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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
Table of Contents
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
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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:
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).
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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.
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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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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).
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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
Aspen Plus models ten different types of crushers and mills. They are summarized in Table 1.
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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).
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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).
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.
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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.
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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).
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
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).
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.
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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
© 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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Jump Start: Modeling Crushers and Mills in Aspen Plus ® V8.0
Additional Resources
Public Website:
www.aspentech.com/products/aspen-plus
www.aspentech.com/products/solids
Online Training:
www.aspentech.com/products/aspen-online-training
Jump Start: Solids Process Modeling for Experienced Aspen Plus Users:
www.aspentech.com/SolidsModeling-ExperiencedUsers/
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.
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