Dynamic Process Simulation Dynamic Process Simulation

Core now offers dynamic simulation as an additional service for engineering clients. Dynamic simulation of a flowsheet or critical unit operation can mean the difference between guessing at and understanding important transient behaviour. Our dynamic simulation consultation service package delivers process flow diagrams, time-series mass and energy balances, process models and a professional report detailing results and recommendations. Core uses and recommends ITHACA® dynamic chemical process simulator software.

Oscillation of tank level on two time scales

Why dynamic simulation?

Improving performance

Dynamic simulation can be the key to running and maintaining an efficient and safe operational process plant. The only steady-state process is on the drawing board. Processes that experience significant non-steady state periods – repeated input step changes, shutdown-restart cycles, batch process cycles, weather impingement – are at risk of running sub-optimally and even uneconomically unless these transient periods are well understood and planned for. Dynamic simulation empowers Core’s clients with the ability to review current plant operations as they are actually experienced, simulate multiple alternative scenarios, and make data-driven changes.

Robust process design

Some aspects of a process design should always be tested dynamically either before or as part of detailed design: Core routinely simulates pilot plants in order to check batch cycle interactions and time to steady-state; dynamic simulation of full-scale heap leach operations can provide insight into true heap recovery ramp-up times and provides a means of improving project economics by optimising lift schedules and planning for the impact of weather cycles. Dynamic simulation is also crucial for testing and optimising surge capacity, offline tuning of control loops, and testing of hazardous equipment start-up and shut-down procedures.

Why choose Core for process optimisation?

Core is uniquely positioned to debottleneck and optimise metallurgical processes:

Qualified and experienced

Highly qualified process engineers and metallurgists with extensive operational experience.

Modern facilities

Advanced metallurgical and analytical laboratories.

Powerful tools

Use of both industry standard and emerging simulation tools such as ITHACA.

Fundamental skills

Ability to take batch testwork results and develop appropriate rate equations for direct use in dynamic simulations.

Developer affiliation

A strong affiliation with the ITHACA developers, allowing Core to submit software development requests on behalf of clients or to fast-track troubleshooting.


Customised programs designed to make a tangible difference on site.

Whether you’re looking to optimise an existing process plant or require process design, Core has the expertise and rigour to get results for you.

Client case studies

Toowong Process leach circuit model

Pilot plant simulation

Dynamic simulation of the 2012 Toowong Process pilot plant was undertaken to determine time to steady-state, assess interactions of batch process equipment, and assess the impact of sampling on leach kinetics.

Simulation results indicated that approximately 400 hours of operation were required before the process was at steady-state on any new feed-stock; the PLS tank required a minimum active volume of 20L in order to allow for both a short- and long-term oscillation in level; and the effect of sampling was negligible.

Tangible results at client sites

Mine water treatment

A mine with legacy environmental issues requested dynamic simulation to better understand the impacts on pit water level of rainfall, forced evaporation, natural evaporation and tailings deposition; to provide an estimate of the size of paste plant required to direct excess tailings to underground; and to provide an estimate of soluble copper loss from pit water as a result of the deposition of alkaline tailings.

Five-year simulations determined that up to six evaporators would be required to control pit water level; approximately 24% of soluble copper would be lost; and a 312 ktpa paste plant was required.


Please contact us to learn how our clients from around the globe have used dynamic simulation to improved their processes and make informed, data-driven decisions.