Publication: Modelling and simulation on mineral processing system
Date
2025-08-07
Authors
Nur Aida Nazira Malim binti Abdul Kadir
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Abstract
The optimisation of aggregate production in granite quarries requires precise control over comminution processes, particularly when vertical shaft impact (VSI) crushers are employed. This study applies JKSimMet v6.3 software to simulate and calibrate the crushing circuit of a granite aggregate plant, focusing solely on model fitting to replicate actual plant performance. Data from two quarry sites which are one in Juru and another in Pasir Gudang were utilised to construct a representative flowsheet. The VSI crusher was the primary focus of the simulation, with emphasis placed on adjusting breakage parameters such as k1, k2, k3, and t10, which respectively influence particle selection, size dependency, breakage rate, and product fineness. These parameters were iteratively tuned to match the plant’s particle size distribution (PSD) output, using JKSimMet’s graphical output as a validation reference. While mass balancing was not a core component of this project, model fitting alone was sufficient to achieve a high correlation between simulated and actual PSD curves. The results underscore the potential of simulation as a non-intrusive tool for improving circuit understanding and evaluating design modifications before physical changes are implemented. This research demonstrates that by focusing on parameter refinement within the model fitting process, engineers can gain practical insight into VSI crusher performance and its impact on overall plant efficiency and product quality.