Aggregate Plant Simulation Software for Producers and Engineers
Model the aggregate production flow from primary crushing through screening, to understand product yield, throughput limits, and the impact of plant changes before you make them.
Aggregate plant decisions are made with incomplete data
An aggregate plant produces multiple products from a single feed: various size fractions of crushed stone, concrete aggregate, roadbase, and dust. Each product has a specification and a market value, and the proportion of each that the plant produces depends on feed gradation, crusher settings, screen apertures, and how those variables interact through the full circuit.
Changing a screen aperture to produce more of one product size affects carry-over to other fractions. Adjusting a cone CSS changes the feed gradation to downstream screens. The total product mix shifts when any parameter changes, and those shifts are not always easy to predict without a simulation.
Aggregate plant simulation software makes these interactions visible, so plant managers and engineers can make informed decisions about settings, product mix, and equipment changes.
Why product split matters, not just throughput
A technically valid plant may still produce too much low-value material. If the circuit is generating large quantities of crusher run or dust when the market wants 10–20 mm concrete aggregate, total throughput is not the right measure of plant performance.
Small changes to CSS or screen aperture can shift significant tonnage between products. A cone crusher tightened from 28 mm to 22 mm CSS may increase fine aggregate yield by several percentage points and reduce coarse yield by the same amount. Whether that shift is commercially beneficial depends on your product prices and market demand.
Aggregate plant simulation lets you quantify that shift before you make the change. You can evaluate whether the product mix produced by different CSS and aperture combinations matches your sales mix, not just your throughput target.
Illustrative product yield: comparing scenarios
The table below illustrates the kind of product yield comparison that aggregate plant simulation supports. These are example values only — actual results depend on feed gradation, rock properties, equipment specifications, screen efficiency, and operating conditions.
| Product | Current settings | Scenario A (tighter CSS) | Scenario B (wider aperture) |
|---|---|---|---|
| 0–6 mm dust | example t/h | ↑ higher | similar |
| 6–10 mm | example t/h | ↑ higher | ↓ lower |
| 10–20 mm | example t/h | similar | ↑ higher |
| 20–40 mm | example t/h | ↓ lower | ↑ higher |
Illustrative only. Quorr calculates actual projected tonnages based on the feed gradation, equipment specifications, CSS, and screen aperture settings you enter.
How Quorr models aggregate plant flows
Quorr models the aggregate plant as a connected flowsheet, tracking material from primary feed through each stage to product stockpiles. Each crusher and screen is a node with defined performance parameters, and the mass balance runs through all nodes simultaneously.
Crushing stage simulation
Model primary, secondary, and tertiary crushing stages using jaw, cone, or impact crushers with real performance data. See throughput and discharge gradation at each stage.
Multi-deck screening
Model vibrating screens with multiple decks, each with its own aperture. See how material is classified across each deck and what each product fraction contains.
Product yield analysis
See the projected tonnage for each aggregate product fraction and understand how plant settings affect the balance between products.
Bottleneck identification
Identify which stage limits total plant throughput, including crusher overload, screen overload, excessive recirculating load, and stages where product split cannot be achieved.
Washing, classification, and dewatering
Aggregate plants may also include washing, classification, and dewatering stages: log washers, scrubbers, hydrocyclones, dewatering screens, and fines recovery systems. These are significant parts of many aggregate production processes, particularly in sand and gravel operations and limestone plants with high clay content.
Where washing and wet classification stages are outside the current simulation scope in Quorr, they should be treated as downstream process considerations rather than detailed crusher-circuit calculations. The crushing and screening circuit can be modelled to the point where material exits to washing, and the washing and classification stages assessed separately.
Contact us to discuss what is currently supported for washing and classification in your specific application.
How aggregate plant simulation works in Quorr
A typical aggregate plant in Quorr is modelled as follows:
Feed definition
Set the feed material type (hard rock, limestone, gravel), feed gradation, bulk density, and target fresh feed rate. The feed gradation at the secondary stage input depends on primary crushing output and any intermediate screening.
Crushing and classification
Build secondary and tertiary crushing stages using cone or impact crushers, connected to multi-deck screens. A triple-deck screen with, for example, 40 mm, 20 mm, and 6 mm apertures classifies the crusher discharge into four fractions: oversize, 20–40 mm, 6–20 mm, and minus 6 mm. Oversize returns to the cone crusher in a closed circuit.
Product yield
Quorr shows the projected tonnage at each product stockpile. For the same circuit, different cone CSS settings produce different proportions of each size fraction. The simulation shows the yield change for each CSS option, which has direct commercial implications for a plant selling multiple products at different prices.
All projected tonnages are illustrative estimates based on the equipment data and feed conditions you enter. Actual results depend on manufacturer specifications, feed variability, screen efficiency, and operating conditions.
Simulating an aggregate plant in Quorr
Define feed material and target production
Set rock type, feed gradation, and target feed rate. Define the product specifications you need to meet.
Build the crushing and screening circuit
Add crushers and screens, connect them in the correct sequence, and set CSS and screen apertures for each stage.
Define product stockpiles
Connect each product fraction from the screens to a labelled stockpile. Name the products (e.g. 20–40 mm, 6–20 mm, dust) for clarity in the simulation output.
Run the simulation
See throughput at each stage, product yield at each stockpile, recirculating loads in closed circuits, and which machine is the constraint.
Adjust settings and compare
Change CSS, screen aperture, or feed rate and re-run the simulation. See how the product mix changes and which products gain or lose tonnage.
Simulation limits and engineering judgement
Quorr is a design and scenario comparison tool. It helps users estimate mass balance, product yield, utilisation, and likely bottlenecks, but it does not replace manufacturer guarantees, detailed engineering design, site trials, pilot testing, commissioning data, or professional judgement.
Product yield predictions are sensitive to feed gradation assumptions and screen efficiency values. Small changes in these inputs can shift projected tonnages significantly. Use simulation to compare options and understand sensitivities, not to commit to precise production forecasts.
Aggregate plant scenarios you can model and compare
- Single-product versus multi-product aggregate plant layouts
- Hard rock aggregate plants with three-stage crushing and multi-deck screening
- Limestone aggregate plants with softer rock and higher fines generation
- Product yield analysis: how CSS changes affect the mix between coarse and fine fractions
- Throughput increase scenarios: what adding a second cone crusher achieves
- Screen aperture optimisation: balancing product quality with carry-over to the next fraction
- Bottleneck analysis: which stage limits production at different feed rates
- Comparison of open and closed secondary circuit configurations for a given product specification
Who uses aggregate plant simulation software
Aggregate producers
Model existing plant to understand production limits, identify bottlenecks, and evaluate the impact of settings changes on product yield before making them on site.
Process engineers
Design new aggregate plants or plan upgrades with a mass balance behind every equipment decision. Validate sizing before procurement.
Consultants
Model aggregate plant scenarios for clients, compare equipment options, and present findings as a shared browser-based model rather than a static report.
Simulate your aggregate plant in the browser
Register your interest and we will be in touch when Quorr is ready for your aggregate plant design.
Frequently asked questions
How is aggregate plant simulation different from crushing plant simulation?
Crushing plant simulation focuses on the reduction stages: crushers, screens, and the mass balance through the crushing circuit. Aggregate plant simulation adds a focus on multiple saleable product fractions and the commercial implications of different plant settings. In practice, many aggregate plants require both, and Quorr models the integrated flow.
Can Quorr model a sand and gravel aggregate plant?
Yes. Sand and gravel plants typically involve screening and classification alongside lighter crushing. Quorr supports screens and classification equipment alongside crushers. For washing stages and wet classification, check with us on what is currently supported for your application.
How does a change in cone CSS affect my product mix?
A tighter cone CSS produces a finer discharge gradation, which increases the proportion of material passing through smaller screen apertures. This typically increases yield in fine product fractions (e.g. 6–20 mm) and reduces yield in coarser fractions (e.g. 20–40 mm). Quorr shows the projected yield change for each product fraction when you adjust the CSS.
What happens if my feed rate increases by 20%?
Quorr will show which stage hits its capacity limit first at the higher feed rate, flagging it as the constraint. You can then evaluate what equipment change (upsizing the crusher, adding a screen deck) would be needed to handle the increased production rate.
Can I share the aggregate plant simulation with colleagues or clients?
Yes. Designs can be shared with colleagues, clients, or contractors. Recipients do not need a paid Quorr account — they may need to create or log into a free account so access can be controlled securely.