Why a simulation system doesn't match the plant

Process simulations, or mathematical models, are widely used by plant engineers and planners to obtain a better understanding of a particular process. These simulations are used to answer questions such as how can feed rate be increased, how can yields be improved, how can energy consumption be decreased, or how should the available independent variables be set to maximize profit? Although current process simulations are greatly improved over those of the `70s and `80s, there are many reasons why a process simulation doesn`t match the plant. Understanding these reasons can assist in using simulations to maximum advantage. The reasons simulations do not match the plant may be placed in three main categories: simulation effects or inherent error, sampling and analysis effects of measurement error, and misapplication effects or set-up error.