1018
Integration of Process Simulation and Environmental Impact
Estimation for Dry Processing Plants in an Online Platform
Gauti Asbjörnsson, Christina Lee, Magnus Evertsson
Chalmers University of Technology
Monica Soldinger Almefelt
Swerock AB
Anna Johansson
Peab Asfalt AB
ABSTRACT: Mines and quarries are under increasing demand to be transparent with their environmental
impacts and the efforts that they are taking to minimise their footprint. Environmental Product Declarations
(EPD) are a standardised framework for calculating the environmental impacts of different products and services
and the publication of EPDs are increasing exponentially for all construction product, including aggregates. This
article aims to give an overview of the work in creating a simulation platform that integrates process simulations
and environmental impacts to support aggregate producers. A case study for aggregates has demonstrated the
potential to automate the EPD creation and publication process.
INTRODUCTION
All corporations strive for a leaner operation. Utilizing
fewer resources while producing more. In both cases, it
results in both economic and environmental benefits. These
two aspects are not mutually exclusive and seldom conflict-
ing objectives. However, the general attitude when it comes
to environmental improvement is that they must include
significant investments in order to improve environmental
KPIs. For larger disruptive changes this might be correct.
Changes such as going for electrical loading and hauling,
building local solar or wind parks or implementing of some
novel machinery. Significant improvements can still be
made at multiple locations with more appropriate control
and operation, improved internal logistics and connect-
ing mobile machinery to the local electrical grid where it
is possible.
Minerals processing and aggregate production are in
a transition phase with more demand for environmental
reporting. For multiple corporations within Europe the
the Corporate Sustainability Reporting Directive (CSRD)
as a part of Environmental, Social and Governance (ESG)
work have become compulsory for larger organizations,
and many mining and aggregate producers fall under these
regulations. Most aggregate producers fall however under
Small and Medium-sized companies (SME) which are not
covered by the CSRD or the ESG. On the other hand, the
environmental standard EN15804 for sustainable con-
struction products (Environmental Product Declaration -
EPDs) is affecting aggregate producers indirectly as many
construction and infrastructure companies are demand-
ing EPDs in their projects to report their own impacts.
Multiple aggregates producers have started to work actively

Previous Page Next Page

Extracted Text (may have errors)

1018
Integration of Process Simulation and Environmental Impact
Estimation for Dry Processing Plants in an Online Platform
Gauti Asbjörnsson, Christina Lee, Magnus Evertsson
Chalmers University of Technology
Monica Soldinger Almefelt
Swerock AB
Anna Johansson
Peab Asfalt AB
ABSTRACT: Mines and quarries are under increasing demand to be transparent with their environmental
impacts and the efforts that they are taking to minimise their footprint. Environmental Product Declarations
(EPD) are a standardised framework for calculating the environmental impacts of different products and services
and the publication of EPDs are increasing exponentially for all construction product, including aggregates. This
article aims to give an overview of the work in creating a simulation platform that integrates process simulations
and environmental impacts to support aggregate producers. A case study for aggregates has demonstrated the
potential to automate the EPD creation and publication process.
INTRODUCTION
All corporations strive for a leaner operation. Utilizing
fewer resources while producing more. In both cases, it
results in both economic and environmental benefits. These
two aspects are not mutually exclusive and seldom conflict-
ing objectives. However, the general attitude when it comes
to environmental improvement is that they must include
significant investments in order to improve environmental
KPIs. For larger disruptive changes this might be correct.
Changes such as going for electrical loading and hauling,
building local solar or wind parks or implementing of some
novel machinery. Significant improvements can still be
made at multiple locations with more appropriate control
and operation, improved internal logistics and connect-
ing mobile machinery to the local electrical grid where it
is possible.
Minerals processing and aggregate production are in
a transition phase with more demand for environmental
reporting. For multiple corporations within Europe the
the Corporate Sustainability Reporting Directive (CSRD)
as a part of Environmental, Social and Governance (ESG)
work have become compulsory for larger organizations,
and many mining and aggregate producers fall under these
regulations. Most aggregate producers fall however under
Small and Medium-sized companies (SME) which are not
covered by the CSRD or the ESG. On the other hand, the
environmental standard EN15804 for sustainable con-
struction products (Environmental Product Declaration -
EPDs) is affecting aggregate producers indirectly as many
construction and infrastructure companies are demand-
ing EPDs in their projects to report their own impacts.
Multiple aggregates producers have started to work actively

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XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1019
with the EPD framework and the numbers of EPDs is
growing rapidly. For the aggregate industry the emission
per ton is relatively low. However, the sheer volume needed
for our infrastructure makes it significant to address.
There are some software solutions available on the mar-
ket for different segments that aim to support aggregate
producers and minerals processing companies in quanti-
fying their performance or environmental impacts. These
are systems such as different process simulators (Aggflow,
Bruno), LCA software (Life Cycle Assessment Software,
OpenLCA) and EPD generators (One-Click LCA). Most
provide generic solutions, each with its own set of advan-
tages and limitations. Often requiring users to be environ-
mental specialists to work with these impact assessment
tools because they need to be adapted to industry-specific
directives and standards. HSC Sim is one of the excep-
tions, where process results can be linked to Gabi (Abadías
Llamas et al., 2029). For the development of an integrated
digital system is vital to focus on modularity and commu-
nication functionality. Systems need to be able to connect
to external solutions to increase usability in a larger context.
In Asbjörnsson et al. (2024) the modularity of three differ-
ent platforms was described, and how the environmental
module was integrated into a more extensive digital system.
Systems aim both at aggregates and minerals processing.
Plantsmith is one of these platforms. It is a web-based
process simulation and environmental platform developed
by Chalmers University of Technology and Roctim AB in
collaboration with the Swedish Environmental Institute
(IVL). The base platform is openly available at roctimsim.
com with a simple registration, allowing the user to start
exploring the platform and simulating their own aggregate
production. Additional functionalities are enabled with
different subscription levels. Allowing for customisation of
the platform based on user needs and preferences. With a
registered company profile, users are able to set company-
specific equipment models with either open access or lim-
ited access for users outside of their company profile.
The purpose of this work is to demonstrate the capabil-
ity of an industry-specific online simulation and environ-
mental platform, giving insight into the process of creating
an EPD, the improved workflow, and the interpretation
and feedback of the results from the industry.
METHODS
The Plantsmith platform is a multidisciplinary research
tool. The main focus is to integrate process simulation capa-
bilities with environmental impact estimation for course
comminution. These can be either quarries or mines. The
driving factor within aggregate production has been the
introduction of the EPD framework. At the current stage,
the EPDs are voluntary. However, multiple aggregate pro-
ducers have identified the commercial advantage of gen-
erating EPDs for their products. Also, by having either a
certified process or tool can significantly reduce the required
work hours to complete an EPD and LCA documentation.
For the development of the platform with the purpose of
integrating process simulation and environmental impacts,
there are specific modules that are essential.
Life Cycle Assessment
Life Cycle Assessment (LCA) is an environmental impact
assessment approach that focuses on the flows into and
out of a system to estimate the environmental impact of
a product or service. The flows are collected in the Life
Cycle Inventory. These can then be translated into poten-
tial impacts on the environment in a variety of areas of
environmental concern known as impact categories. The
LCI is often converted into estimated impacts in the dif-
ferent impact categories by applying Life Cycle Impact
Assessment models to the LCI while the results are normal-
ized to a functional unit to represent the product or service
in mind. A declared unit of impact per tonne is often used
for aggregate products due to the diverse functions that
aggregates can fulfil. An important part of an LCA is set-
ting and describing system boundaries. The decided system
boundaries impact what data needs to be collected and the
assumptions that are made to conduct the study. They are,
therefore, highly important in interpreting and communi-
cating any results from an LCA study.
Product Category Rules
Considering the many decisions that go into deciding the
system boundary, collecting the appropriate data, calculat-
ing the estimated impacts for different impact categories,
and communicating any results, it can often occur that LCA
studies for the same product will result in different results
(Takano et al., 2014). To help overcome these issues and
improve the comparability of studies, Product Category
Rules (PCR) can be developed by experts or relevant actors
which prescribes how different methodological decisions
should be addressed in reference to a group of products
aiming at public communication of the LCA results. Even
more detailed guidelines can be provided in a sub-PCR for
a specific product within the category for further explana-
tions related to the product system. For aggregate products,
a PCR for construction products is followed. In Europe,
this is often the European Standard EN 15804. Which PCR
should be followed is outlined by a programme operator
who will publish the final EPD document communicating

Previous Page Next Page

Extracted Text (may have errors)

XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1019
with the EPD framework and the numbers of EPDs is
growing rapidly. For the aggregate industry the emission
per ton is relatively low. However, the sheer volume needed
for our infrastructure makes it significant to address.
There are some software solutions available on the mar-
ket for different segments that aim to support aggregate
producers and minerals processing companies in quanti-
fying their performance or environmental impacts. These
are systems such as different process simulators (Aggflow,
Bruno), LCA software (Life Cycle Assessment Software,
OpenLCA) and EPD generators (One-Click LCA). Most
provide generic solutions, each with its own set of advan-
tages and limitations. Often requiring users to be environ-
mental specialists to work with these impact assessment
tools because they need to be adapted to industry-specific
directives and standards. HSC Sim is one of the excep-
tions, where process results can be linked to Gabi (Abadías
Llamas et al., 2029). For the development of an integrated
digital system is vital to focus on modularity and commu-
nication functionality. Systems need to be able to connect
to external solutions to increase usability in a larger context.
In Asbjörnsson et al. (2024) the modularity of three differ-
ent platforms was described, and how the environmental
module was integrated into a more extensive digital system.
Systems aim both at aggregates and minerals processing.
Plantsmith is one of these platforms. It is a web-based
process simulation and environmental platform developed
by Chalmers University of Technology and Roctim AB in
collaboration with the Swedish Environmental Institute
(IVL). The base platform is openly available at roctimsim.
com with a simple registration, allowing the user to start
exploring the platform and simulating their own aggregate
production. Additional functionalities are enabled with
different subscription levels. Allowing for customisation of
the platform based on user needs and preferences. With a
registered company profile, users are able to set company-
specific equipment models with either open access or lim-
ited access for users outside of their company profile.
The purpose of this work is to demonstrate the capabil-
ity of an industry-specific online simulation and environ-
mental platform, giving insight into the process of creating
an EPD, the improved workflow, and the interpretation
and feedback of the results from the industry.
METHODS
The Plantsmith platform is a multidisciplinary research
tool. The main focus is to integrate process simulation capa-
bilities with environmental impact estimation for course
comminution. These can be either quarries or mines. The
driving factor within aggregate production has been the
introduction of the EPD framework. At the current stage,
the EPDs are voluntary. However, multiple aggregate pro-
ducers have identified the commercial advantage of gen-
erating EPDs for their products. Also, by having either a
certified process or tool can significantly reduce the required
work hours to complete an EPD and LCA documentation.
For the development of the platform with the purpose of
integrating process simulation and environmental impacts,
there are specific modules that are essential.
Life Cycle Assessment
Life Cycle Assessment (LCA) is an environmental impact
assessment approach that focuses on the flows into and
out of a system to estimate the environmental impact of
a product or service. The flows are collected in the Life
Cycle Inventory. These can then be translated into poten-
tial impacts on the environment in a variety of areas of
environmental concern known as impact categories. The
LCI is often converted into estimated impacts in the dif-
ferent impact categories by applying Life Cycle Impact
Assessment models to the LCI while the results are normal-
ized to a functional unit to represent the product or service
in mind. A declared unit of impact per tonne is often used
for aggregate products due to the diverse functions that
aggregates can fulfil. An important part of an LCA is set-
ting and describing system boundaries. The decided system
boundaries impact what data needs to be collected and the
assumptions that are made to conduct the study. They are,
therefore, highly important in interpreting and communi-
cating any results from an LCA study.
Product Category Rules
Considering the many decisions that go into deciding the
system boundary, collecting the appropriate data, calculat-
ing the estimated impacts for different impact categories,
and communicating any results, it can often occur that LCA
studies for the same product will result in different results
(Takano et al., 2014). To help overcome these issues and
improve the comparability of studies, Product Category
Rules (PCR) can be developed by experts or relevant actors
which prescribes how different methodological decisions
should be addressed in reference to a group of products
aiming at public communication of the LCA results. Even
more detailed guidelines can be provided in a sub-PCR for
a specific product within the category for further explana-
tions related to the product system. For aggregate products,
a PCR for construction products is followed. In Europe,
this is often the European Standard EN 15804. Which PCR
should be followed is outlined by a programme operator
who will publish the final EPD document communicating

XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1017
Buchmann, M., Schach, E., Tolosana-Delgado, R.,
Leißner, T., Astoveza, J., Kern, M., Möckel, R.,
Ebert, D., Rudolph, M., van den Boogaart, K.,
Peuker, U., 2018. Evaluation of Magnetic Separation
Efficiency on a Cassiterite-Bearing Skarn Ore by
Means of Integrative SEM-Based Image and XRF–
XRD Data Analysis. Minerals 8, 390. doi: 10.3390
/min8090390.
Fernandes, I.B., Rudolph, M., Hassanzadeh, A.,
Bachmann, K., Meskers, C., Peuker, U., Reuter, M.A.,
2021. The quantification of entropy for multicompo-
nent systems: Application to microwave-assisted com-
minution. Miner. Eng. 170, 107016. doi: 10.1016
/j.mineng.2021.107016.
Martínez, O.V., Omar Velazquez Martinez, van den
Boogaart, K.G., K.G. van den Boogaart, K. G. Van
Den Bogaart, Lundström, M., Santasalo-Aarnio,
A., Reuter, M.A., Rodrigo Serna Guerrero, Serna-
Guerrero, R., 2019. Statistical entropy analysis
as tool for circular economy: Proof of concept by
optimizing a lithium-ion battery waste sieving sys-
tem. J. Clean. Prod. 212, 1568–1579. doi: 10.1016
/j.jclepro.2018.12.137.
Parchomenko, A., Nelen, D., Gillabel, J., Vrancken, K.C.,
Rechberger, H., 2021. Resource effectiveness of the
European automotive sector—a statistical entropy
analysis over time. Resour. Conserv. Recycl. 169, 105558.
doi: 10.1016/j.resconrec.2021.105558.
Parchomenko, A., Nelen, D., Gillabel, J., Vrancken,
K.C., Rechberger, H., 2020. Evaluation of the
resource effectiveness of circular economy strate-
gies through multilevel Statistical Entropy Analysis.
Resour. Conserv. Recycl. 161, 104925. doi: 10.1016
/j.resconrec.2020.104925.
Peuker, U.A., van den Boogaart, K.G., Rudolph, M.,
Tolosana-Delgado, R., 2020. The entropy of inter-
grown particle mixtures—a contribution to holistic
flowsheet simulation, in: IMPC 2020. Presented at
the International Mineral Processing Congress, Cape
Town.
Rechberger, H., 2001. An entropy based method to evalu-
ate hazardous inorganic substance balances of waste
treatment systems. Waste Manag. Res. 19, 186–192.
doi: 10.1177/0734242x0101900210.
Rechberger, H., Brunner, P.H., 2002. A New, Entropy Based
Method To Support Waste and Resource Management
Decisions. Environ. Sci. Technol. 36, 809–816. doi:
10.1021/es010030h.
Rechberger, H., Graedel, T.E., 2002. The contempo-
rary European copper cycle: statistical entropy
analysis. Ecol. Econ. 42, 59–72. doi: 10.1016
/s0921-8009(02)00102-7.
Schach, E., Buchmann, M., Tolosana-Delgado, R.,
Leißner, T., Kern, M., Gerald van den Boogaart, K.,
Rudolph, M., Peuker, U.A., 2019. Multidimensional
characterization of separation processes—Part 1:
Introducing kernel methods and entropy in the con-
text of mineral processing using SEM-based image
analysis. Miner. Eng. 137, 78–86. doi: 10.1016
/j.mineng.2019.03.026.
Schach, E., Buchwald, T., Leißner, T., Peuker, U., Delgado,
R.T., 2024. Concepts of entropy for raw materi-
als. Powder Technol. 435, 119398. doi: 10.1016
/j.powtec.2024.119398.
Shannon, C.E., 1948. The Mathematical Theory of
Communication.
Sobantka, A., Pons, M.-N., Zessner, M., Rechberger,
H., 2014a. Implementation of Extended Statistical
Entropy Analysis to the Effluent Quality Index of the
Benchmarking Simulation Model No. 2. Water 6,
86–103. doi: 10.3390/w6010086.
Sobantka, A., Thaler, S., Zessner, M., Rechberger, H.,
2014b. Extended statistical entropy analysis for the
evaluation of nitrogen budgets in Austria. Int. J.
Environ. Sci. Technol. 11, 1947–1958. doi: 10.1007/
s13762-013-0401-2.
Velázquez-Martinez, O., Kontomichalou, A., Santasalo-
Aarnio, A., Reuter, M., Karttunen, A.J., Karppinen,
M., Serna-Guerrero, R., 2020. A recycling pro-
cess for thermoelectric devices developed with
the support of statistical entropy analysis. Resour.
Conserv. Recycl. 159, 104843. doi: 10.1016
/j.resconrec.2020.104843.
Velazquez-Martinez, O., Valio, J., Santasalo-Aarnio, A.,
Reuter, M.A., Serna-Guerrero, R., 2019. A critical
review of lithium-ion battery recycling processes from
a circular economy perspective. Batteries 5, 68. doi:
10.3390/batteries5040068

Previous Page Next Page

Extracted Text (may have errors)

XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1017
Buchmann, M., Schach, E., Tolosana-Delgado, R.,
Leißner, T., Astoveza, J., Kern, M., Möckel, R.,
Ebert, D., Rudolph, M., van den Boogaart, K.,
Peuker, U., 2018. Evaluation of Magnetic Separation
Efficiency on a Cassiterite-Bearing Skarn Ore by
Means of Integrative SEM-Based Image and XRF–
XRD Data Analysis. Minerals 8, 390. doi: 10.3390
/min8090390.
Fernandes, I.B., Rudolph, M., Hassanzadeh, A.,
Bachmann, K., Meskers, C., Peuker, U., Reuter, M.A.,
2021. The quantification of entropy for multicompo-
nent systems: Application to microwave-assisted com-
minution. Miner. Eng. 170, 107016. doi: 10.1016
/j.mineng.2021.107016.
Martínez, O.V., Omar Velazquez Martinez, van den
Boogaart, K.G., K.G. van den Boogaart, K. G. Van
Den Bogaart, Lundström, M., Santasalo-Aarnio,
A., Reuter, M.A., Rodrigo Serna Guerrero, Serna-
Guerrero, R., 2019. Statistical entropy analysis
as tool for circular economy: Proof of concept by
optimizing a lithium-ion battery waste sieving sys-
tem. J. Clean. Prod. 212, 1568–1579. doi: 10.1016
/j.jclepro.2018.12.137.
Parchomenko, A., Nelen, D., Gillabel, J., Vrancken, K.C.,
Rechberger, H., 2021. Resource effectiveness of the
European automotive sector—a statistical entropy
analysis over time. Resour. Conserv. Recycl. 169, 105558.
doi: 10.1016/j.resconrec.2021.105558.
Parchomenko, A., Nelen, D., Gillabel, J., Vrancken,
K.C., Rechberger, H., 2020. Evaluation of the
resource effectiveness of circular economy strate-
gies through multilevel Statistical Entropy Analysis.
Resour. Conserv. Recycl. 161, 104925. doi: 10.1016
/j.resconrec.2020.104925.
Peuker, U.A., van den Boogaart, K.G., Rudolph, M.,
Tolosana-Delgado, R., 2020. The entropy of inter-
grown particle mixtures—a contribution to holistic
flowsheet simulation, in: IMPC 2020. Presented at
the International Mineral Processing Congress, Cape
Town.
Rechberger, H., 2001. An entropy based method to evalu-
ate hazardous inorganic substance balances of waste
treatment systems. Waste Manag. Res. 19, 186–192.
doi: 10.1177/0734242x0101900210.
Rechberger, H., Brunner, P.H., 2002. A New, Entropy Based
Method To Support Waste and Resource Management
Decisions. Environ. Sci. Technol. 36, 809–816. doi:
10.1021/es010030h.
Rechberger, H., Graedel, T.E., 2002. The contempo-
rary European copper cycle: statistical entropy
analysis. Ecol. Econ. 42, 59–72. doi: 10.1016
/s0921-8009(02)00102-7.
Schach, E., Buchmann, M., Tolosana-Delgado, R.,
Leißner, T., Kern, M., Gerald van den Boogaart, K.,
Rudolph, M., Peuker, U.A., 2019. Multidimensional
characterization of separation processes—Part 1:
Introducing kernel methods and entropy in the con-
text of mineral processing using SEM-based image
analysis. Miner. Eng. 137, 78–86. doi: 10.1016
/j.mineng.2019.03.026.
Schach, E., Buchwald, T., Leißner, T., Peuker, U., Delgado,
R.T., 2024. Concepts of entropy for raw materi-
als. Powder Technol. 435, 119398. doi: 10.1016
/j.powtec.2024.119398.
Shannon, C.E., 1948. The Mathematical Theory of
Communication.
Sobantka, A., Pons, M.-N., Zessner, M., Rechberger,
H., 2014a. Implementation of Extended Statistical
Entropy Analysis to the Effluent Quality Index of the
Benchmarking Simulation Model No. 2. Water 6,
86–103. doi: 10.3390/w6010086.
Sobantka, A., Thaler, S., Zessner, M., Rechberger, H.,
2014b. Extended statistical entropy analysis for the
evaluation of nitrogen budgets in Austria. Int. J.
Environ. Sci. Technol. 11, 1947–1958. doi: 10.1007/
s13762-013-0401-2.
Velázquez-Martinez, O., Kontomichalou, A., Santasalo-
Aarnio, A., Reuter, M., Karttunen, A.J., Karppinen,
M., Serna-Guerrero, R., 2020. A recycling pro-
cess for thermoelectric devices developed with
the support of statistical entropy analysis. Resour.
Conserv. Recycl. 159, 104843. doi: 10.1016
/j.resconrec.2020.104843.
Velazquez-Martinez, O., Valio, J., Santasalo-Aarnio, A.,
Reuter, M.A., Serna-Guerrero, R., 2019. A critical
review of lithium-ion battery recycling processes from
a circular economy perspective. Batteries 5, 68. doi:
10.3390/batteries5040068