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Process Flows, Mining Operations, & Chemical Engineering

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

fuel-transfer

Fuel Transfer

After 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...

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pit-to-port-modeling-2

Pit-to-Port Modeling

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...

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pulp-and-paper-mills

Pulp and Paper Mills

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....

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waste-reduction

Waste Reduction

ExtendSim 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.

ExtendSim in Process Flows, Mining Operations, & Chemical Engineering

  • 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.

ExtendSim in Process Flows, Mining Operations, & Chemical Engineering

  • 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 in Process Flows, Mining Operations, & Chemical Engineering

  • DNV GL used ExtendSim for a concept selection study to optimize the system design and help convince shareholders of Borouge (an Abu Dhabi Polymers Company) that Borouge 2 would be a viable project that would be a good return on their investment. This new plant would be capable of producting two million tons of polyolefins. The model created was a rather complicated flow model with complex rules for running the plant in case of component failures. Though the time-frame was short, the model helped convince shareholders to move forward with the project.
  • In another project, DNV GL used ExtendSim to optimize the field development of an oil and gas site based on the analysis of possible component failures and flow assurance issues (e.g. hydrate formation, wax deposits and sand erosion) which might arise. Instead of this being a simple flow rate model, it was a complex thermo-hydraulic flow vector.
  • An 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 pyro-processing 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.

Who is using ExtendSim in Process Flows, Mining Operations, & Chemical Engineering

  • DNV GL used ExtendSim for a concept selection study to optimize the system design and help convince shareholders of Borouge (an Abu Dhabi Polymers Company) that Borouge 2 would be a viable project that would be a good return on their investment. This new plant would be capable of producting two million tons of polyolefins. The model created was a rather complicated flow model with complex rules for running the plant in case of component failures. Though the time-frame was short, the model helped convince shareholders to move forward with the project.
  • In another project, DNV GL used ExtendSim to optimize the field development of an oil and gas site based on the analysis of possible component failures and flow assurance issues (e.g. hydrate formation, wax deposits and sand erosion) which might arise. Instead of this being a simple flow rate model, it was a complex thermo-hydraulic flow vector.
  • An 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 pyro-processing 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.

Trusted by Leading Process Flows, Mining Operations, & Chemical Engineering Teams

astrazeneca
dow-chemical-company
kadant-inc
savannah-river-site

Case Studies

Check out this model of an Iron Ore Grade Movement Model where Insight Acumen was contracted late in the company model development process to support the decision maker, continue model development...

Check out this case study for a coal handling and processing plant model built using ExtendSim. The intent was to be able to test operational strategies for run-of-mine. There were business rules...

Concept model for a deployable bulk fluid distribution system using ExtendSim. A good example of Item and Rate library blocks being used together. Simulates a Defence littoral area of operations,...

Although there are opportunities to reduce electrical energy demand in unit processes of mechanical pulp-based paper and paperboard production, this may not be financially beneficial. This is...

Integrated sites are tightly interconnected networks of large-scale chemical processes. Given the large-scale network structure of these sites, disruptions in any of its nodes, or individual...

Simulations offer valuable insights into how an instrument can be expected to perform and can also point to areas for improvement. In the case of polarimeters described in this article, it is of...

Mechanical 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...

This 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...

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...

Videos

(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...

Solution Providers

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

Process simulation software for the pulp & paper, oil sands, chemical, consumer products, and mining industry.

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

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...

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.