator training simulators, this challenge became particularly evident. Industrial partners consistently emphasized the need for specialists who are able to understand process dynamics, operate equipment, and respond to abnormal situations from the very beginning of their careers.
This gap between theory and industry became the foundation for the development of RTsim.Career — a simulation-based educational platform designed to prepare future engineers through practical, scenario-driven training.
2. RTsim History and Ecosystem
RTsim is a technology company with nearly three decades of experience in mathematical modeling and industrial simulation for the Energy Industry.
The company’s development began in 1997 with the creation of a mathematical model of a complex chemical process. By 2009, this work evolved into a simulation platform, and in 2014, the first industrial solution for process simulation and operator training was introduced.
These industrial systems, developed for real production facilities, became the foundation for understanding how operators interact with technological processes and where critical knowledge gaps occur.
Over time, it became clear that many challenges in industrial operations originate not only from equipment or systems, but from insufficient practical training of personnel.
As a result, a separate educational direction emerged, leading to the development of RTsim.Career — a platform specifically designed to transfer industrial experience into the learning environment.
Today, the RTsim ecosystem includes:
- RTsim OTS — industrial operator training simulators used in real production environments
- RTsim.Career — an educational platform focused on training future specialists using real process scenarios
- RTsim.Process (in development) — a modeling environment for advanced engineering simulation
While RTsim OTS focuses on industrial personnel, RTsim.Career represents a dedicated solution for bridging the gap between academic knowledge and real operational practice.
3. Technical Specifications
The mathematical models are based on nonlinear differential equations of material and heat balance for each process unit, such as reactors, columns, and heat exchangers. The simulator represents a complete digital twin of an industrial unit, including all major equipment, pipelines, and control elements.
A full process simulation flowsheet is presented in Figure 1.
Figure 1. Full process simulation flowsheet of the amine treatment unit, including absorber column, pumps, heat exchanger, and control system elements.
The simulator environment includes two key interface levels that reflect real industrial operation.
The Field Workstation represents the simulation of all operations performed directly at the process unit level. It allows users to interact with equipment such as valves, pumps, and pipelines, replicating the actions of field operators within a technological installation.
The Distributed Control System (DCS) represents the centralized control layer of the process. It simulates the interface of a real industrial control room, where operators monitor process parameters, analyze system behavior, and make control decisions.
An example of the DCS interface for the amine treatment unit is presented in Figure 2.
Figure 2. DCS (Distributed Control System) of an Amine Treatment Unit, simulating a real industrial Control Room screen interface.
Similarity theory is used to simulate complex separation processes and reactions. Model parameters are calibrated using process control data and theoretical calculations.
The simulator reproduces the operator workstation interface of a distributed control system, including dashboards, process simulation diagrams, and trend graphs. The system also supports field-level control emulation, such as operation of valves and pumps.
An example of a butane separation column control interface is presented in Figure 3.
Figure 3. Digital control interface of the butane separation column training simulator showing process parameters, control valves, and equipment status
The system operates in two main modes: individual training and control testing.
- In individual training mode, users have access to prompts, a virtual instructor, training videos, and system feedback. Performance is evaluated using a pass/fail logic, where successful completion requires execution without critical errors.
- In control testing mode, prompts are disabled, and user performance is evaluated using a 100-point scoring system, providing a more detailed assessment of operational accuracy and decision-making quality.
A built-in virtual instructor, implemented as an integrated expert system with interactive guidance, allows users to study both theoretical and practical aspects of safe operation without continuous supervision.
Simulation speed is adjustable, allowing slow processes to be accelerated and fast ones to be slowed down. This enables better understanding of process dynamics and improves reaction time during training. The system also allows simulation of different equipment configurations and operating conditions.
4. Applications in Education and Industry
Simulation-based education plays a critical role in addressing the gap between theoretical knowledge and industrial requirements.
Unlike traditional learning methods, simulation platforms allow students to interact with real process models, make operational decisions, and understand the consequences of their actions in a safe environment.
The RTsim.Career platform was specifically designed to translate industrial experience into educational scenarios, enabling students to develop practical skills before entering the workforce.
Joint Programs.
In 2025, 50 educational events were organized, including webinars and training sessions conducted in collaboration with universities and professional associations in more than 15 countries, including Qatar, Saudi Arabia, Nigeria, Uganda, Congo, and Ghana. Training initiatives were also conducted in cooperation with more than 30 SPE chapters worldwide.
Sponsored Competitions.
Simulation-based competitions, such as the 2025 RTsim Downstream OTS Competition, provide participants with the opportunity to apply their skills in realistic scenarios. For example, in November 2025, the RTsim International Championship attracted over 100 applications from 15 countries, demonstrating high engagement and practical relevance.
Platform Growth.
The adoption of simulation-based learning has increased significantly. In 2025, the number of new users increased 6.9-fold, while active users nearly quadrupled. Total training hours increased by a factor of 17.5, indicating growing demand for this type of training.
University Integration.
Simulation platforms are integrated into courses in chemistry, thermodynamics, and process control. Students can visually explore process diagrams and develop practical operational skills. Studies show that hands-on simulator training improves knowledge retention up to 90% and significantly reduces training time.
Safety and Practice.
Emergency procedures, including leaks, shutdowns, and system failures, are modeled in detail. Repeated execution of such scenarios helps develop stable operational skills and improves confidence in decision-making under critical conditions.
Case-Based Training.
The platform includes predefined training scenarios such as buffer and reflux tanks, columns, heat exchangers, absorbers, and dynamic equipment. Each case focuses on specific engineering principles, including hydraulics, mass transfer, heat transfer, adsorption, and distillation.
Each training scenario is designed to replicate real industrial situations, requiring users to analyze process conditions, make operational decisions, and maintain system stability.
During training sessions, users perform sequential operational actions while monitoring system behavior and responding to changing process conditions. Through repeated interaction with process models, users develop not only technical competence but also confidence in working with complex industrial systems and making decisions under dynamic conditions.
An example of process workflow during a training scenario is shown in Figure 4.
Figure 4. Example of process workflow during a training scenario demonstrating operational control of the butane separation unit
5. Achievements and Global Reach
The product line currently includes RTsim.Career and RTsim OTS, both commercially available and actively used. RTsim.Process is in alpha testing and is designed for advanced modeling.
The Dubai office serves as the regional hub from which the company expands its presence. Clients and partners are located in more than 11 countries, including the UAE, Nigeria, Ghana, Uganda, Qatar, Malaysia, Indonesia, etc. A local partnership model, particularly in the Nigerian market, supports the growth of the ecosystem.
RTsim has partnered with SPE, the world’s largest professional association of petroleum engineers, with 150,000 members, and has held joint events with over 30 local SPE chapters.
The platform has also been presented at industry events such as ADIPEC and student conferences including The Industry Discourse. In 2025, it held a winter intensive program dedicated to key simulators, with one session for each technology block.
Furthermore, RTsim actively hosts livestreams in English for an international audience on topics such as careers, simulators, and plant emergencies. This strengthens the company’s global image as an educational platform.
6. Conclusion
RTsim demonstrates how digital twin technologies and simulation-based training can effectively bridge the gap between engineering theory and industrial practice in the chemical and energy Industry. The development of the RTsim.Career platform shows that simulation-based learning enables future engineers to acquire practical skills, improve decision-making abilities, and develop confidence before entering real production environments. By transforming industrial experience into structured training scenarios, such platforms address one of the key challenges of modern engineering education — the lack of practical readiness among graduates.
Simulation-based approaches also contribute to improved training efficiency, enhanced skill retention, and increased operational safety. As digital twin technologies continue to evolve, platforms such as RTsim.Career represent an important step toward closer integration between education and industry, supporting the development of a new generation of engineers prepared for real-world challenges.
