Crusher en Aspen

Jump Start: Modeling Crushers and Mills
in 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.
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 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
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
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.
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
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.
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
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
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
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
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

10
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 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
11
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/
12
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,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the worlds 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: +17812216400
fax: +17812216410
info@aspentech.com
Regional Headquarters
Houston, TX | USA
phone: +12815841000
So Paulo | Brazil
phone: +551134436261
Reading | United Kingdom
phone: +44(0)1189226400
Singapore | Republic of Singapore
phone: +6563953900
Manama | Bahrain
phone: +97317503000
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
For a complete list of offices, please visit

www.aspentech.com/locations

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Jump Start: Modeling Crushers and Mills

in Aspen Plus V8.0

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

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

Specify Solid Components

Figure 1: Specify component as a solid

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

Specify Stream Class

Figure 2: Specify stream class

Create a Particle Size Mesh

Figure 3: Edit a PSD mesh

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

Figure 4: Select PSD mesh type

Build the Flow Sheet

Select the Crusher Unit Operation

Figure 5: Select the Crusher unit operation

Figure 6: Streams associated with a crusher

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

Define the Crusher Select equipment

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

Table 1: Available crusher types

Figure 8: Select crusher type

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

Define the Crusher Comminution power and distribution function

Figure 9: Specify distribution function parameters

Table 2: Particle size ranges for each comminution law

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

Figure 10: Select a comminution law and Bond work index

Define the Crusher Distribution function

Define the Crusher Tabular data

Figure 11: Tabular PSD specification

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

Analyze the Model

Figure 12: Open the results form

Figure 13: The Results form for a crusher

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

Figure 14: Export your data to Excel

Figure 15: Aspen Summary Grid options

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

Generate Particle Size Distribution Plots

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

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

On-Demand Short Presentations

AspenTech Youtube Channel

Jump Start Tutorials Series

Aspen Simulation Workbook

For a complete list of offices, please visit

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