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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

Jump Start: Modeling Crushers and Millsin Aspen Plus V8.0

A Brief Tutorial (and supplement to training and online documentation)

Julie Levine, Product Marketing, Aspen Technology, Inc.

Claus Reimers, Software Development, Aspen Technology, Inc.

Ajay Lakshmanan, Product Management, Aspen Technology, Inc.


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

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IntroductionSolids 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 smallerparticles. 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 PropertiesAll 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, seeJump 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). PSDs 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 Perrys Chemical

Engineers Handbook. The Hardgrove grindability index indicates the ease of grinding coal. The HGI from some United

States coals are available in Perrys 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 operations 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


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Generate Particle Size Distribution Plots

You can generate a PSD plot for the crushers 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 aplot 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 Modelhttps://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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Technology, Inc. All rights reserved. 11-2820-0113

About AspenTech

AspenTech is a leading supplier of software that optimizes process manufacturingfor 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,

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