Chemical Processes, Mining, and Process Flows

Chemical Engineering, Mining Operations, & Process Flows

Minimize computational requirements using the ExtendSim discrete rate approach for quicker and more efficient model execution.

Using ExtendSim increases the veracity of the model due to its ability to directly emilinate highly variable feed rate data; simulating highly varying, realistic feed rates to allow for a more accurate reconciliation of volume over the global, between primary cuts, and between sample collection events perspective.

ExtendSim Suite ExtendSim AT

SRSExtendSim models examine the process plutonium and spent uranium fuel rods undergo as they are being turned into waste and/or mixed oxide fuels at the Savannah River Site. The Tonkolili Iron Ore Project managed by African Mineral Limited uses a complete pit-to-port model inclusive of mine processing operations and stockpiling, single line rail network (for supply and export), port landside (car dumper, stockpiling, etc), and port marine (shiploading/unloading, inbound/outbound movement to anchorage etc).The model was calibrated to engineering and operational design specifications and real environmental conditions.
A New Zealand pulp and paper mill models their integrated pulp mill, recycle facility, and sack kraft machine to determine the optimum mix of products and grades for specific economic conditions. Pulp and paper millThis mill now boasts bleached softwood kraft production costs in the bottom quartile worldwide. Nuclear facilityAfter the decommissioning of an experimental reactor at a national laboratory, ExtendSim was used to experiment with different nuclear fuel transfer strategies. The model identified which operational changes would play important roles in minimizing the required time to complete the rector refueling task. And, it gave management a better picture of system bottlenecks in need of removal in future operations.

ExtendSim for Process Flow Analysis

Water and wastewater facility management.

Evaluate possible combinations of shovels and trucks in order to achieve minimum production costs and reduce capital expenditures.

Articulate sample theory.

Test parameter changes to understand impacts before deployment and to reduce field trials.

Help understand the different combination of mass and time.

Examine the impact of making adjustments to settings.

Who is Using ExtendSim

Mining operationAn international manufacturer of heavy duty mining equipment built a custom library of blocks in ExtendSim. Each block represented a different piece of their rock crushing equipment. Their sales team was able to bring this tool to a customer site and build a model of the customer's entire crushing and screening process on the spot. They were quickly and easily able to create a technically, and economically, optimized solution for each customer's actual combination of feed material and operating conditions.

Optimizing the design and operation of a bio-refinery based on high-yield pulp, paper, and paperboard systems.

Modeling sensor output from a nuclear fuel pyroprocessing plant to assess alternative safeguard approaches.

Duplicating the complete infrastructure of pulp and papermaking processes for training, testing, and optimization.

An international metallurgical corporation uses ExtendSim to successfully maintain ISO compliance whilst optimizing sample sizes for health and safety requirements.

Mining operations.

Pulp and paper mills.

Petrochemical industry.

Pharma solutions.

Case Studies Case Studies

BHP Billiton Simulating Time versus Mass Basis Sampling
By M. Handyside and J. Ta'ala
Presented at SAMPLING 2014 - The Australasian Institute of Mining and Metallurgy: Melbourne
July 29-30, 2014 in Perth, WA Australia

BHP BillitonMechanical sampling from conveyors has historically been a staple in the iron ore industry when information related to chemistry, sizing, and moisture is required. In order to optimize automatic sample stations in a changing production environment, BHP Billiton Iron Ore (BHPBIO) developed an ExtendSim model that enables the various combinations of mass–mass, mass– time, time–time and time–mass to be investigated. Their sample station model can utilize actual (variable) feed rates to achieve high resolution and enables the simulation of sample size variation. Cutter speeds and other settings can then be adjusted to better optimize the performance of the sample station with regards to optimal sample size. The model can also assist process engineers in adjusting settings to better optimize the sample station and reduce unwanted events such as blockages. The model can be easily modified to conform to various sample station designs. It is anticipated that the sample station model will be used by process engineers when looking at optimization and trouble shooting. The model is also being used as part of a training package to help new engineers understand the workings of a sample station and the impact minor adjustments to settings can have on sample mass and therefore compliance. Download PDF
Dow Chemical An Efficient Method for Optimal Design of Large-Scale Integrated Chemical Production Sites with Endogenous Uncertainty
By Sebastian Terrazas-Moreno, Ignacio Grossmann of Carnegie Mellon University
John Wassick, Scott Bury, and Naoko Akiya of Dow Chemical Company

Terrazas modelThis paper addresses the design of large-scale, integrated sites considering random process failures. Using a novel mixed-integer linear programming (MILP) model, the authors are able to maximize the average production capacity of an integrated site while minimizing the required capital investment. In this case study, ExtendSim is used to analyze a scenario reduction technique, reporting the results of simulating the operation of the Pareto-optimal designs.Download PDF
International Journal of Production Research A Simulation-Enhanced Value Stream Mapping Approach for Optimisation of Complex Production Environments
By David Schmidtke, U. Heiser, and O. Hinrichsen of the Technical University of Munich
Published in the International Journal of Production Research
May 16, 2014

Value stream mapping (VSM) is a widely adopted method for transformation of production environments into a lean operational state. However, attributes of the ‘paper and pencil’ approach result in limitations when applying VSM in complex production environments. Using ExtendSim, an enhanced VSM method is developed featuring a feasibility and trade-off analysis which is incorporated into the VSM procedure. A case study covering a process of exhaust gas purification catalyst production is then conducted to test the newly developed method. The VSM project yields a shop floor lead time reduction from 11.4 to 1.4 d.Go to page

Expert Solution ProvidersSolution Providers

Analytical Chemistry
LightStone LightStone
Prof. Ed Voigtman, University of Massachusetts

Optical calculus solution to a wide variety of research and teaching problems.

Chemical Process Control
Andritz AG IDEAS Simulation
Andritz AG

Process simulation software for the pulp & paper, oil sands, chemical, consumer products, and mining industry.
Microfusion Engineering Laboratories THINK™ (Thermal Hydraulic Integrated Network)
Microfusion Engineering Laboratories (MEL)

Models that provide MEL clients with reliable simulators for their critical training requirements.

SmartSimulation MineSimulator

To assist the decision making process in determining the number of productive resources (i.e. trucks, extraction equipment, and crushers) necessary to optimize mining operations and maximize production.

Pulp & Papermaking
FrontWay PaperFront
Frontway AB

Library of blocks for ExtendSim describing the infrastructure of pulp and paper mills - pumps, chests and towers, mixing and splitting functions, and input/output of material.
Opdal SimTech FlowMac & PaperMac
Opdal SimTech

FlowMac contains a series of libraries with in total more than 500 blocks as chests, pumps, valves, meters, head boxes, etc. Most of them designed for use in pulp and papermaking models, but other processes can also be modeled.

PaperMac blocks can be combined with the regular FlowMac blocks to create models for a specific Paper Machine.


Play VideoSmartSimulation Value Proposition

(Video available in Spanish only) SmartSimulation has created a module of blocks in ExtendSim, MineSimulator, specifically designed to "Assist in maximizing production, optimizing the use of resources, and improving mine operations through a smart combination of Computer Simulation and Theory of Constraints principles."


Play VideoMore videos being created now. Stay tuned for their posting.