MSc (EMEC)

Computer Modelling and Simulation Module

Surveying Comminution Circuits.

Introduction:
The quality and nature of the information collected from the circuit is the key to being
able to assess the performance of the operation.

Need representative samples collected over a period of operation:

• may be over several hours and samples cumulated to even out fluctuations i.e.
sampling period longer that the time for circuit fluctuations
• simultaneous sampling if the circuit is at steady state
Sampling a crusher feed is obviously different from sampling a hydrocyclone overflow.
Some of the errors and disturbances that can contribute to the overall error:-
• plant dynamics
• sample cutter design
• sub-sampling a primary sample
• analytical errors
• propagation in calculations
• fundamental statistical uncertainty in a small sample of a large population
Need to minimise the errors above in order to produce data that will make the modelling
exercise worthwhile.

Sample size:
As large as possible, but there is frequently a practical limit.
You will have come across Gy’s theory which can be used to assess sample size required
to achieve a desired confidence in a sample.

Barbery1 derived an expression based on Gy’s theory:-

fρd 3m
M= 2
θ p
where: M = mass of sample required (g)
f = shape factor for material (0<f<1)
ρ = density of material (g/m3)
dm = mean size in size range of interest (cm)
p = expected proportion of material in size range of interest (to be measured)
θ = standard deviation of the number of particles in that size range.

f=0.1 for flat plate-like particles and approaches 1 for spherical particles.
For most natural ores and coal, 0.3<f<0.7, and 0.6 is not a bad guess.

1
Barbery G. 1972 “Derivation of a formula to estimate the mass of a sample for size analysis”, Trans AusIMM, 81, (784), March,
C49-C51

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 3d 13 + d 32
d =m
2
where d1 and d2 are the limiting sizes of the size range of interest.
The size range of interest is that which is likely to have the least number of particles in it,
which is nearly always the coarsest size interval. This ensures a conservative choice, as
all other errors estimated for other size ranges will be smaller.
A good rule of thumb is that the coarsest size interval should be chosen to give p≈5%.

θ is determined from the precision of estimation and confidence required.

φ
θ=
z
where: φ = chosen precision (relative proportion)
z = normal ordinate at the chosen confidence limit.

Confidence Level (%) z

50 0.6745
80 1.2816
90 1.6449
95 1.9600
99 2.5758
99.9 3.2905

A confidence level of 90% is usually adequate.

Initial Data Inspection:

The accuracy of survey data required depends on the objectives of the exercise. But it is
always necessary to evaluate the data, and simple mass balancing allows us to do this.

We are going to use a computer to do this, but there are a number of simple procedures
that should be applied to the data set to establish an initial estimate of its accuracy. Mass
balancing bad data will not improve it!

Lets look at the simple example of a hydrocyclone.

There are two simple manual analyses that can be performed:-

• a water balance
• a calculation of the mass split in each size fraction

Both of these are based on the two product formula.

2
Hence from each size fraction,
U fi − o i
total mass split to u/f, =
F ui − oi
or, from the percent solids measurements,
1 1
−
U % SOL f %SOL o
total mass split to u/f, =
F 1 1
−
% SOL u % SOL o

Example of inconsistent data:-

size(µm) fi oi ui U/F
212 10.1 1.8 21.7 0.42
150 12.4 4.5 19.1 0.54
106 15.5 11 16.8 0.78
75 16.2 11.2 11.9 7.14
53 7.8 3.9 4.8 4.33
38 4.9 7.9 3.7 0.71
-38 33.1 59.6 21.9 0.70
%SOL 49 44 67 0.30

The 75 µm and 53 µm data are inconsistent. (Feed values must lie between the o/f and
u/f). The average mass split of the other size fractions is 0.63, compared to 0.30 from the
percent solids!, there is a problem with the data.

On mass balancing this data set using the computer software JKSimMet, the following
was obtained:-

Stream Feed Overflow Underflow

Data Expt val Calc val Expt val Calc val Expt val Calc val
t/h sols 340 340 - 142 - 198
t/h water 354 298 - 195 - 103
% sols 49 53.3 44 42.1 67 65.8
p80 (mm) 0.160 0.172 0.097 0.098 0.214 0.213
Size (mm)
0.212 10.1 12.6 1.8 1.7 21.7 20.4
0.150 12.4 12.9 4.5 4.4 19.1 19.0
0.106 15.5 14.8 11.0 11.3 16.8 17.4
0.075 16.2 13.2 11.2 12.4 11.9 13.8
0.053 7.8 5.0 3.9 4.3 4.8 5.6
0.038 4.9 5.3 7.9 7.6 3.7 3.6
-0.038 33.1 36.2 59.7 58.4 22.0 20.3

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This confirms that the 75 µm and 53 µm data are suspect
The sampling procedure would need to be reviewed to see if there was a weakness that
needed addressing. Mass balancing cannot correct bad data, it is very useful for
identifying problem areas. It can adjust for small data inconsistencies.

A prerequisite for mass balancing is data redundancy, i.e. excess data.

The method used for adjusting the data is a standard statistical technique which involves
minimising the sum of squares of the errors. The data are adjusted, the errors between the
original data set and the adjusted values are squared and summed, and this is repeated
until the function is minimised. Knowledge of the accuracy of the data can be used in the
form of standard deviations, i.e. the data is weighted so that the more accurate the
experimental value (those you have the greatest confidence in) the greater will be its
influence on the solution. Thus weightometer readings, values from finer streams, assay
values that have a small error etc., can all be used to influence the results of mass
balancing based upon experience.

Interpreting JKMBal Output.

There are various ways to judge the results from mass balancing;
• Compare the size or order of magnitude of the stream SDs with that of the
associated flow value. When the SD is small compared with the value, as a
ratio, it indicates that flowrate is well defined by the data. If the SD is large,
the flow rate is poorly determined.
• The summary values at the foot of the screen also indicate the success of the
balance. Low values in the estimated SSQ fields indicate a good balance;
large values, a poor balance. Moreover, in the case of these fields, cross
comparisons between fittings can be made. If these values are smaller in the
most recent balance than they were in the previous run, the balance is getting
better. If they are getting larger, you are going in the wrong direction.
If the data are consistent and the error estimates are in agreement, the SSQ
will be approximately equal to the number of data points (i.e. size fractions
and assays) adjusted by JKMBal.
• The engineer can also judge the relative success of the balance by looking at
the Stream Data screen (the Stream option from the Balance Configuration
flowsheet). Examine the Error column. Weighted Error and Relative Error
versions of the difference between calculated and experimental data for
sizings are most useful.
• The graph plotting facility of JKMBal allows the engineer to plot raw and
adjusted size data on the same screen. Discontinuities in size data highlight
poor data or a change in size measurement technique.