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The design of industrial installations using digital design techniques (digital twin), aligned with the concept of Industry 4.0, provides a tool to optimize maintenance costs, process gas emissions, energy consumption and to reduce the risks associated with production testing. Modern manufacturing plants conduct chemical processes by combining production experience with model-based research. Analyzing processes using advanced digital techniques can replace traditional methods of technological process balancing. The methodology based on the digital twin already serves as a holistic system of process connections, supporting production, research and development, production planning, and quality control. This paper presents the digital design, optimization, and comparison of process data obtained through simulations for two different types of ammonia recovery units in soda ash production using the ammonia–soda process. Using specialized modeling software and relying on historical data, engineering assumptions, and new concepts, virtual models were created in which the material and thermal balances of the process were simulated. This research is divided into two stages. In the first stage, a model-based approach and model optimization techniques are presented, while in the second stage, the preparation of models of the distillation installation is presented, and the influence of various structural parameters of the equipment on the temperature profile and gas flow rate in the ammonia recovery section is discussed. The process of the research method, based on simulations in a virtual environment, allows for evaluating the implementation potential of the proposed concepts, optimizing process parameters, and redefining the approach to conducting chemical processes. A series of simulations conducted in studies on ammonia recovery indicated a potential increase in gaseous ammonia recovery by up to 14.09%, taking into account the type of distillation apparatus or the height of the packing section. Full article