Crusher en Aspen

Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0 A Brief Tutorial Tutorial (and supplement to training and online online documentation) Julie Levine, Product Product Marketing, Marketing, Aspen Technology, Technology, Inc. Claus Reimers, Software Development, Aspen Technology, Inc. Ajay Lakshmanan, Lakshmanan, Product Management, Management, Aspen Technology, Technology, Inc.

© 2013 Aspen Technology, Inc. AspenTech ®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Technology, Inc. All rights reserved. 11-2820-0113

Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0

Table of Con tents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Set Up Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specify Solid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specify Stream Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Create a Particle Size Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Build the Flow Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Select the Crusher Unit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Define Streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Define the Crusher – Select equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Define the Crusher – Comminution power and distribution function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Define the Crusher – Distribution function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Define the Crusher – Tabular data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Analyze the Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 View Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Generate Particle Size Distribution Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

© 2013 Aspen Technology, Inc. AspenTech ®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-2820-0113

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Introduction Solids process modeling with Aspen Plus provides an integrated solution for simulating processes involving solid particles. With the tools provided, it is easy to characterize and model solids handling equipment. In this guide, we will talk about getting started modeling crushers and mills, which mechanically break solids into smaller particles. Aspen Plus V8.0, features a substantial step forward in comminution modeling, helping users improve simulation integrity, cut energy consumption, and increase process throughput. This is not meant to be used as a stand-alone reference document. We recommend that a range of other resources be called upon to give the new user a comprehensive view of how to use solids modeling in Aspen Plus. These may include: • AspenTech support website (support.aspentech.com) • AspenTech courseware available in on-line and in-person versions • AspenTech business consultants • Additional Jump Start Guides This document covers crusher modeling in Aspen Plus. It assumes that the user has Aspen Plus V8.0 or higher installed on her or his computer and some experience building process models.

Set Up Properties All Aspen Plus simulations start in the properties environment, where you must select your components, units of measure, and property sets. This guide will only discuss select steps that are relevant to this process. If you required a more detailed tutorial, see Jump Start: Solids Modeling in Aspen Plus V8.0 (additional resources).

Specify Solid Components When you specify a component, its default type is Conventional. However, in order to model solid components you must change this to Solid (Figure 1).

Figure 1: Specify component as a solid


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Specify Stream Class Once all of the property specifications are complete, you can move on to flow sheet specifications in the Simulation Environment. In the “Setup” folder, open the Specifications form. Here, you must select an appropriate stream class. To determine which is best, hover over the different choices on the dropdown menu to see suggestions (Figure 2). When conventional solids are present with a particle size distribution, MIXCIPSD is a good choice.

Figure 2: Specify stream class

Create a Particle Size Mesh In Aspen Plus, you can characterize solid streams using particle size distributions (PSD). PSD’s can be defined as either a list of values or a mathematical function. To perform PSD analysis, you must first create a mesh to characterize each particular PSD. On the PSD Mesh tab of the Solids form, either open the default PSD or select “New...” to generate additional meshes (Figure 3). You can generate as many meshes as necessary to describe your different solid streams. You may also reuse meshes with as many solid streams as you need.

Figure 3: Edit a PSD mesh

There are four PSD mesh types (equidistant, geometric, logarithmic, and user) which use different methods to specify the particle size intervals (Figure 4). Later, you will have to define the actual PSD for each solid stream by filling in the weight fractions of particles in each interval (either manually or by distribution function). Once you select a mesh type, fill in the required inputs and click “Create PSD Mesh.”


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Figure 4: Select PSD mesh type

Build the Flow Sheet Now that you have set up all of the necessary properties, it is time to build the flow sheet.

Select the Crusher Unit Operation The Crusher unit operation is located on the Solids tab of the Model Palette. There are several icons to choose from (Figure 5).

Figure 5: Select the Crusher unit operation

Define Streams Once you have instantiated a crusher, you must connect the appropriate streams. A crusher takes two streams: inlet and outlet solids (Figure 6).

Figure 6: Streams associated with a crusher


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If there are any liquids in your solid inlet stream (for example in the case of wet milling), you must define the stream using the specifications on both the Mixed and CI Solid tabs. If there are no liquids, only fill out the CI Solids tab (Figure 7).

Figure 7: Fill out the CI Solid tab for the inlet stream input form – if the stream contains liquids, also fill out the Mixed tab

Define the Crusher – Select equipment Open the form for the crusher block. There are several ways to define your crusher: • Select equipment type • Determine outlet PSD from comminution power and distribution function • Specify outlet PSD with a distribution function • Specify outlet PSD with tabular data. Aspen Plus models ten different types of crushers and mills. They are summarized in Table 1.


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Table 1: Available crusher types

Once you select your crusher type, you must specify the selection function and breakage function (except for ball mill and rod mill). The selection function, in each size interval, describes what fraction of the particles are broken by the crusher. The breakage function describes how the broken particles are distributed among the finer particle size classes. The remaining parameters are specific to the type of equipment you select (Figure 8).

Figure 8: Select crusher type


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Define the Crusher – Comminution power and distribution function The next way to calculate the outlet PSD for a crusher is to define a comminution power and a distribution function. Choose distribution function parameters and the power or inlet work stream on the Specifications tab (Figure 9).

Figure 9: Specify distribution function parameters

On the Grindability tab, choose a comminution law. The comminution law is used to determine the characteristic particle diameter d80 (80% of the product mass is smaller than this size). For the other models (Select Equipment Type, etc.), the comminution law is used to calculate energy demand. This can be found in View Results (page 9). Table 2 summarizes the common range of application for each comminution law.

Table 2: Particle size ranges for each comminution law


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You must also define either the Bond work index (BWI) or the Hardgrove grinability index (HGI) (Figure 10). The BWI describes the work consumed in size reduction. Bond work indices for many materials are available in Perry’s Chemical Engineers’ Handbook. The Hardgrove grindability index indicates the ease of grinding coal. The HGI from some United States coals are available in Perry’s Chemical Engineers’ Handbook.

Figure 10: Select a comminution law and Bond work index

Define the Crusher – Distribution function If you choose to specify the outlet PSD with only a distribution function, you must only fill out the specifications tab of the input form. The required inputs vary with the type of distribution function you choose.

Define the Crusher – Tabular data If you choose this option, you only have to fill out the PSD tab of the input form. Here, you must select the Substream ID and fill in the weight fractions for each interval, manually (Figure 11).

Figure 11: Tabular PSD specification


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Analyze the Model View Results Once your model has run and converged, you can view the results a variety of ways. Open the crusher Results tab by either right clicking the unit operation in the flow sheet and selecting “Results…” (Figure 12), or selecting the Results form in the unit operation’s sub-folder (which is in the Blocks folder) in the Navigation pane.

Figure 12: Open the results form

This form has three tabs, which show a summary of the equipment performance, the mass balance, and the status of solver calculations for the block (Figure 13).

Figure 13: The Results form for a crusher


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You can also view this information in the Summary form (this can also be accessed from the Models form in the Results Summary folder in the Navigation Pane – not shown). From here, you can export the data directly to Microsoft® Excel by clicking the “Send to Excel” button in the upper right corner (Figure 14).

Figure 14: Export your data to Excel

You will be prompted by the Aspen Summary Grid window, which asks what data you want to export and how you want it formatted in Excel (Figure 15). You also have the option of generating a live Aspen Simulation Workbook model, which links the simulation to the excel workbook, so you do not have to manually transcribe changes from one to the other. Learn more about Aspen Simulation Workbook in additional resources.

Figure 15: Aspen Summary Grid options © 2013 Aspen Technology, Inc. AspenTech ®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-2820-0113

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Generate Particle Size Distribution Plots You can generate a PSD plot for the crusher’s inlet and outlet streams. To do so, open the form for the crusher, navigate to the Plot group on the Home tab on the ribbon, and select the PSD button (Figure 16). Because plots are contextual, you will not have this option unless the form for the crusher is active. If a stream form is open, this button will only generate a plot for that stream.

Figure 16: Generate a PSD plot

Figure 17 shows a typical PSD plot for a crusher.

Figure 17: Typical particle size distribution plot for a crusher


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Additional Resources Public Website: www.aspentech.com/products/aspen-plus www.aspentech.com/products/solids

Online Training: www.aspentech.com/products/aspen-online-training

On-Demand Short Presentations Creating a Crusher Sieve Model https://www.brainshark.com/aspentech1/create-crusher-sieve Creating a Granulator Model https://www.brainshark.com/aspentech1/create-granulator Creating a Classifier Model https://www.brainshark.com/aspentech1/create-classifier

AspenTech Youtube Channel Crusher Modeling Overview http://www.youtube.com/watch?v=e8N9c7YB-tw&list=PL0ADEB58FD49C6EBC&index=9 Granulator Modeling Overview http://www.youtube.com/watch?v=REIdxJh7-RU&list=PL0ADEB58FD49C6EBC&index=8 Dryer Modeling Overview http://www.youtube.com/watch?v=u3sJjkvG3fc&list=PL0ADEB58FD49C6EBC&index=17 Classifier Modeling Overview http://www.youtube.com/watch?v=vuwg1Q6njkM&list=PL0ADEB58FD49C6EBC&index=10

Jump Start Tutorials Series Jump Start: Solids Process Modeling in Aspen Plus V8: www.aspentech.com/SolidsJumpStart/ Jump Start: Solids Process Modeling for Experienced Aspen Plus Users: www.aspentech.com/SolidsModeling-ExperiencedUsers/ Jump Start: Modeling Convective Dryers in Aspen Plus V8.0: http://www.aspentech.com/JumpStartConvectiveDryers/

Aspen Simulation Workbook http://www.aspentech.com/products/aspen-simulation-workbook.aspx Video: Creating Excel Reports with Aspen Plus https://www.brainshark.com/aspentech1/excel-aspen-plus Tutorial: Getting Started With Aspen Simulation Workbook (Aspen HYSYS and Aspen Plus) http://www.aspentech.com/ASW_Getting_Started/


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About AspenTech AspenTech is a leading supplier of software that optimizes process manufacturing—for energy, chemicals, engineering and construction, and other industries that manufacture and produce products from a chemical process. With integrated aspenONE® solutions, process manufacturers can implement best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become more energy efficient. To see how the world’s leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit www.aspentech.com .

Worldwide Headquarters Aspen Technology, Inc. 20 Crosby Drive Bedford, MA 01730 United States phone: +1–781–221–6400 fax: +1–781–221–6410 [email protected]

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Crusher en Aspen

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