Articles

Simulation is a critical exercise in process engineering for the design and operation of chemical and mineral processing plants. Process modelling allows engineers to study and understand the behaviour of their process under a range of conditions to optimise efficiency, maximise product value, and minimise environmental impact. However, creating an accurate and robust process model can be a daunting task…

SysCAD process modelling software has a range of applications as a teaching and learning tool in industry and academia. Flowsheet-based process simulation within a robust solver provides the ideal environment for students, researchers and engineers to test hypotheses and familiarise with new systems without costly real-world impact. A well-tuned process model provides a comprehensive repository of process design and operating…

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….

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),…

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…

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…

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…