Power optimization in mill plant design: Theoretical analysis and AggFlow simulation

Purpose. This study aims to optimize the power consumption of a mill plant by combining theoretical analysis and process simulation using AggFlow software, since power optimization is a crucial factor in enhancing the efficiency and sustainability of industrial milling operations. Methods. The mill plant, comprising a primary jaw crusher, a secondary double roll crusher, a ball mill, multiple screens, and conveyors, was modeled in AggFlow. A field survey collected specifications of equipment components, and product samples were used for simulation. Theoretical power consumption was calculated and compared with actual field data. Various operational scenarios were simulated to identify opportunities for power consumption reduction. Findings. The optimized settings, including precise adjustments of gap width, rotational speed and belt speed, resulted in measurable power savings of 17.65% for jaw crusher, 7.69% for roll crushers, 13.33% for ball mill, and 20% for conveyor belts, with a total power consumption reduction of 14.29%. Originality. This study highlights the effective use of AggFlow software for power optimization in industrial milling processes, providing a new approach to reducing energy consumption in mill plants. Practical implications. The results provide practical insights for industries aiming to enhance energy efficiency in milling operations. The successful reduction in power consumption demonstrates the potential for integrating process simulation tools like AggFlow into sustainable plant management strategies.