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FlowState

Process simulation · scheduling · techno-economics

Design, simulate and evaluate batch, continuous and hybrid processes. FlowState combines rigorous material and energy balances, recipe scheduling, equipment sizing, cost estimation and life-cycle assessment in one fast desktop application, for biotech, pharmaceutical, food, chemical and materials engineers.

Request early access Read the user guide

Windows · macOS · Linux  ·  Runs entirely on your computer  ·  No account, no telemetry

98unit procedures
38library examples
< 1 mstypical re-simulation
6property methods
Features

From a sketch to a costed, scheduled plant

Drag unit procedures onto the canvas, connect them, and give each one a recipe of operations: charge, react, ferment, centrifuge, filter, distil, crystallise, dry and more. FlowState re-solves the balances, the schedule and the economics on every edit.

Modelling

  • 98 unit procedures for batch, continuous and hybrid plants, with automatic recycle convergence (tear selection and Wegstein acceleration).
  • Thermodynamics: Ideal, NRTL, Wilson and UNIQUAC activity models, Peng–Robinson and SRK equations of state, three-phase VLLE flash, IF97 steam tables.
  • Reactions and fermentation: stoichiometric and kinetic reactions, CSTR and plug-flow reactors, fed-batch, perfusion, oxygen transfer and intracellular products.
  • Separations: rigorous MESH and shortcut distillation, multi-effect evaporation with MVR/TVR, extraction, crystallisation, dryers, membranes, reverse osmosis, ion exchange, chromatography including PCC and SMB, electrodialysis.
  • Utilities: compressors and air supply, heat exchangers, pinch analysis, boilers, turbines and combined heat and power, wastewater treatment.

Scheduling & economics

  • Recipe Gantt charts over several batches, with batch time, cycle time, bottleneck and batches per year.
  • Campaigns, shared and staggered equipment, CIP skids and SIP panels.
  • Resource profiles: labour, power and utility demand over consecutive batches, storage inventories and availability limits.
  • Equipment sizing and purchase-cost estimation, capital investment, operating cost, labour, consumables and single-use equipment.
  • Profitability: cash flow with financing and depreciation, NPV, IRR, payback and minimum selling price.
  • Sensitivity: tornado charts, named scenario comparison and throughput scale-up.

Sustainability

  • Waste and emissions: per-vessel vent models, COD/BOD, suspended solids, VOC and CO₂ vented.
  • Wastewater characterisation with discharge-limit checks, E-factor and process mass intensity.
  • Life-cycle assessment: inventory per functional unit, ReCiPe 2016 midpoint impacts with contributions, mass or economic allocation.
  • SimaPro CSV import and export, dataset mappings, scenario parameters and chained upstream projects.

Interoperability

  • Examples Library of 38 ready-to-run processes, including reproductions of published case studies.
  • Imports SuperPro Designer (.spf) project files.
  • Reports in HTML, Excel, Word and RTF, SVG charts and electronic batch sheets with editable templates.
  • flowstate-cli for simulation, variable get/set, sweeps, Monte Carlo, reports, import and LCA.
  • Local automation API (127.0.0.1 only) for Excel, Power Query and Python.
Screenshots

A clean, fast workspace

A GPU-rendered interface with seven workspace tabs, a searchable procedure library and an inspector for every object. Click any image to enlarge it.

FlowsheetBuild flowsheets visually and solve material and energy balances instantly.
StreamsDetailed stream tables with thermodynamic properties.
ScheduleRecipe scheduling, Gantt charts and bottleneck analysis.
EconomicsCapital, operating cost and profitability at a glance.
EnvironmentWaste, emissions and life-cycle assessment.
Examples Library38 ready-to-run examples from published case studies.
Examples Library

38 ready-to-run processes

Four tutorials, plus 34 models that reproduce published techno-economic studies. Each example shows the study it reproduces and its headline figures, and a comparison document lists every calibration and assumption.

Biopharmaceuticals & nutraceuticals 6

Antibody-drug conjugate, continuous mAb with perfusion and PCC capture, polysaccharide vaccine, semaglutide API, vitamin B12 and retinol by precision fermentation.

PerfusionPCCSingle-useFed-batch

Food & nutrition 8

Cultured meat, mycoprotein, cricket protein, recombinant egg-white protein, bio-collagen, cocoa butter equivalent, tequila from agave, and pectin from citrus peel.

ChemostatBatch distillationDrying

Chemicals 8

Aspirin, erythritol, isobutanol from corn stover, malonic acid (two studies), formic acid from CO₂ (two studies) and vitamin C by two-step fermentation.

KineticsRigorous columnsElectrodialysis

Starch & sweeteners 7

Glucose and high-maltose syrups from wet and dry starch, HFCS 42, spray-dried sorbitol and maltitol, imported from the SWEET project's published process models. Main-product flows agree within 0.05 %.

Ion exchangeSMBHydrogenation

Materials & environmental 5

Cellulose nanocrystals, a kraft pulp and tissue mill, lithium carbonate from geothermal brine, a microalgal biostimulant from wastewater, and PHA in a photobiorefinery.

CHPCrystallisationWastewater

Within about 10 %

Most examples come within about 10 % of the published production, capital, operating cost and unit cost. The misses are documented and explained.

See the comparison tables

Plus four tutorials: Getting Started, Recombinant Enzyme, API Intermediate and Bioethanol Recovery.

Platforms

Native on Windows, macOS and Linux

FlowState 1.0 is in a controlled release. Every package below is available to early-access users; download links are sent by invitation.

Windows

Early access
  • Microsoft Store, as FlowState Process Studio
  • Installer for Windows 10/11 x64, per-user or all-users, plus a portable .zip
  • Includes flowstate-cli and the .flow file association

macOS

Early access
  • Universal app for Apple silicon and Intel, macOS 11 or later
  • Signed with a Developer ID and notarised by Apple
  • flowstate-cli ships inside the app bundle

Linux

Early access
  • .deb for Debian 12+ and Ubuntu 22.04+ (amd64)
  • Flatpak for any distribution (x86_64), app id uk.yaylali.FlowState
  • Wayland and X11, with a desktop entry and MIME type

See the installation guide for system requirements and per-platform notes.

Early access

Request early access

FlowState is being released to a small group of engineers and researchers first. Tell me a little about your work and which platform you use, and I will send an invitation with download instructions.

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  2. Send the email to [email protected].
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Kemal Yaylali
About the developer

Kemal Yaylali

Senior AI & Bioreactor Engineer at Cellcraft, Cambridge, UK

Bioprocess Engineer, Machine Learning Dreamer.

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