USIM PAC 2 for Windows: Advanced simulation of Mineral processes

USIM PAC 2 FOR WINDOWS: ADVANCED SIMULATION OF MINERAL PROCESSES

M.-V. DURANCE, J.-C. GUILLANEAU, J. VILLENEUVE, S. BROCHOT, G. FOURNIGUET

BRGM - Process Simulation Group

ABSTRACT

Steady-state simulation has been proving its usefulness and efficiency in the process design
and optimization, for many years. Software packages exist in a variety of fields, such as the
chemical, food processing and hazardous waste industries. Process engineers in the mineral
industry have also felt the need for such tools, and simulators have been created for this
particular field.
USIM PAC is one of these. Developed by the Process simulation group of BRGM, it has been
marketed since 1988 by an international network of representatives and more than a hundred
copies are now in use in 25 countries It has been successfully used at different stages of
mineral processing such as crushing, grinding, gravity or magnetic separation, flotation, etc.,
and since its initial creation, USIM PAC has been continuously improved.
In the latest version, USIM PAC 2.0, the Windows graphic environment is used to increase
calculation capabilities and make the interface much more friendly and intuitive for process
engineers. The algorithms of version 1.3 have been improved and others have been added to
increase simulation accuracy and efficiency.
A powerful and adaptable structure has been built to enable the study of new fields of
application. A very flexible description of the processed material is now embedded in the
software, making it possible to describe hydrometallurgical, soil decontamination or waste
treatment processes. All these operations can co-exist in a single complete flowsheet.
The basic functions of USIM PAC and the main developments in the new version are
described and some applications are presented.

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

INTRODUCTION

Since 1988 with the beginning of the USIM PAC distribution, steady-state simulation has
been proving its usefulness and efficiency for plant design and optimization. Of course, during
all these years, research has been carried out by several teams throughout the world, to
improve all the existing software packages.
Through successive versions of USIM PAC, the Process Simulation Group of BRGM
(France) made special developments in modelling unit operation, in increasing algorithm
accuracy and in defining utilization methodologies.
These works conducted to the version 1.3 of USIM PAC which is well known for mineral
dressing processes. The development team then decided to approach new fields of application,
such as hydrometallurgy, soil decontamination or other environmental treatments; the shell
has been completely reorganized to integrate original properties as well as new requirements.
The USIM PAC 2 version includes a really flexible way to describe processed materials,
allowing infinite kinds of description. With this new structure, complete flowsheets, from
comminution to purification can be studied. New algorithms have been embedded to improve
the accuracy of calculation and simplify the methodologies to meet the industry requirements.
The interface takes advantage of the Windows environment, and flexible configuration
capabilities are offered to allow the user to adapt the shell to his applications (units or
currencies, equipment names, etc.). A Development kit is also provided to allow the user to
integrate his own models into USIM PAC.
First, steady-state simulation and its main utilization methodologies are presented. In a second
part, the main innovations of the version 2 are detailed and two applications are described.

1. BASIS OF STEADY-STATE SIMULATION

A steady-state mineral processing plant simulator is a software package capable of predicting

plant operation according to the characteristics of the ore feed and the circuit. The prediction
of water, ore and other phase streams of the plant operated at steady-state under given
conditions is called direct simulation; the back calculation of parameters of plant
configuration (such as the required size of a piece of equipment) to obtain a given operation of
the plant is called reverse simulation (Broussaud 1989), (see figure 1).
Steady-state simulation does not compete with dynamic simulation: it is not a lower or higher
level of simulation. Whereas dynamic simulation is an essential tool for the design of
process-control strategies and a key element of advanced process-control systems, steady-state
simulation is an essential tool for plant design and pre-control optimization: it is typically
used to optimize the circuit design and the sizes of the units of equipment before the
implementation of a process-control system.
Steady-state simulation is a very effective approach for plant design since it enables:
· a great number of hypotheses to be considered regarding flowsheet, equipment, etc.,
· the processing equipment and the material handling equipment units to be sized,
· the configuration of an almost optimal industrial plant to be attained in a very short time.
· It is also used as an operational aid for decision-making in existing plants, such as:
· improving the flowsheet or adapting it to changes in the ore or in the concentrate market,
· choosing the settings or operating parameters of certain units of equipment.
The changes generated by the availability of mineral processing plant simulators are very
substantial and the time has come when the role of the experiments is being reconsidered.

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

Whereas experiments traditionally aimed at small-scale reproduction of the different possible

process configurations for an industrial plant, the aim in the near future will be to help in the
selection of unit operation models, to generate data to fit unit operation models and to verify
simulation results.

Physical properties

Input

• Flowrates
• Sizes, MODEL Output (s)
• Grades,
• etc.

Parameters

• Feed stream • Plant operation

description Direct Steady-state Direct
• Plant capital
• Equipment Reverse simulator Reverse cost
configuration

Figure 1. Basis of steady-state simulation

USIM PAC includes the basic functions required to apply design and optimization
methodologies, namely:
· capabilities for data input and results display,
· a data reconciliation function for the establishment of coherent material balances. This
function was proved to be necessary to process raw experimental data before model
calibration (Hodouin 1980, Herbst 1988),
· direct and reverse simulation,
· capital cost estimation.

1.1. Design methodology

Figure 2 shows the methodology to make the preliminary design of a new plant. The first
steps use feed characteristics and main objectives to define the future plant requirements for
flowsheet and all stream descriptions.

The next step back-calculates with reverse simulation the sizes of the main pieces of
equipment. The latest step simulates the future plant operations and calculates the cost
investment. These results allow the process engineer to compare several flowsheets according
to their technical performances but also economical ones.

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

Conventional flowsheet O bjective:

hypothesis Pre-feasability study

Preliminary simulation Set of data for the

with flowsheeting models complete flowsheet

Size and setting calculation Complete description of

with design models the plant equipment

Simulation of the full Comparisons between

operation of the plant several possible flowsheets

Estimation of the overall

cost of the plant

Figure 2. Design methodology

1.2. Optimization methodology

In the methodology described above, the models were used without previous calibration. The
authors have experienced that, even without previous model calibration, properly used
simulation can provide better predictions than human experts who rely on their "feelings"
rather than on calculations, as it is still sometimes the case in the mineral processing industry.
However, without model calibration, simulation is not accurate enough for the optimal final
design of a new plant or for making a decision to modify the flowsheet of an existing plant.
As it is not possible to measure all parameters affecting the behavior of the ore and as the
existing models do not account for all the details of real, complex phenomena, reliable results
can be obtained only if certain coefficients (calibration parameters) are determined from or
fitted to experimental results. The calibration parameters of the USIM PAC models include:
· Ore parameters. In USIM PAC these parameters are called the physical properties.
· Specific parameters of the equipment simulation models, allowing quantitative adjustment
of the equations to fit experimental results.
Some of these parameters are determined, depending on the methodology of the study, by
direct measurement in the laboratory or by calibration - i.e., by fitting them to the ore behavior
observed in a pilot or industrial plant. The calibration of parameters based on measurements
made in the plant (pilot or industrial) is very easily implemented using reverse simulation.

Collection of data on the Objective:

operation of the existing plant flowsheet optimization

Material balance Set of coherent data for

establishment the complete flowsheet

Calibration of the
Plant simulator
simulation models

Simulation of the
operation of the plant Design of additional
with new feed properties equipment

Figure 3. Optimization methodology

Figure 3 shows simplified methodologies for:

· optimizing the flowsheet of an existing plant (pre control optimization or adaptation of a
plant to new objectives or constraints),
· designing a concentrator, based on pilot-scale experiments.
· Methodologies involving model calibration steps are used systematically for the
adaptation or the optimization of existing plants.

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

2. POWERFUL IMPROVEMENT OF THE VERSION 2.0

2.1 The Windows environment

The version 2 of USIM PAC benefits from the memory management capabilities of
Windows 3.1. These include very large calculation capabilities and no limit to the number of
streams or units in a flowsheet, or the number of phases, size classes or components used to
describe the material.
Besides, the Windows environment provides a very friendly interface. The software is
centered on a sensitive flowsheet from which any kind of operations is possible (data input,
results display, calculations, etc.)
USIM PAC is also highly configurable to take into account the great diversity of users. The
labels of icons and model parameters can be changed; units and currencies from any country
can be easily added to adapt the software to the user's environment.

2.2 Flexible processed material description

For a steady state simulator, a good material description is as fundamental as good unit
operation models. Furthermore, a detailed phase description allows a more precise modelling
and can increase the model capabilities and accuracy.
For the physical treatment, such as comminution, gravity separation or flotation, a rather
simple phase model is required, with ore and water; in the former versions of USIM PAC, the
phase model contained these two phases, the ore was described in terms of size distribution
and composition. With such a phase model, all the mineral dressing operations (i.e., crushing,
grinding, gravity separation, flotation,...) could be simulated. However, hydrometallurgical
processes can include other phases, such as gas, other solids (carbon, resins, etc.), other
liquids - but also additional concepts, such as chemical reactions or exchanges between
phases.
To study simple as well as complete flowsheets the phase description must be highly flexible.
Depending on his objective(s), a process engineer will describe the material in different way
(see figure 4):
· if the project consists of a preliminary grinding plant design, the only necessary
parameters are the ore flowrate, the feed size distribution and the water flowrate.
· if the project concerns a grinding and flotation plant, the engineer will be interested in the
grinding selectivity. He must describe all the components in the ore but also define
sub-populations according to their floatability.
· if the project deals with gold ore processing, (grinding, flotation, leaching and CIP stages),
the ore model must be described as in the previous case, the liquid phase composition
must be detailed, and the carbon phase must be taken into account in terms of global
flowrate and composition.
For that, four phase types have been predefined: ore, solid, liquid and gas. Thus the ore type
can have particular properties that the other solids (carbon, resins,...) do not need. (Durance
1993)

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

View of the processed material

Floatability
Ore Particle size per component
Ore Particle size per component Floatability

Water

Water Carbon Component grade

Ore
Size distribution
Gold
Objectives
Solution
Grinding
and flotation
plant Gold ore
treatment
Grinding plant
plant

Figure 4 - Influence of the project objective on the level of details of the material description

2.3 New Algorithms

Material balance. The material balance algorithm included in USIM PAC 1.x was not adapted
to this new phase description. As the software can take into account much more data, it was
necessary to create a new algorithm. Besides the memory management capabilities of
Windows allow more powerful and precise calculation. In the latest version of USIM PAC, all
the measurements and all their accuracies are taken into account at the same time while they
were used at different steps in the previous versions. This makes a more accurate algorithm
and gives more consistent results.

Objective Driven Simulation. As seen above, an optimization project needs many runs of the
direct and reverse simulations to create the existing plant simulator. To prevent that and to
increase the accuracy of calculation, a new algorithm has been created which chains the direct
and reverse simulations in one run. This algorithm, called Objective Driven Simulation, has
been detailed by Broussaud 1991 and Villeneuve 1992.

Simulation supervisor. A new level of algorithm is currently being defined above the
simulator to answer the user's questions directly. It will be implemented in the next version,
the 2.1, of USIM PAC.
This level is called the supervisor of simulation, which is using the automation concepts of
sensors and actuators. At any place of the flowsheet (i.e., a stream or an equipment), the user
may indicate which value could change by graphically implementing an actuator. Then, he can
evaluate the effect of the variation of this value at any other place of the flowsheet by inserting
a sensor. It becomes possible to look at the evolution of the recoveries and/or the circulating
loads when scanning an interval of the possible feed flowrates.

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

This approach eases the uses of a simulator and the analysis of the predictions. It is also a very
valuable tool to characterize the sensitivity of the simulation results to the variation of some
settings (e.g., load of grinding media, rotation speed, water addition, etc.) or feed
characteristics (e.g., flowrate, sizes, grades, grindability, etc.). Thus, the most important
variables can be identified for design and pre-control optimization of plants

3. APPLICATIONS

The authors and their coworkers have already addressed problems for many existing plants,
including:
¨ a barite plant in France (Broussaud 1985),
¨ a phosphate concentrator in Senegal (Conil 1988),
¨ a polymetallic sulfide ore project at the pilot stage in Portugal (Conil 1989,
Védrine 1991),
¨ a gold-ore processing plant in France,
¨ a gold-ore processing plant in Peru (Guillaneau 1993),
¨ a gold-ore processing plant in India,
¨ a feldspar/silica flotation plant in Spain,
¨ two sand and gravel processing plants in France.

The optimization of a crushing and grinding circuit is detailed below. This case study shows a
simple example of the kind of project that can be carried out with USIM PAC.
The second example concerns the simulation of the Baccon Quarry process. It shows the easy
adaptation of USIM PAC to fields of activity close to metal mining industry.

3.1. The optimization of the crushing and grinding plant of the Shila Gold Mine (Peru)

Minera Shila S.A. (jointly owned in equal shares by Cedimin S.A., a 65% subsidiary of the
French Group BRGM and Buenaventura S.A., a Peruvian company) has been operating the
Shila gold and silver mine since the first months of 1990 (southern Peru).
The original plant design called for a 100 tpd throughput with an average grade of 8.6 g/t
(0.25 oz/t) Au and 200 g/t Ag. The ore is treated by gravity and flotation to produce gold and
silver concentrates that are shipped for further processing.
A few months after start up, Minera Shila decided to increase the throughput to 135 tpd. The
equipment was originally scaled up to allow such an increase, but it soon became obvious that
the ball mill was unable to adjust to this increased capacity. About 31 tpd of ungrounded
material were rejected by the outlet screen ("Granza" flowrate) and stored on an outside pad.
The project described here consisted of two phases:
· the first phase, after an audit of the plant, consisted of simulating preliminary ideas
proposed by the process engineer to decrease the production of oversized material at the
ball mill discharge (see figure 5). The selected configuration was then implemented and
evaluated by the plant operators.
· the second phase consisted of designing new equipment to maintain the plant performance
while increasing capacity.
First Phase: Decreasing the "Granza" flowrate at the Shila plant. Three possibilities were
proposed by the process engineer for improving the plant performance by decreasing the

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

"Granza" flowrate while reducing the d80 of the flotation feed. The proposed new
configurations were simulated with a capacity of 150 tpd.

Figure 5 - Initial flowsheet of the Shila gold and silver processing plant

The following observations were made: the first configuration, integrating the secondary
cone crusher into a closed circuit, gives the best improvement to the ball mill operation. The
coarse ("Granza") product flowrate is divided by three (9 tpd) and the d80 of the flotation feed
is only 210 µm instead of 270 µm. The second one, reducing the cone crusher opening, did
not conducted to satisfactory results. The third configuration, replacing the 6' x 6' ball mill by
a 7' x 6' ball mill, improves the results only if the cone crusher is included in a closed circuit.
The "Granza" flowrate becomes negligible and the d80 of flotation feed goes down to
150 µm.
The first configuration was accepted by the plant management and is used with a capacity of
135 tpd. At this capacity, the "Granza" flowrate is only a few tons per day. The costs involved
in the circuit modifications were recovered in two months.

Second Phase: Increasing the Shila plant capacity. Having adopted the modified flowsheet,
with the secondary crusher included in a closed circuit on a screen, Minera Shila S.A. later
decided to increase the plant capacity from 135 to 230 tpd. Different configurations were
proposed by the operators and the process engineer and evaluated with the USIM PAC
software, taking into account local opportunities (e.g., availability of equipment near the site).
The technical conclusions for increasing the plant capacity can be the following: As seen
above, replacing the 6' x 6' ball mill by a 7' x 6' one is not sufficient to provide the capacity
increase. The "Granza" flowrate becomes too important and cannot be recirculated. A larger
8' x 8' ball mill implementation gives good results in terms of process, the "granza" flowrate
can still be recirculated and the flotation feed is decreased to 170 µm. However, energy
consumption is too high (20 kWh/sht) Besides, this ball mill is not available on site. This
solution is therefore not economical. In the same way, using two ball mills in parallel or in

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

series gives satisfactory results in term of "granza" flowrate, but energy consumption is high.
Adding a rod mill into the circuit gives very interesting results. With a rod load of only 20%,
objectives are reached. As this solution is oversized, further development is possible. In terms
of energy consumption, it is the most economical configuration.
wo phases of process optimization have been illustrated through the Shila project. The first
phase involved the use of USIM PAC to verify and quantify the ideas of the process engineer.
The good results obtained after implementing the proposed first phase solution increased the
confidence of the plant management in simulation techniques. A second, more ambitious
phase of plant optimization was then decided. Again, the proposed solution has been
implemented and the results are very satisfactory.

3.2. Simulation and optimization of the Baccon quarry process (Morillon Corvol)

The Morillon Corvol (SEMC) company belongs to the RMC group, which is one of the world
leader in the sand, gravel and concrete industry. SEMC is the fourth of the French sand and
gravel market. It operates 60 quarries with productions from 100 000 to 2 Mt/year.

Figure 6. The flowsheet of the Baccon quarry process

TThe project objective was to build a simulator of the Baccon plant. The aims were to be able
to adapt the production quickly to:
· different rock qualities,
· new customer requests,
· new quality constraints,
· market evolution or
· technology evolution.
The plant flowsheet is presented on figure 6. Two rock qualities are present in the quarry: they
are called "soft" and "hard" limestone. The simulator has been built with data collected when
processing the soft limestone and validated with data collected when processing the hard.

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

Figure 7 shows the comparison between coherent and simulated data for the soft facies, for
some product streams of the plant.

4/10

10/20

Figure 7. Comparison between coherent and simulated data for the soft limestone

Figure 8 contains the comparison between experimental and simulated data for the hard rock.
The results validate the simulator.

4/10

10/20

Figure 8. Comparison between experimental and simulated data for the hard limestone

CONCLUSION

USIM PAC version 2 represents a new generation of steady-state simulators. Widely open to
new developments with a flexible and adaptable structure, it is a research framework for unit
operation modelling. Its structure allows the introduction of powerful algorithms, currently
being developed, and other tools that the current research, carried out by the Process
Simulation Group of BRGM, will soon produce.
The flexibility of the processed material description allows the modelling of operations in new
fields of applications, extending its capabilities. USIM PAC is clearly a real partner for the
mineral processing engineer while also becoming a powerful tool for many process engineers
in various fields.
The first example described in the paper shows the efficiency of such a tool and the help it can
provide for a project. The second example presents another crushing circuit optimization in a
field close to the mining industry with some specificities.
The adaptablity of USIM PAC to different fields, possible with the open structure, the
flexibility of material description and the configuration capabilities, makes it a valuable tool
for the processes. Research is in progress in unit operation modelling of hydrometallurgical
and environemental processes to widen its fields of applications.

ACKNOWLEDGMENT

The authors thank Minera Shila S.A. and Morillon Corvol for their agreement to the
publication of this paper, BRGM contribution no. 94015, for which the work was in part
financed by a BRGM research project.

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USIM PAC 2 for Windows: Advanced simulation of Mineral processes

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