DE LANGE, T. and VENTER, P.E.

The use of simulated Tromp partition curves in developing the flowsheet

of plant extensions at Grootegeluk Coal Mine. APCOM 87. Proceedings of the Twentieth International Symposium
on the Application of Computers and Mathematics in the Mineral Industries. Volume 2: Metallurgy. Johannesburg,
SAIMM, 1987. pp. 295 - 311.

The Use of Simulation Tromp Partition Curves in

Developing the Flowsheet of Plant Extensions at
Grootegeluk Coal Mine
T. DE LANGE and P.E. VENTER
Grootegeluk Coal Mine, [scor Ltd, South Africa

Extensions to the beneficiation plant at the Grootegeluk Coal Mine are currently being planned in order to provide power station coal for Escom's Matimba Power Station, presently under construction. A simulation model was
developed on the Olivetti M-24 microcomputer to facilitate the development
of the envisaged flowsheet. The computer program simulates the heavy-medium
separation and screening unit operations. The model is based on the construction of the Tromp partition curve described by an arctangent function, allowing
ideal and non-ideal separations.
The paper discusses the determination of the parameters required by the
arctangent curve from standard process parameters such as Epm, Wolf cutpoint, Tromp cutpoint and screening efficiency. The accuracy and shortcomings of the model are discussed, while an overview of the application of the
model to evaluate borehole and bulk sample analyses is also given. It is concluded that the model is an invaluable aid to general flowsheet development.

Introduction
The Grootegeluk Coal Mine, situated in the

model involved,

Waterberg coal-field 20 km west of Ellis-

for both heavy-medium separation

ras,

and screening operations,

is

coal.

Iscor's

major source of

coking

The beneficiation plant treats some

000 t/h of raw coal from the Upper

yielding approximately

the

Ecca,

coking

coal and 24% of a middlings frac-

and bulk sampling campaigns were

launched
development

tons

The

Escom's

Matimba Power Station,

under construction,

coal

the

flowsheet

detailed

to

currently

design

to

facilitate

evaluation of borehole and bulk

sampling data.
This

paper

describes

the

heat value

of

simulation

the

as

of the

analyses

included,

was awarded to Iscor.

A computer model was developed as part

the

System demands

Extensive plant expansion became necessary when the contract to supply 12 x 106
of middlings

during

12%

Borehole

annum

and illustrates

application of the model

tion.

per

circuits

flowsheet development phase.

and

Middle

the accuracy of the model

envisaged

among others,
~

steps

flowsheet.
samples

sink/float analyses.
these

sets

of

data

been manipulated by hand

fractional densimetric

Mayer

curves.

THE USE OF SIMULATED TROMP PARTITION CURVES

the

fractional ash,

yield
be

in

specified on these

Conventionally,
would have

first

curves

to
and

Ideal cutpoints would then

utilized to calculate graphically

the
295

expected

yields at specified heat

values

or ash values.
However,

this

conventional method

had

the following disadvantages:

a)

The

method

was

the

tedious

and

time
into

tations; and

To

separations

while

practical

could

a)

compute blended washability data

different boreholes; and

the

organic

and
be

accept

model

in

order

disadvantages of the

the

available,
required
and

to

hand

raw data in

the

to draw washability

c)

curves

summarized

the heavy-medium

and

size

flowsheet

bulk

and

data,

thus

practically

orientated

than would have

been

plant

possible

Overview of existing models

The

specific

above,
an

parameters

requirements

together

as

discussed

with the given time con-

virtually excluded the use

existing simulator

l'DDSIM

using a his-

Wd.S

negotiating

from

University

package.

Prof.

of

the

the

R.P.

Al though

purchase

King<

of

1)

of

the

Witwatersrand,

the

package

coal beneficiation plant;

as it was still being prepared for distri-

allow a choice of Epm values, organic

bution.

and other parameters in

non-ideally,

cess

required

at each point in

,the
pro-

screening

process had to be

tated

the

by

choice

of

compute

the

excluded owing to
a)

inability to cater for the format

b)

equipment

screen analyses

of both products

The

available APPLE II + microcomputer

an

permit a step-by-step development

of

develop

step,

a logical flowline.
model

therefore had to be able

i.e.

decision was therefore taken to use

to

separation

involved,

purchasing and commissioning.

in order

each

by

which was unavailable

the time constraints

and

of

required

at that stage of the design; and

screening

sink/float

information

such packages,
c)

total

of

the raw data;

facili-

efficiencies;

stage,

The use of other simulation packages was

the

flowline. Simulation of the non-ideal

was not available at that

of

accumulated on the Grootegeluk coking

specific heavy-media separation

296

borehole

could be manipulated extensively,

and

ting partition factors,

order to simulate,

The

rate

Iscor

of standard process

from

permitting the development of a more accu-

separation unit processes by calcula-

efficiencies

d)

samples

straints,

simulate

tory

data

format

calculate the information

present results in a

supplied

otherwise.

format.;

b)

expected yields at specified

maximising the usage of given

method. The model had to be able to

a)

compute

By using this model it is clear that the

efficiencies proved to

simulation

for

the extrapolation to

need therefore existed to utilize a

eliminate

charac-

ash, heat value or density cutpoints.

complicated and time consuming.

computer

The

be

expected

screening
The

operation.

evaluate borehole data (in addition

b)

ideal

induced,

screening

to the above) this model had to be able to

data could not be analyzed

only

computation of separation product

satisfactory depth, due to time limic)

or

teristics could then be facilitated.

consuming;
b)

compute full partition curves for either a

density

a model in-house.

The APPLE

and

was

later replaced by an Olivetti M-24.

to
METALLURGY: SIMULATION

The performance evaluation program

Modelling
an

Heavy-medium separation

Iscor

Grootegeluk

washer

performance

metallurgical
dy.

had been using a

This

program for

partition

coal

program is similar to

the

one

was therefore available for

the feed,

(This

to

the

(4,5):

to

the

P3)

[1 ]

fitted

Tramp

partition factor

(ie.

probability that a coal particle

of a given density, d, will report to

the

the overflow ) ( %

metallurgical
samples of

sink-float

taken

density ( g/cm3

PI - P4

analysis.

conventional

way<

The

parameters describing the shape

general

shape

of

this

curve

(referred to as the fitted curve) is given

3)

is referred to as the observed par-

of the specific separation curve.

Tromp partition factors are then

in

Arctan(P2(d

where

the

product and tailings are

calculated

according

observed

cutpoints

incorporation

of a coal washer,

applied

Discrete

the

to

PI - P4

the model.

Performance curve fitting

In order to determine

and

= lOO(PI

An extensive

errors and Wolf curve

performance

factors

following equation

weekly

database, including Tromp curve cutpoints,

into

curve

audits for some time alrea-

described by Wizzard(2).
probable

arctangent

fits

in

tition factors).

Figures

The use

01

1 and 4.
"he::

c;.';:".' Ji

,:~ent

function

dif-

100-r--------------------------------------------------------~

Hx; - Shift for asymmetry

~-----

1------

Ideal Epm - no asymmetry

~-------

WWg

o
1,490

1,470

1,450

1,510

DENSITY (g/ cm3)

FIGURE 1. Plot of the overflow Tramp distribution factor against density showing the development of
the HMS simulation model
Points A
B
C
I
W
Wg

=
=

(d",,,)
(d so ,5o) Tramp cutpoint

= (d'5,25)

(d;. t;) Arctan in flection point

True mass based Wolf cutpoint
= Two-dimensional Wolf cutpoint based on graphic integration
=

THE USE OF SIMULATED TROMP PARTITION CURVES

297

fers

from the method followed by Wizzavd,

who

made use of a

The

arc tangent

Weibull
approach

since it culminates in a

distribution.
is

preferred,

1000

of

iterations required from

to +/- 120,

correlation

a
b

=
=

two- dimensional

search, instead of four, thus reducing the

number

d = density (g/cm3)

whilst still

coefficients

objective
simple:

to

performance

starting

of the simulation model

reverse the

This meant

evaluation.

with

process

calculated results

and

tailings streams

avail-

have

been

Four

which

the

information

parameters and

is

obtain

of

distributed evenly on the

four parameters a, b, c and e. Finding the

of the

Arctan

immediately,

around

are
the

Le.

the

would solve parameter c

thus

to find.

equation,

making

ita

logical

The points (d2s ,25)

distributed

evenly

and

enough

inflection point in order

to

Transform

only

the

into

continuous

discrete

partition

intervals,

by

one point not yet defined.

Ideally,

one would endeavour to use the

means of integration;

Tromp cutpoint

in order to find the

apply

flection

and

the discrete partition factors

point

the

Ecart

Probable

Moyen

calculate

solve d2s and d 75 , since these values have

the simulated product

t~ilings

streams;

compare

the

simulated

and

(Epn) as a degree of

in-

to the feed stream washability data;

found
streams

to

sharpness

widespread application in the

to

coal

processing industry.

observed and refine the model;

the

historical

performance

with those desired on

the

new

Tramp cutpoint
At

this

stage

substitute

the

it

is

Tromp

not

possible

cutpoint

for

to
the

inflection point, because of the asymmetry

The influence of

~ach

of the parameters Pl

to P4 is better understood by rearranging

involved.

However,

asymmetry

is known,

for,

Equation [1] as follows:

by using

assumed
Arctan[b (d - c)] + e

[2]

where

the

if

the

it can be
linear

degree

of

corrected

relationship

to apply in the centre region

of

the partition curve.

Wolf cutpoint
overflow

Tromp distribution

as before(%)
298

degree

consider finding them as well. This leaves

Parameter solving

describing the

inflection point,

plant.

would be

simulated Tromp partition curve;

replace

=a

partition curve, are required to solve the

(d7 5 , 75)

data

symmetrical

parameter

points,

PI to P4 ;

those
g)

Under

in-

asymmetry of the partition curve

choice

curve

f)

parameter

required to solve the four parameters

Solve

el

root

Determine

d)

point

of the arctan

that

This was approached as follows:

c)

of

found.

b)

of

equal to 50, in which case c would be

and

one had to work backwards until the

product

a)

sharpness

equal to the Tromp cutpoint)

The

able,

shift

conditions,

higher.
was

describing

horizontal
flection

+/-

0,995

parameter
separation

obtaining

of

overall efficiency parameter

factor,

When

integrating the top error area

from

the left of the curve and at the same time

METALLURGY: SIMULATION

integrating

the

right,

arrives at the point of equal

one

bottom area

from

the

error area intersection. Under synmetrical

condi tions ,
cide
try,

= 50,25

- 377,2 x

tI

50.

=Abscissa of inflection point

= Tramp cutpoint - Wolf cutpoint

the larger the extent of asynme-

the

larger will be the

between these two cutpoints.

gration

from

two sides is

difference

Since

inte-

nothing

else

The

relationship is considered signifi-

cant with a coefficient of correlation

0,91 as exemplified in Figure 2.

than a two-dimensional version of the Wolf

more,

cutpoint calculation, it followed that the

would expect that with

the

equal to 50.

difference between the Tramp and Wolf

cutpoints was a key in the search for

the

is

inflection point. Therefore, the relationship between the difference in the

and Wolf
the

cutpoints and

inflection

point

the abscissa

had

to

be

means

if

no

asynmetry is

determined

one

tI would be

The constant in Equation [3]

acceptably close to

this

theoretical

value, at 50,25.
Sharpness of separation

of

esta-

In

order

to obtain the ordinat,e

inflection point,
relationship was

Further-

present,

x =0,

of

Tromp

blished.
This

[3]

where

this intersection will coin-

with the Tramp cutpoint at t

However,

tI

by

of linear regression on 25 observa-

tions as

cessary

parameter e,

of

the

it is ne-

to find the horizontal difference

between this point and the Tramp cutpoint,

defined as follows:

54

....
o
ti

46

'';:::

;::l

:9
b<JJ

;a 42
0-

o....
E-

:::

38

.:;::

1i:l

:>

34

+
30;---~--~--~--~--~--~--~--~--~--~--~--~--~~

-0,002

0,01
0,014
0,018
0,006
Tramp cutpoint - Wolf cutpoint (g/cml)

0,002

o Included

0,022

0,026

+ Excluded

FIGURE 2. Plot of the difference between Tramp and Wolf cutpoints against the distribution factors of
the Arctan inflection point.
Liner regression: t;

50,25 - 377,2 x (correlation coefficient

THE USE OF SIMULATED TROMP PARTITION CURVES

0,91)

299

[4]

XI = dI - dso

metrically

around an imaginary axis lying

in an opposite direction from ds 0 than the

This

can

slope

be done

by

determining

the

in the linear section of the parti-

inflection point,
tance,
found

difference,

asymmetry:

which

is already known (tr -

Therefore, d 7 s and dz 5 may be

XI.

tion curve and applying it to the vertical

dI, but with equal dis-

by compensating for this

shift

in

50). Assuming that the linear relationship

holds from dz 5 to d75,

m,

the slope,

is

= ds

XI - Epm

[10]

dzs = dso - XI + Epll

[11]

d7 5

given as:
and

= (75

- 25) I (d75

dzs)

[5]

For coal processing, m is always negative.

Applying
Probable

the

definition of

the

Ecart

Moyen to coal beneficiation,

Solving arctan parameters

The

we

a., b, c and e may now

parameters

solved by assigning the following

find:

be

initial

values:
Epm = (d.z 5 - d? 5) I 2

(positive)

[6 ]

= 100 Ire

[12]

=
=

dI

[13]

tI

[14]

leaving

b to be solved by substitution in

a
and

subst,i tution

thereof

into

Equation

[5], we find m in terms of Epm:

ID

= -25

c
e

I hpn

[7]

[2] with (d,t) = (d7S. 75).

Solving for asymmetry

The

horizontal

difference

between

the

Refinement of parameters

Tromp cutpoint and the inflection point is

'fhe

above

therefore:

owing

to

Equation

[8]

5Ql

parameters
the

found

dr,

Equation [12].

may now

be

narrow

in terms of the Tramp cutpoint,

by

[12]

rearranging [4]:

IJlade
IJlade

in
in

Furthermore, an additional

dr and d 7 5 lie in a

ds 0,

band on the curve.

is

based

on

an

Since Equation

assumption,

the

additional point required must lie closely

to

dI=dso+XI

[9]

the

curve
of

Solving d 75 and d25

The

approximation

[3] and the assumption

the points dz s,
inflection point,

refined,

be

point on the Tromp curve is required since

The

must

end points

tributed

symmetrically around

dso.

research

has shown that the Epm tends

disOur
to

the

distribution

in order to incorporate the

overall

observed

Ecart Probable is generally not

of

here,

efficiency.

~ximum

The

distribution factor

effect

was

chosen

e.g. (1,24 ; 99), referred to as

dM

and tH.
An

i terati ve procedure is then followed

shift according to the extent of asymmetry

whereby the four calculated data pairs are

present

substituted into Equation

300

and that it is

distributed

sym-

[2],

according

METALLURGY: SIMULATION

to following four equations:

b

=a

= Tan[(t7s-e)/a]

(d-c) Arctan[b(d-c)] + e(d-c)

[15]

a(ln[1+b2 (d-c)2)

d 7s -c

[19]

2b

[16)

which results into

(17]

TJ

[20]

T(dJ-l }-T(dJ )

Arctan[b (dr.!: - c)]

dJ - dJ-I

and

where

TJ is the discrete partition factor

for the Jth interval.

c = dso - Tan[(tso - el/a]

[18]
Size separation

Apling
sure

applied in the order as shown.

It

was found that the set of parameters

( 1985) describes a method t.o

the performance of screens, ( 6

meawhich

is

essentially the same as that

followed

those

in

the coal washer

program.

cases where the originally observed parti-

In

this

tion factors were fitted adequately by the

screen aperture is plotted on the ordinate

arctan

axis instead of the density.

converge

found

within

curve.
in

iterations

However ,

the

in

divergence

cases where

the

observed

partition curve had exhibited a low

ciency
This

was

tail in the lower density

effi-

situation

was

and

method the natural logaritmn

Following
it

was

The

screening

rectified by limiting

the

Tramp

thus achieving

a meta-stable convergence.

general

(See Figures
form

of

the

to

simulate

Apling

non-ideal

operations too by means of

partition

similar
in

the exemplary work of

decided

laboratory.

number of iterations to 2,

for the

of

distribution curve.)

region.

tail can often be ascribed to analy-

tical errors made in the

performance

curve

and to

follow

route to the one described

generating

the

partition

the
a

above

curve.

problem at hand was that very little plant:

Discrete partition factors

The

arctan curve describes

partition factor.
densi ty

continuous

practice,

discrete

intervals are used to obtain

partition
thus

In

factors.

calculated

midpoint

The partition

factor

is associated wi th

of the density interval.

the

It

Tromp

curve

across

the

interval in order to obtain the

discrete
T

arctan curve, then

method

of

computing

performance
been

implemented.)

undersize

since
the

screening

had not been

The

available were

Apling's
used

at.

(It has since

only

process

therefore

screen efficiency and

(i)

(ii) the

nominal cutpoint.

density
simulated

Model assumptions

As

less

required
the integral

curve

Grootegeluk at that stage.

is

partition factor for that partirepresents

available,

parameters

cular interval.
If

was

the

therefore necessary to integrate the simulated

history

of

the

information was

available

to describe the partition

accurately,

than
curve

the following assumptions had

to be made (see Figure 3):

THE USE OF SIMULATED TROMP PARTITION CURVES

301

100 .-------------------------------------------------------~_,

'
~

80

J-.

.2u
oj

'-

.9

::l 60

oD

"5en

:.a

0-

E 40
0
J-.

f-<
~

J-.

<l)

;0-

20

o ~----~----~--~----_r~--~----~--~~--~--~_r~~
2,2

2,0

2,4
2,6
fn (Screen size) (mm)

2,8

3,0

FIGURE 3. Plot of the overflow Tromp distribution factor against the natural logarithm of screen size
showing the development of the screening simulation model.
Points A = (d,5.2')
B = (dsll"o) Tramp cutpoint (15,3 mm)
C = (d",,,)
= (d" t) Arctan inflection point (18,5 mm)

(1)

The nominal cut size of the screen is

~luivalent

to the size where material

to

vary between 75 and 92% instead of the

90% assumed initially.

has a 90% probability of reporting to

the overflow, i. e.
( 2)

The

(]g 0

Parameter solving

vertical range of the

undersize

distribution is between 0 and 90%

(3 )

The

inflection

point of

curve coincides with

(4)
(5 )

The

oversize

the

Based on

(]go.

[21]

ranges

distribution

according to assumptions (1) and

The lower size limit, dL, is taken as

parameter c is defined as

cannot be used

since

the

logarithm of 0 is not defined.)

Based
available

on

the
all

largely valid.
was

found

historical

data

these

assumptions

are

further work was

done

As

that the ordinate

of

1,25.

the abscissa of the inflection

[22]

In (~o)

= 90

This

[23]

leaves only b yet to be

determined.

the

coincide

with the nominal size but differs within a

ratio between 1,0 and

(3)

and

li ttle

inflection point does not always

302

= 180 /7r

and

(Zero

is

Tramp

between 90 and 100% ,

2.

defined as

the smallest size fraction divided by

it

assumption (2) parameter

Tramp undersize efficiency

By defining f as

Futhermore,
point tend

(24)

METALLURGY: SIMULATION

and substituting into [19], the error area

interval

of true tmdersize separation, Eu,

EffuT

may be

calculated as follows:
Eu

= af

[25]

f2)

undersize
100f,

area

the

preselected

discrete partition factors

may

once

again be calculated as discussed previous-

2b
by

until

Discrete partition factors

The

Furthermore,

EffUR is less than a

used

tolerance.

Arctan(-bf) + ef

+ a In( 1 + 1>2

halving routine was

defining

the

as the rectangular

Tramp undersize

ly.

Once

obtained,

these are applied to

total

the

size intervals of the feed stream

block

order

to generate the overflow

in

(product)

and underflow (tailings) streams.

efficiency,

EffuT, may be defined as

Model accuracy
EffuT

[26]

100f - Eu

Heavy-medium separation model

A typical
By

entering

efficiency EffuR,

required

a
b

iteration until EffuR

vary

between

0,1

can

undersize

shown

simulated partition
Figure

in

be

solved by

partition

= EffuT.

Since b can

calculated

and 2000

geometric

program.

factors

4,

with

and the

the

can

be seen that

lS

observed

fitted

by the performance

It

curve

curve

evaluation
both

the

100lF======e=~~==~::::;:::::~==~----------------------1

Simulated

O;---~--~-.---r--'---~-'~-.---r--,---,--,~-,~~--4

1,2

1,24

1,28

1,32

1,36

1,4

1,44

1,48

Density (gl cm )
o Observed
FIGURE 4. Plot of overflow Tramp distribution factor against density showing the accuracy of the HMS
model
Observed Determined from sampling.
Fitted
Curve generated by the performance evaluation program.
Simulated Curve generated by the HMS simulation model.

THE USE OF SIMULATED TROMP PARTITION CURVES

303

simulated
the

and fitted curve

observed

density

points

region,

fonns of interpolation than

deviate

from

accurate

in

high

linear fonn that was used. Recent investi-

only

by more or

the

less

equal

amounts.

gations

at

Grootegeluk

logarithmic

The

accuracy

of

the

heavy-med.ium

accurate,

showed

while

interpolation

Lagrange polynomials yields

Figures

6 to 8,

results.

between

simulated

various

confidence

being

and actual

detennined

evaluation
others,

program.

errors

values
the

by

perfonnance

These

latter

results,

and

are further summarized in

Table

is no doubt that other simulators

Acceptable accuracies were obtained only

in

those

cases where it

experience
showed

that

in

were considered accurate enough for the

particular application, with the advantage

nominal
cutpoint

that only process paramaters are utilized.

parti tion

The

instead of 90%.

cutpoint
for

predicting

may be enhanced by

the

compensating

the difference between the

cutpoint
value

and

is

mass based

more

or

Wolf

graphical

cutpoint.

less

fixed

This

for

the

had

could
of

be

ordinates

of

made

acceptable
when

the

was replaced

with

the

the

true

of inflection was

used

and

In other words,
This is

(dI ,tI )

of

course

since usage of

the

the inflection point

concept

in

obtained

be known.

factor

from

Further work

cases

inflection,

factor

limiting
novel

other

cutpoint

to

known

MiS

that the assumptions

accuracies

in

by using

Size separation model

might achieve better accuracies, but these

accuracy

more

unpredictable

the screen model were valid.

1.

There

at

levels,
the

that

interpolation is by far

separation model is further exemplified in

representing the

the

introduced in this

cois

paper.

application at Grootegeluk at 0,003 g/cm3.

More research will therefore be

(See

to establish the relationship between more

Figure

1 - points W and

Wg).

The prediction of organic efficiency may

also

be

erilianced

by

utilizing

more

used

nominal size,

parameters,

Epm values etc.

Furthermore, there
Parameter

Absolute errors

Confidence level*

80%

50%

such

as

the
those

and

mentioned above.

Accuracy of HMS model

TABLE 1.

widely

necessary

95%

is no reason not

to

follow the same route as had been used

in

the

HMS

database
have

model,
where

been

apart from a lack

the

relevant

established.

This

of

parameters

had

only

Concentrate ash, %

0,24

0,48

1,00

become

Misplaced material,%

0,6

1,0

2,0

of the perfonnance evaluation program

Wolf cutpoint, g/cm3

0,002

0,004

0,006

screening operations.

Epm (Ecart)

0,001

0,002

0,004

Organic efficiency,%

1,6

3,0

9,0

lated partition curves are shown in Figure

Clean coal yield, %

0,5

0,9

1,4

5,

A typical plot of the fitted and

read as follows:

c~es

errors

of

the

typical

the simulated concentrate

ash

given

differed

in 50%

less than 0,24%

absolute

for

simu-

whilst Table 2 summarizes the relative

HMS
To

available after the bnplementation

(root mean squared)

parameters.

of

some

Relative errors are

since a logarithmic

transformation

was used to normalize the size ranges.

from the actual.

304

METALLURGY: SIMULATION

,.
~

100 ,,----------------------------------------------------~~

o ~~~~~~TrMT~~~TM~rnTrMTrn~rnTM~~~~TM~rnTM~~
1,0

1,5

2,2

3,3

5,0

7,4

11,0

16,4

Screen size (mm) (logarithmic scale)

o Observed
FIGURE 5. Plot of overflow Tromp distribution factor against screen size showing the accuracy of the
screening model
Observed Determined from sampling.
Fitted
Curve generated by the performance evaluation program.
Simulated Curve generated by the screening simulation model.

Accuracy of Screening Model

TABLE 2.

Upper

Ecca contains bright and dull coal,

suitable
Parameter

HMS

errors

coal.

for

For

the

production

mining operations,

of

coking

benches

have been developed, with bench 1 as overTramp cutpoint, mm

2,1%

burden.

bench

5,

Wolf

3,5%

exhibits too high a phosphorus content

to

cutpoint, mm

transition

zone,

be rendered suitable for the production of

11,9%

Epm (Ecart)

The

Tramp U/f efficiency, %

1,5%

Abs

coking

coal.

Olf yield, %

0,8% Abs

bright

coal and is only suitable for

Misplaced material, %

1,3%

Abs

The Middle Ecca contains no

prodL'Ction of power

station

coal.

the
This

is divided into mining benches 6

section
----~----~----~-------------

to 14, of which bench 14 will not be mined

Application of the model

as

Geology and mining

The
into

Upper and Middle

be

divided

Ecca

series,

Ten

were

stratigraphic

each

boreholes,

mining

while the Lower Ecca is not developed. The

zones

bench

drilled

coal

determine

wi th interbedded shale layers

with

of

into

samples.

The

the

spaced over the planned

operations for the next 40

series consists of 11

zone subdivided

layer,

13, is too thick.

Waterberg coal field can

the

the overlying sandstone

and

analysed,

years,

in order to

the quality and expected

raw

coal to be

treated

yield

in

the

envisaged beneficiation plant.

THE USE OF SIMULA;rED TROMP PARTITION CURVES

305

Borehole evaluation

The

borehole cores were crushed to -25

and

the

-0,5

Evaluation
done
the

of

fraction

DID

various zones from

tical data,

removed.

the borehole analyses

by using the model

to

was

reconstitute

the sample analy-

and subsequently the benches.

A modified version of the computer

was

DID

then

used

to

calculate,

in-situ characteristics;

(b)

mass

for

each

yields

at

a density of

2,0

ideally and non-ideally sepa-

at

other

densities

ranging

if the

pi t

is

yields

at

such

density where

be

eliminate

properly.

This
to

unusable excess

capacity

once

these production peaks had been passed.

Bulk sample evaluation

kers

in

the existing

results

were

sensitivity
yields

analysis

on

the

DID

(b)
(c)

and

performed at

the

35,

25

and 15

IIIID,

30,

20 and

10

at 92% U/f efficiency;

feed preparation screens:

1

5,

3 and

at 75% U/f efficiency;

DID,

static bath HMS:

2,0

g/cm3

1,7; 1,8

at

0,025

1,9 and
90%

and

Epm

organic efficiency;

beneficiated by spirals to yield a product

were incorporated into the

computer

degradation screens:

fractions were assumed to be

the

simulations

Analytical

at 88% U/f efficiency;

(d)

of 20 MJ /kg and a discard of 4 MJ /kg;

fed into the

primary screens:

at other heat values (ranging

from 12 to 22 MJjkg).

plant.

following cutpoints:

IIIID,

obtained; and

cyclone HMS:

(e)

g/cm3

above

1,7;

1,8;

1,9 and 2,0

at 0,017 Epm and 90%

organic

efficiency.

calculations.
From

developed

designed for dual purposes in order to

product with a 20 MJjkg heat value is

results

to be

implied that certain plant modules had

(a)

between 1,8 and 2,0 ;

The -0, 5

ini tial production stages,

extensive

yields

(e)

during

and crushed by the primary Bradford brea-

rated;

(d)

occur,

Bulk samples were collected bench by bench

(a)

(c)

from the upper benches must

model

bench, the

g/crn3

peaks

the in-situ characteristics it was

possible to determine which benches

be mined without any beneficiation
from size reduction.

could
apart

From the sensitivity

From the above simulations the optimized

cutpoints
the

were chosen and correlated with

minimum and maximum

obtained

from

expected

the borehole

yields

evaluations.

and constant heat value analyses ( items d

Thus the average, minimum and maximum mass

and

flowrates

above) it

was

determined which

could be established

stream,

which

and the reticulation balance completed.

separate

flowline designed in

each

benches could be beneficiated together and

had to be beneficiated in

the

for

detail

plant modules.
Simulation results
Production constraints

Figure 9 shows a typical simulation

The constraints introduced by the simul ta-

performed

neous adherence to product quality control

bench 2, which contains 13% coking coal in

and pit development were also elicited, by

situ.

planning production,

of 1,8 g/crn

available
40
306

years.

blending options and

clean coal stocks for the

This

showed

that

next

production

on

g/cm

in

sample

results

from

shows that with pulp densities

It
3

bulk

study

in the cylcone plant and

the

static

maximum densities

bath

achievable

1,9

plant,

(the

with

con-

METALLURGY: SIMULATION

32.0

32.0

----

~ 20
;>,
u

t::

<l)

;:l

0'
<l)

<.'::
<l)

.!::
~

c:.:

10

-0,25

0,00

0,25

0,50
0;75
1,00
Absolute error (0/0 Ash)

1,25

1,50

1,75

~ Root mean square = 0,59%

FIGURE 6. Histogram showing the relative frequency distribution of absolute error in concentrate ash
values - HMS simulation model

50,-----------------------------------------------------,

-0,005

-0,004

-0,003

(222J

-0,002
-0,001
Absolute error

0,0

0,001

Root mean square = 0,0018

FIGURE 7. Histogram showing the frequency distribution of absolute error in Epm values - HMS simulation model

THE USE OF SIMULATED TROMP PARTITION CURVES

307

40.-------------------------------------------------,
36.0

30
~

-
~

>.

c<1)
;:l

er
<1)

....

20

'<1)

.~

vp;::

10

-15,0

-12,0

-7,5

-10,0

-5,0

0,0

-2,5

5,0

2,5

Absolute error (070 organic efficiency)

~ Root mean square = 4,5070

FIGURE 8. Histogram showing the frequency distribution of absolute error in organic efficiency - HMS
simulation model

ventional

equipnent) ,

yield was 44,6%,

tent

of

the total expected

with a product ash

26,1% and a heat value

of

be

done by hand.

The developnent of
and

programming

con-

simulation

23,5

thereof took approximately 2 weeks.

model

the

the

MJ/kg. Since the contract specification is

35%

ash and a heat value of 20 MJ/kg,

was

clear

pulp

that either

higher

densities were required,

Conclusions

it

operating
or that

low ash coking coal stream had to be

(a)

stream,

sheet

density of 2,28 g/cm3 was

the

static bath plant,

obtain the desired product

would

in

or-deI'

quali ty.

(b)

to

only

This

than

ash

into

possible,

84%, compared to 80% previously.

flowsheet

the

180 separations were

course of 6 days,

different
taken
308

flowsheets.

performed in

prone

thus producing 145

This

would

available

considerably more

would

content would have been very acceptable at

Over

not

enabled the design engineers to

opportunity to exploit the

data

the

sample

meet their deadlines, but allowed the

vious

this case

of borehole and bulk

The availability of such a model

55,8%, which was 11% more than in the preIn

developnent as far as the eva-

analytical results were concerned.

have resulted into a total yield of

situation.

flow-

re-

quired in the cyclone plant and 2,05 g/cm3

in

here

invaluable for general

luation

10 shows that with the same feed

a

simulation model described

proved

bled

off in order not t,o discard valuable coal.

Figure

The

otherwise

detail

have

been

thus

arriving at a

final

that

should be much

to the development of

less

bottle-

necks and other design errors.

have

approximately 2 months if it had to

(c)

The

simulation accuracy achieved

by

METALLURGY: SIMULATION

>-3

Cl)

-<
tr1

:;0

(j

23

>-3
......
>-3

~
:;0

"1:J

:;0

>-3

tritl

:;

Cl)

o"!j

tr1

Cl)

:r:tr1

55,4
80,4
4,2

Tailings

r---

.1J~

S1,80

Tromp 1,80
Epm
0,018
Org Eft 95%

CV MJiI<g

%ROM
ASH%

LEGEND

24,6
76,2
5,7

47,4
49,2
15,3

22,8
20,2
25,6

+1

,
I

r8,7
31,9
21,2

S1,90

90%

Eff

+35

1mm

-35

46,5
16,2

12,8

100,0
56,1

iill"

ROM

7' 7 I Cut
-1

Eff 9 %

L--

1'&

-150 mm

Cut 35mm

Simulation study of blast 2/161 at conventional pulp densities

FIGURE 9.

o
30,8
83,7
2,9

43,9
68,1
8,5

44,6
26,1
23,5

Product

13,1
32,4
21,6

F 1,90

Tromp 1,90
Epm
0,012
Org Eft 95%

44,6% Yield
26,1% Ash
23,5 MJ/kg

FINAL
PRODUCT

o
z

c
~...,

......

[/J.

Cl

G
:;0

~
r<

~
tI:I

.....

44,2
83,6
3,1

Tailings

.....-

T~

S2,28

Tramp 2,28
Epm
0,020
Org Eff 95%

%ROM
ASH%
CV MJ/kg

LEGEND

14,7
81,3
4,0

47,4
49,2
15,3

32,7 '
34,8
20,3

+1

8,7
31,9
21,2

-1

+35

S2,05

Eft 90%

Cut lmm

46,5
16,2

100,0
56,1
12,8

ROM

lUfr

- 35

\: 7\:

Eft 9 %

L-

1"7

-150 mm

Cut 35mm

Simulation study of blast 21161 at optimum product qualities

FIGURE 10.

o
29,5
84,7
2,6

43,9
68,1
8,5

55,8
34,4
20,5

Product

14,4
35,1
20,5

F2,05

Tromp
2,05
Epm
0,015
Org Eft 95%

55,8% Yield
34,4% Ash
20,5 MJ/kg

FINAL
PRODUCT

the

model

was more than

acceptable

for

the application in which it

and GOTl'FRIED, B. S. The Department of

was

Energy's

used. Further refinement of the model

computer

to

achieve

adapt ion
left
as

higher

for

accuracies

to the research

computer

sidered

as

the primary

not
task

performance

FToc.

program.

of

1st

AIME, August 1983, ch

Coal Industry,

is

24, pp. 215 - 221.

organizations,

modelling is

washer

Conference on Use of Computers in the

and

other applications

coal

conof

3.

production engineer based on a mine.

K.F. New Methods of Computing

'I'Ra1P,

the

Washability of

Coal.

GlUckauf,

Vol 37, Feb 1937. pp 125-131,151-156.

Acknowledgements
4.

The

authors would like to thank the

agement

of

publish

this paper and the personnel from

the

Iscor Ltd for

man-

Ore dressing

section,

permission
Research

ERASMUS, T.C. The fitting of a smooth

curve

to
and

to

the experimentally

deter-

mined coordindates of a Tromp

curve.

Fuel

Report

Research Inst.

of S.A.

No. 4, 1973.

Development for their valuable assistance.

5.

Erasmus,

aid
KING,

R. P. and W<X>LLACXYIT, L. Compu-

ter-aided-engineering
processing.

in

of

a mathematical

Research Inst.

minerals

Fuel

of S.A. Report No. 8,

1975.
6.

APLING,

J.T. ,

KILI11EYER ,

R.P.

THE USE OF SIMULATED TROMP PARTITION CURVES

Measuring

A.C.

performances.
WIZZARD,

model.

GEE course, Uni v. of the

Witwatersrand, 1986.

2.

the

performance of a coal washer with the

References
1.

Predicting

T .C.

Mine

& Quarry,

screen
April

1985. pp 31 - 25.

311