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From Digital Prototype to Digital Twin

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Why Process Simulation? Metallurgical and chemical plants are complicated, consisting of interconnected areas with equipment of varying availability and reliability. Due to their complex nature, maximising asset utilisation and planning efficient production is inherently challenging. Process simulation within a robust solver allows for capturing and balancing the interaction of process units and analysing their effect on plant productivity and consumption….

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Thermodynamic Calculation Engines in SysCAD

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Many industrial and mineral processes are dependent on highly complex chemical interactions. These reactions and thermochemical processes are often simplified in traditional process simulation. Process efficiencies, however, are often found “close to the edge”. As such, a thorough understanding of process chemistry is key to better design, efficient operation, and real-world optimisation. With the introduction of Thermodynamic Calculation Engines (TCEs),…

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Potash – Process Modelling for a Growing Industry

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As the global population increases and the diets of people around the world include more protein, potash production is becoming increasingly important. Primarily used to produce fertiliser, potash refers to a broad range of compounds bearing potassium (K). As one of the “Big 3” essential nutrients in commercial fertilisers, NPK – Nitrogen, Phosphorus & Potassium[1], potassium is vital to crop…

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Bayer Process Modelling for the Alumina Industry

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Aluminium oxide (Al2O3), or alumina, is an important feedstock in a range of industries, primarily aluminium smelting, but also the production of abrasives, refractories, ceramics, glass, electronics and even cosmetics. Purity and particle size of this white powder must be carefully managed during its refining to meet strict downstream criteria. Alumina refineries employ the Bayer process (named for its inventor…

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SysCAD in the Life Cycle of Plant Development

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Process Development Life Cycle Mineral and chemical processing operations tend to follow a typical life cycle – starting with feasibility studies and detailed engineering design, through to construction, commissioning, operation and maintenance, and often followed by process improvement projects and plant expansion. At all stages, different process options or methodologies must be considered. Decisions are made based on factors such…

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