Abstract: A representative hardware-in-the-loop simulation system was established for the mixed separation process to meet the demands of industrial process control technologies with complex characteristics. A hardware-in-the-loop simulation system was developed composed of a virtual object computer, a controller-design computer, a monitoring computer, virtual actuators, virtual detecting instruments, and a control system to achieve mixed separation. The control algorithm of the system was based on actual industrial software, and Matlab was use to design the virtual object, virtual actuators, virtual detecting instruments, and online identification system. The mechanism modeling of controlled object, parameter identification of controller design model, controller design and controller performance evaluation were completed on the virtual object computer, controller-design computer and monitoring computer. The proposed system lays the foundation for future industrial applications of control algorithms for complex industrial processes.