JKSimMet

Steady State Processing Plant

Simulator
Review 2.0 of the 31-03-15

Split Engineering LLC. Split Engineering Chile Ltda.

2555 N. Jackrabbit Avenue CP 85745
Tucson, Arizona, USA
Fono: (1)-(520)-3273773
http://www.spliteng.com
General Salvo #331 oficina 201
Casilla 16807 Sucursal Panorámico
Providencia – Santiago, Chile
Fono: (56)-(2)-25978200
http://www.spliteng.com
Mathematical Modelling

Why bother?
What is a mathematical model?

Process
Measured Inputs Model
Predicted Outputs

Model Parameters
 Example of a Model

Feed Ball Product

Mill

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

 Applications of Simulation
 Process optimization studies
 What if - - - - ?

 Process design studies

 Green field studies
 Existing plant modifications
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
 Process Design Studies
 Based on data from sources other than the
operating plant
 Ore - laboratory testing
 Machine - other operations (JKTech Data
Base)
 Less accurate than optimization
 Gives information about likely circulating loads
 Allows sensitivity analysis
 JKSimMet Development - I
 JK - from Julius Kruttschnitt Mineral Research
Centre
 Sim - from Simulation (50 years of JKMRC
Research)
 Met - from Metallurgical Processes (perhaps a
little optimistic)
 JKSimMet Development - II
JKSimMet is useful for
 crushing and screening

 grinding and classification

 mass balancing
 JKSimMet Development - III
 1970’sFortran 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 V5.0 for Windows
 2001 JKSimMet V5.1 for W 2000 & NT
 2003 JKSimMet V5.1 for XP
 2006 JKSimMet V5.2
 2012 JKSimMet V5.3
 2012 JKSimMet V6.0
 JKSimMet Development - IV
 JKSimMet V6
 Move into the more modern JKSimFloat structure
 Provision for multi-component modelling
 Possibility of expanded capability across processes
 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, balance, 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
 Project
 The block of data which is a pair of identifiable
files (with .jksm6 and .jksysdb extensions)
 Can contain several independent flowsheets
 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
 Streams- I
 The place in the equipment where the feed and product
information (flows and size distributions) are stored.
 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, simulated, balanced and
fitted data
 Streams- II
 Take their name of the equipment item of which
they are a product

 Can be renamed
 Cell Colours
 Black text on white background - User entered

 Black text on grey background - System

generated
 Toolbars - I
Main Toolbar

New Save Paste Lock Zoom Zoom to Stream Redraw Sieve Equipment Simulation View Graphing View % View Cum
Project Project Selection Flowsheet Tool selection Labels Flowsheet Series Manager Manager Streams Retained % Passing

Open Copy Help Select Zoom Equipment Show System Survey Stream View Reports Info View Cum
Project Selection Tool to Fit Labels Ports Properties Data Overview Equipment Blocks % Retained
 Toolbars - II
Flowsheet Toolbar

Component Draw Insert Rotate Flip Align Align Align Space Same Same Nudge Nudge Send To
Properties Rectangle Image Left Vertical Top Bottom Center Across Width Size Down Right Back

Draw Text Rotate Rotate Flip Align Align Align Space Same Nudge Nudge Bring To
Line Box Icon Right Horizontal Middle Left Right Down Height Up Left Front
Toolbars - III
Engine Room Toolbar

Mass Model Simulation

Balance Fitting
 Flowsheet Colours

 Blue Outline - on the select list

 Simulation - I
 Convergence

Unknown

Known
 Simulation - II
 Convergence Controls
 Assumption about circulating stream
 Zero

 Measured

 Last time

 Convergence Limit
 0.1 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, rotating, 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
 Entering Data
 Lock the flowsheet
 Set up sieve series
 For simulation, just need the “master” series
 For analysing survey data, 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).

 Streams
 Enter directly or copy and paste
 Equipment
 Enter directly or copy and paste
 Simulate
 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
 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, Select SD option
 Click Calculate
 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 +0.1 with max value of 1.0 (Sizings only)
 Others explained in manual/help files
 Click Calculate
 Repeat for other properties and/or streams
 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, 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 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
 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, linear or log, number format
 Grid on or off
 Custom lines
 P80 highlight
 V5 – V6 Changes VIII
 Info Blocks
 Similar to V5 but more flexible
 For streams
 Select multiple streams to apply
 Select from 2, 4, 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
 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, all else to missing
 Run Balance
 Set TPH Solids SDs to Fixed, 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
 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, set
TPH Solids, TPH Water , Sizes to fixed, % 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
 Manual Structure
 Part I - Overview
 Part II - Changes from Version 5
 Part III - Installing JKSimMet
 Part IV - Learning JKSimMet
 Part V - Using JKSimMet
 Part VI - Mass Balancing
 Part VII - Model Fitting
 Part VIII - Model Descriptions
Thanks for your attention!