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USIM PAC 3.0: New Features for a Global Approach in Mineral Processing Design
Brochot, S., Durance, M.-V., Guillaneau J.-C., Villeneuve, J. BRGM Environment & Process Division Avenue C. Guillemin, 45060 0rlans CEDEX 2 France process@brgm.fr

APCOM 2002 - February 25-27

Summary

USIM PAC story Simulation based approach Main features of USIM PAC 3.0
New features of version 3.0 Global approach tools

The global approach through an example

Gold ore treatment

Conclusion

APCOM 2002 - February 25-27

USIM PAC story

Version 1: Physical treatment
Grinding, classification, density separation, flotation Various design tools in one software

Version 2.0: Windows application

Crushing, hydrometallurgy for gold ore treatment User friendly interface

Version 2.1: Hydrometallurgy

SX, EW, bioleaching Chemical engineering concepts

Version 3.0

APCOM 2002 - February 25-27

Simulation based approach

Simulation assists mineral processing engineers in
preliminary design plant sizing capital and operating cost evaluation waste management environmental impact study process optimization circuit adaptation waste recycling (water, tailings) waste treatment process modification (effluent treatment)

Steady-state simulation Full Material Balance

APCOM 2002 - February 25-27

Basis of steady-state simulation

Physical properties Physical properties MODEL MODEL Parameters Parameters

Input Input Flowrates Flowrates Sizes ,, Sizes Grades, Grades, etc. etc.

Output (s) Output (s)

Feed stream Feed stream description description Equipment Equipment configuration configuration Model Model parameters parameters Equipment Equipment configuration configuration

Plant operation Plant operation Plant capital cost Plant capital cost

Steady -state Steady -state simulator simulator

Plant operation Plant operation Objectives Objectives

APCOM 2002 - February 25-27

Design methodology

Conventional flowsheet Conventional flowsheet hypothesis hypothesis Preliminary simulation with flowsheeting models Size and setting calculation with design models Simulation of the full operation of the plant Estimate of the overall cost of the plant

Objective: Pre-feasibility study Set of data for the Set of data for the complete flowsheet complete flowsheet Complete description of the Complete description of the plant equipment plant equipment Comparisons between Comparisons between several possible flowsheet several possible flowsheet

APCOM 2002 - February 25-27

Main features of USIM PAC 3.0

Project management Simulator description
Flowsheet drawing Material description: Phase model Stream data Equipment description

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Phase model

Ore

Ore

Water Water Carbon

Ore
Grinding and flotation plant

Solution
Gold ore treatment plant

Preliminary grinding plant design

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Example of phase model

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Example of phase model

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Chemical reaction

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Pulp definition

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Main features of USIM PAC 3.0

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Mathematical models of unit operations

Performance models (level 0) Unit sizing models (level 1) Optimisation models (levels 2 and 3)

APCOM 2002 - February 25-27

Unit operation in USIM PAC Final product

SX SX EW EW Leaching Leaching Bioleaching Bioleaching Solid- liquid Solid- liquid Separation Separation Size Size Classification Classification Crushing Crushing Grinding Grinding Flotation Flotation Precipitation Precipitation Carbon In Pulp Carbon In Pulp Adsorption Adsorption

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Gravity Gravity Separation Separation

Run-of-Mine

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Workshop

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Data processing in USIM PAC 3.0

Data reconciliation by Material Balance Direct simulation Reverse simulation
Unit sizing, model calibration, physical property calculation Objective Driven Simulation Flowsheet optimisation Objective function description

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Capital cost estimate Supervisor of simulation

Actuators and sensors

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Objective function

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Objective function

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Supervisor of simulation

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Actuators and sensors

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Supervisor results

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100 90 80 70 60 50 40 30 20 10 0 2 2.2 2.4 2.6 2.8 3 3.2 3.4 3.6 3.8

700 600 500 400 300 200 100 0 Circulating load of stream 6 relative to stream 1 (%) d80 of phase Global Ore of stream 8 (m)

APCOM 2002 - February 25-27

Main features of USIM PAC 3.0

Results display
Graphs: size distribution, stream bar graph Sheets: overviews, global results

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Configuration
Equipment model parameters Phase model Measurement units and currencies Results display

Development Kit
Icons and mathematical models defined by user

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Model parameter variant

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Global approach tools

Phase model
Valid material description whatever process

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Process split up using workshop Reagent consumption

Distribution lines and regulators Chemical reactions

Water recycling
Wastewater treatment and distribution line recycling effect

Waste treatment and long term behaviour Flowsheet optimisation and supervisor of simulation

APCOM 2002 - February 25-27

Water recycling

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Water recycling

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Conclusion
USIM PAC 3.0
Improved version New tools: supervisor, flowsheet optimization New models: hydrometallurgy, utilities, workshop Allowing global approach

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New fields of application

APCOM 2002 - February 25-27

Modeling of the composting

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OM Brutes - Qualit du compost (1 Tapis slectionneur) 200

80 Crible 55% Crible 62% 70 Crible 76% Norme Classe A

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Teneurs

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Influence of the screen on the compost content in Hg, Ni, Cd...

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20

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0 MONS (en %) Films > 5 mm x10 (en %)

APCOM 2002 - February 25-27

Lourds > 5 mm (en %)

Inertes tot. (en %)

Hg (ppm)

Cd (ppm)

Ni (ppm)

Pb /10 (ppm)