Modelling and simulation of dynamic crushing plant behavior with MATLAB/Simulink

Every process is subjected to changes in performance and efficiency over time. These dynamics can originate upstream and be inherent through the process or occur anywhere in the downstream process. Traditional plant simulations are performed with steady-state simulation, which are limited to give the performance in an ideal situation. However, plant performance usually tends to deviate away from the predicted plant performance. These dynamics are usually consequences of an altered state of the plant due to factors such as natural variation, unmatched, inappropriate or degrading equipment performance and/or stochastic events.This paper presents a novel approach for simulating dynamic plant behavior and evaluating effects from process modification through dynamic simulations with MATLAB/Simulink. An example of an existing crushing circuit is used to illustrate the functionality and the advantage of using a dynamic simulator. The results and knowledge gained from the simulation can provide a base for optimizing a robust production output in the form optimal utilization, energy efficiency or higher product quality.

► Every process is subjected to changes in performance and efficiency over time.
► Identifying problems requires detailed information about the process.
► Plant performance saturation depends on how it is configured and controlled.
► Process simulations revealed possible improvements, 4.7% in one scenario.
► Empirical study confirms simulation result with approx. 4.9% increase in throughput.