Steady State Processing Plant
Review 2.0 of the 31-03-15

Split Engineering LLC. Split Engineering Chile Ltda.
General Salvo #331 oficina 201
2555 N. Jackrabbit Avenue CP 85745 Casilla 16807 Sucursal Panorámico
Tucson, Arizona, USA Providencia – Santiago, Chile
Fono: (1)-(520)-3273773
Fono: (56)-(2)-25978200

Mathematical Modelling

Why bother?

What is a mathematical model?

Measured Inputs Model
Predicted Outputs

Model Parameters

Example of a Model

Feed Ball Product

Pi = Fi - Ri  Ci +  Aij  Rj  Cj

Measured Data Model Parameters
Sizings etc Appearance (Ore)
Breakage Rate (Machine)

Simulation by Computer  Models of the required unit operations  A method of combining the models to predict circuit performance  A software system which is easy to use .

?  Process design studies  Green field studies  Existing plant modifications .. Applications of Simulation  Process optimization studies  What if ...

Methods for Optimization Studies  Experience and/or inspired guess work  Plant test work following an experimental design  Modelling and simulation to assess options and identify likely solutions .

Process Optimization Path • Define objectives and constraints • Measure (Sample) • Analyse (Mass Balance & Model Fit) • Simulate (Optimize) • Adjust Circuit (Equipment) • Measure (Sample) .

For Useful Simulation Studies  Process knowledge  Suitable models and an understanding of the model limitations  Good quality data to develop parameters  A useable computer/software system  Engineering judgement to assess results .

laboratory testing  Machine . Process Design Studies  Based on data from sources other than the operating plant  Ore .other operations (JKTech Data Base)  Less accurate than optimization  Gives information about likely circulating loads  Allows sensitivity analysis .

from Metallurgical Processes (perhaps a little optimistic) .I  JK . JKSimMet Development .from Julius Kruttschnitt Mineral Research Centre  Sim .from Simulation (50 years of JKMRC Research)  Met .

II JKSimMet is useful for  crushing and screening  grinding and classification  mass balancing . JKSimMet Development .

2  2012 JKSimMet V5.0 .3  2012 JKSimMet V6.III  1970’s Fortran IV and punched cards  1981/2 Fixed flowsheet simulator  1983/4 JKSimMet V1 (Hitachi + PDP11)  1985 JKSimMet V2 (PC AT + PGC)  1988/9 JKSimMet V3 (Halo)  1992/3 JKSimMet V4  1999 JKSimMet V5.1 for W 2000 & NT  2003 JKSimMet V5.0 for Windows  2001 JKSimMet V5.1 for XP  2006 JKSimMet V5. JKSimMet Development .

JKSimMet Development .IV  JKSimMet V6  Move into the more modern JKSimFloat structure  Provision for multi-component modelling  Possibility of expanded capability across processes .

balance. JKSimMet V6 Enhancements  New drawing package  Better control of positioning of flowsheet items  Can still use V5 icons  Auto labeling of streams and equipment  Control of icon and stream properties (colour. thickness etc)  Conversion of all experimental sizings to master sieve series  Simplified simulate. model fit and graph interfaces  Data input and editing through configurable stream overview and info blocks  More flexible info blocks  Enhanced SD control and data entry  Extensive Help files  Simulation manager  2D Mass Balancing .

Simulation Process  Build flowsheet or use existing flowsheet  Assign characteristics  Machine dependent parameters  Engineering/Geometry (from measurements or drawings)  Model Parameters (from model fitting or data base)  Ore dependent parameters (from ore testing)  Simulate  Assess the results .

Important Concepts  Project  Flowsheet  Equipment  Streams .

System. Project file. Flowsheet Equipment list Flowsheet list Stream Equipment labels label .

jksysdb extensions)  Can contain several independent flowsheets . Project  The block of data which is a pair of identifiable files (with .jksm6 and .

Flowsheet  A combination of equipment and streams connecting the equipment  Can be bigger than the screen but can not be connected to other flowsheets .

Equipment  Icons comprising mathematical models  Each equipment item contains  Combiner port (the sum of the streams flowing in)  Can and should be renamed from the default names .

Special Equipment  Feeder  a feeder is an item of equipment and its equipment properties are flow and size distribution data  Liquid feeder  a liquid feeder is also an equipment item and its properties are % solids or liquid flow  Can and should be renamed from the default names .

balanced and fitted data .I  The place in the equipment where the feed and product information (flows and size distributions) are stored. simulated.  The Combiner stream  stores the sum of all the streams feeding the equipment  can not usefully contain experimental data (mostly)  The Product Streams  stores the product data  can contain experimental. Streams.

II  Take their name of the equipment item of which they are a product  Can be renamed . Streams.

System generated . Cell Colours  Black text on white background .User entered  Black text on grey background .

I Main Toolbar .Toolbars .

II Flowsheet Toolbar .Toolbars .

Toolbars .III Engine Room Toolbar .

on the select list . Flowsheet Colours  Blue Outline .

I  Convergence Unknown Known . Simulation .

II  Convergence Controls  Assumption about circulating stream  Zero  Measured  Last time  Convergence Limit  0. Simulation .1 to a very small number x Volume flow of circulating stream .

Assess Results  Data in streams and equipment  Data in labels  Graphs  Overview  Standard and configurable  Streams and equipment  Print  Copy and Paste .

Build a Flowsheet Walk Through  Open a new file  Choice of Icons – V5 or V6  Add equipment  Moving. flipping. changing size of icons  Naming equipment  Icon properties  Labels  Add streams  Single click or right click to add/remove nodes  Moving streams  Must have product streams  Labels . rotating.

just need the “master” series  For analysing survey data.  Streams  Enter directly or copy and paste  Equipment  Enter directly or copy and paste  Simulate . Entering Data  Lock the flowsheet  Set up sieve series  For simulation. may need multiple sieve series  Can copy and paste data into groups of streams using Survey Data entry screen but must be in correct sequence in Excel (Will change later).

V5 – V6 Changes I  Master sieve series  Users choice  Up to 40 size fractions – 10 m to 13 m  If converting from V5. default will be the series containing the coarsest particles  Click OK converts all sizings to the master sieve series using the interpolation method in the drop down box. Choose linear if unsure of effects  Survey data entry  Can set up many sieve series to accept survey data  Enter data on the relevant sieve series  Click Transfer converts all survey data to master sieve series for use in JKSimMet – Original survey data are preserved for later retransfer if necessary .

V5 – V6 Changes II  System properties  Set solids and liquid density values  Define Element data and units if required  Accessing models is a two step process  Click on icon to open Equipment window  Click to open Model window  Can access other equipment items or streams from this window  Configurable Equipment Manager  Allows easy access to selected parameters for all equipment of one type in a flowsheet for data entry or reporting  Stream data entry or viewing  Double click on stream to open Stream Window .

Select SD option  Click Calculate . V5 – V6 Changes III  Stream data entry or viewing  Double click on stream to open Stream Window  Four tabs  Totals (used in JKSimMet fitting. simulation and balancing)  Sizing Data (used in JKSimMet fitting. simulation and balancing)  Elemental assay data (used in balancing only)  Size by elemental assay data (used in 2D balancing only)  Columns displayed on each tab controlled by Data View Type  Automatic SD Calculation  Click on SD button on Stream Data window  Select streams required. Select Property as basis of SD calc.

1 with max value of 1. V5 – V6 Changes IV  Automatic SD Calculation  Click on SD button on Stream Data window  Select streams required  Select Property  Select SD option  Many to choose from  Fixed = 0.001  Poor = 20% of exp value  Average = 10% of exp value  Good = 5% of exp value  Excellent = 2% of exp value  Whiten = 10% of exp value +0.0 (Sizings only)  Others explained in manual/help files  Click Calculate  Repeat for other properties and/or streams .

selection of all available streams requested  Can be used for data entry and/or reporting  Can be exported to Excel  Can be cloned . V5 – V6 Changes V  Configurable Stream Overview  Columns  are properties selected by clicking on title to open selection window  can be added or deleted  Rows  are streams  Can be added or deleted  On adding.

V5 – V6 Changes VI  Simulation Manager  3 tabs  Simulation Scenario  Columns control parameters to be varied  Rows control values of parameters  Results – Streams  Displays selected stream data  Results – Equip  Displays selected equipment data  Reporting  Very similar to V5  Difference is that report is exported directly to Excel .

number format  Grid on or off  Custom lines  P80 highlight . linear or log. V5 – V6 Changes VII  Graphing  No quick graph but flash graph easier and quicker  Similar structure to V5  Configurable graphing window  Select stream data for graphing  Global data type and Y-axis type  Format  Axis and Graph Labels  Axis max and min.

4. V5 – V6 Changes VIII  Info Blocks  Similar to V5 but more flexible  For streams  Select multiple streams to apply  Select from 2. 6 or 8 cells per info block  Expanded choice of variables for display  For equipment  Select multiple equipment items of same type using same model  Select from 1 to 4 cells per info block  Selection of parameters for display using same structure as equipment model window  Can enter data through info block .

V5 – V6 Changes IX  Select Lists (Simulate. Model Fit or Balance)  Same as for V5 – items outlined in blue on select list  Can select or deselect equipment or streams by click on item  Whole Circuit is special case – entire flowsheet always selected including new streams or equipment added  Whole Circuit is default  Model fitting  One main window  Select for inclusion in simulation with Model Fit Case list  Whole Circuit is special case  Cursor on Equip item in list displays parameters for that equipment item and automatically selects streams for error calculation (Can be manually set if required)  Parameter fit list automatically built by selecting parameters .

TPH water to adjust and % Solids to Influence  Run Balance  For TPH Solids figures that were guessed or estimated. replace Exp guessed values with balanced values with average SDs  Run Balance  Continue process until Total RMS error reaches minimum . all else to missing  Run Balance  Set TPH Solids SDs to Fixed. V5 – V6 Changes X  Mass Balancing  Different algorithm from V5  Selection and Control in a single window  Allows balancing of assay and size by assay data  Staged process for operating  Select required equipment and streams  Set TPH Solids and size distribution data to Adjust.

TPH Water . V5 – V6 Changes XI  Mass Balancing continued  Stage processing continued  If assay data and or size by assay data are to be balanced as well. Sizes to fixed. set TPH Solids. % Solids to unused and Elements to adjust  Run Balance  Set Elements to Fixed and Size by Element to adjust  Run Balance  Balancing is definitely an iterative process and takes practice .

Mass Balancing  Part VII .Installing JKSimMet  Part IV . Manual Structure  Part I .Overview  Part II .Model Fitting  Part VIII .Model Descriptions .Learning JKSimMet  Part V .Using JKSimMet  Part VI .Changes from Version 5  Part III .

Thanks for your attention! .