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For Windows
The World’s Premier P C Simulation Package
for complex Metallurgical & Chemical Engineering Processes.
BROCHURE CONTENTS
- Introduction ................................................................................................................................................
3
- Components ................................................................................................................................................
8
- Unit Operations Overview & Overview of Some Generic Unit Operations ...............................
12
- Reactions ...................................................................................................................................................
20
METSIM is Controls
- Process Developed by: Mr Kevin Charlesworth, Director
......................................................................................................................................
21
PROWARE Kevin Charlesworth Consulting
Mr. John Bartlett Australian and Asian
- METSIM Mechanics ...............................................................................................................................
Agent For METSIM
Tel: 23 (1-520)-299-7834
Fax: (1-520)-299-8009 PO Box 2021
E-Mail: jtbartlett@metsim.com Port Macquarie, NSW 2444
- APL .............................................................................................................................................................
Homepage: http://www.metsim.com Australia
24
Tel & Fax: 612) 6583
3274
- Value Functions Overview ....................................................................................................................
25 Email:
ozmetsim@ozemail.com.au
Web Page:
- Value Functions .......................................................................................................................................
http://members.ozemail.com.au/~oz
26 metsim/
- METSIM Flowsheets ..............................................................................................................................
Introduction
The basis for analysis of all chemical and metallurgical processes is the mass and energy balance. Plant
design, capital costs, and technical evaluations are all dependent on such calculations. METSIM is a
general-purpose process simulation system designed to assist the engineer in performing mass and energy
balances of complex processes. METSIM uses an assortment of computational methods to effect an optimum
combination of complexity, user time, and computer resources usage.
METSIM originated as a metallurgical process simulation program, written to perform mass balances
around the major unit operations of complex process flowsheets. Application of the program proved so
successful that it was expanded to include detailed heat balances, chemistry, process controls, equipment
sizing, cost estimation, and process analysis. The unique nature of the programming language, APL,
allows modification and expansion of the system with minimum effort and permits the incorporation of
continuing technological innovations in process simulation.
Many diverse processes, including chloride leaching of molybdenum concentrates, hydrochloric acid leaching
of alumina clays, gold cyanidation / precipitation, roasting and flash smelting of copper concentrates, SAG
milling of various ore types, acid and carbonate leaching of uranium and vanadium ores, heavy media coal
preparation plants, base metal smelting, and gold and copper heap leaching, have been modeled with
METSIM.
9.METSIM requires the engineer to develop a detailed understanding of the process and provides a
format for evaluating process design criteria.
10. METSIM allows evaluation of operating techniques and anticipation of potential problems.
The complexity of METSIM models created is dependent on the purpose of the computer simulation and
the ingenuity of the engineer. It is suggested that users become familiar with the program through the on
line-help system before attempting to build a model. Only in this way can the user take full advantage of
all the unique attributes of the METSIM program. This on-line help is organized such that the user is
first acquainted with the basic components of the system and the procedures to be followed to get the
program running. It also provides the detailed data requirements of the various components and the
mechanics of entering process model data in the METSIM program.
METSIM provides the power of the largest computers with the complexity of advanced engineering
mathematics. METSIM was designed to take full advantage of the work space characteristics, interactive
capabilities and functional power of APL. The need for complicated job control language, file handling,
text editing, and debugging programs has been eliminated.
3
METSIM performs mass and energy balances for chemical processes using the sequential modular approach.
This method is used because of its elegance and amenability to simplify divers and complex flowsheets.
METSIM can easily be expanded to encompass new processes and techniques. A major advantage of this
approach is that intermediate results may be obtained from any stage of the process in an intelligible
form. This attribute of METSIM is invaluable when attempting to detect possible modeling or specification
errors.
In conformance with the sequential modular approach, METSIM comprises modules containing subsets
of equations describing the design specifications and performance characteristics for each process step.
The system solves the equation subset for each module, allowing for an individual analysis of each unit
operation in the flowsheet. Given data on design variables and input stream composition, each module
calculates all of the output stream variables, which can then be used as input stream values for the next
process step. The modules access data on all independent stream variables from the data arrays contained
within the APL global workspace. Additional input data required to solve the equations in each module
are requested by the program and are stored as global variables. The user may supply actual data obtained
from operating or pilot plants, from similar processes, or from estimates supplied by the engineer.
Unlike several process simulation programs currently in use within the chemical process industry, METSIM
eliminates the need for user involvement in recycle stream tearing. METSIM employs a technique whereby
the user is required only to provide initial estimates of the recycle stream content of critical process
streams. Multiple stream numbers are not required and METSIM determines which streams are to be
torn. Rapid recycle stream convergence is assured by using the Wegstein convergence accelerator. This
technique almost always results in recycle stream convergence in less iteration than the direct substitution
method.
METSIM’s flexibility is further enhanced by the use of feedforward and feedback controllers for process
adjustment and control. Since the dynamic behavior of METSIM’s controllers is similar to that of process
controls in operating plants, unstable control strategies can often be located during the modeling stage,
avoiding costly field modification and retrofit.
The successful application of the METSIM system of programs involves more than simply entering fixed
data on standardized input sheets. Due to the wide variation in chemical and mineral processing techniques,
available data, process criteria, and output data requirements, the development of process models is as
much an art as it is a science. METSIM is not a panacea for the engineer; it supplements not replaces,
sound engineering practices and judgment. The user must be familiar with process engineering mass and
energy balance calculations. Familiarity with mathematical modeling, numerical analysis, and process
control is most helpful when modeling complex processes.
4
Model Planning
The old adage ‘No one planned to fail. They failed to plan‘, applies to process modeling as any other
complex activity. Modeling is not a trivial task. METSIM is a powerful tool, which can easily be abused by
not ‘getting it right’ from the beginning. The following sequence is strongly recommended from experience
with many flowsheeting projects. Whilst it is recognized that information, especially about new processes,
will be incomplete, this sequence should be followed as closely as possible. Due to the wide variation in
metallurgical and chemical processes, purposes of models, and availability of data, individual judgement
must be made as to the amount of time and detail given to each step.
2 Sketch a process flowsheet with all unit operations and streams present.
3 Make a list of all phases present and list all components in each phase.
5 Use the 'Model Parameters' Task Bar Button to set the major switches and select the units of mass and
time.
6 Select the components from the database ‘DBAS Component Database‘ and edit component data ‘ICOM
Edit Components‘.
7 Select appropriate METSIM unit operation modules listed under the screen object buttons, and
compile the data required to execute each.
9 Build the flowsheet using the Screen Interface palette entering all unit operations and streams
section by section.
10 Add unit operation data, equipment sizes, and separation parameters, and add unit operation
chemistry and heat balance data.
11 Provide precise flowrates and compositions for all input and estimates for recycle streams.
13 Calculate flowsheet and check results to verify input and mechanisms, and debug the model.
18 Provide a detailed process description, and track revisions of the model underneath.
5
Model Flowsheet Development
The developed flowsheet should be as complete as available data permit and structured to produce levels
of accuracy desired in the final results. Input data can be readily revised as the flowsheet evolves from
general to detailed, but it is desirable to make allowances for the addition of flowstreams and unit operations
as complexity increases. One should examine the flowsheet carefully for omission of any streams. All mass
entering or leaving the process must be associated with a process stream. Typical omissions included pump
gland water, evaporative losses, open tank off gases, and infiltration air. These types of flows are often
omitted in general process evaluations but should be included in detailed design calculations.
METSIM unit operation modules should be defined at each point where one or more of the following
conditions exist.
3One or more streams undergo a chemical reaction, phase change, temperature change, particle size
change, or any physical changes resulting in the formation of a new stream of different chemical or physical
properties.
The user need not be concerned with the precise nature of the unit operation module at this time. Generally
unit operations are numbered sequentially following the path of process flow. METSIM allows addition of
unit operations through the screen interface and changes in the sequences of calculations through the
routine ‘ IFLS Use "ONLY" to Rearrange Flowsheet “. Unit operations and their data are renumbered
automatically.
Unit operations modules forming recycle loops should be listed consecutively. Flowsheets having multiple
and / or nested recycle operations complicate application of this guideline; however, experience gained
through repeated use of the system will enable the user to assign unit operation numbers to maximize
system efficiently.
Key Definitions
To prevent misunderstanding and confusion the following key definition should be noted:
COMPONENTS - mass balance entities such as molecular compounds, pure elements, pseudo
compounds, ions, etc.
UNIT OPERATIONS - process units where streams merge, interact and separate.
6
Files and Directories
When METSIM is installed, a METSIM directory is created containing the following files and
subdirectories.
METSIM DIRECTORY
DBF contains about 100 thermodynamic database files as METDBxx.SF, where xx is the element
symbol. Components are stored in file with the highest element number first.
Stemp Contains APL Windows 95, 98 and NT subdirectories, and application S file setup
XXX additional sub-directories can be created to store model files in. The pointer to the
model sub-directory may be changed to any directory on any drive. It should be noted
that these sub-directories should not have further sub-directories, or the file handling
will indicate an error.
7
Comp on en ts
METSIM carries out mass balance calculations by tracking material flows, which are made up of a
mixture of components. These are the chemical species, such as pure chemicals, minerals or elements,
and can exist in one or more of eight phases. The phases are identified by their phase number. Prior to
using any of the component input routines, first prepare a comprehensive list of the components, which
it is anticipated will appear in the flowsheet. Components are assigned to the phases in which they are
present.
Components can be entered into a flowsheet model through one of three methods: -
2- User Database, stored in the file METDBUS.SF in the DBF sub-directory. This file is automatically
loaded with the METSIM database. The file is created and edited via the routine ‘IUSR Edit User
Database ‘.
3 – Created directly through the component input/edit routine ‘ ICOM Edit Components’.
The process model components are saved with the model in the model storage file Filename.sfw, and
automatically reloaded when the model file is re-loaded into the workspace. This ensures continuity of
data.
Model components can be saved into the User Database file using the routine ‘ IUS2 Add Model Comp
to database’.
8
Drop Down Menus
The following drop down menus are located along the top of the screen and contain programs used to
create, build, develop, analyze and save flowsheet models i.e.:
Input Definition of flowsheet parameters, case, flow matrix, stream qualities and controls
Weather Input, calculation plotting and output routines for weather patterns for heap leach
and solar evaporation flowsheets data
Heap All Routines associated with Heap Leach Option -Input, parameter definition,
checking, calculation and outputs.
EquipList Design, Editing and Output of Equipment Lists and Equipment Specifications
Tools Miscellaneous programs for developing user objects, flowsheet evaluation, and saving
and comparing flowsheet data.
9
New Model - used to clear and initialize the M E T S I M workspace ready to build a model. On activation it
requests the user to confirm replacement of the existing model in memory.
Load Model - used to loading an existing flowsheet model file On activation it requests the user to
confirm replacement of the existing model in memory.
Save Model – used to save a flowsheet model directly to file. On activation it overwrites the old file data
with that in memory.
Print Flowsheet – used to print either the full flowsheet or selected sections.
Model Parameters – used to set flowsheet site, case, calculation setup and calculation limit parameters.
Error Checking – used to check out a flowsheet model immediately it has been loaded into the
workspace. The routine checks for: Stream errors.
Enlarge Drawing Size – enlarge the palette area, to expand the flowsheet
Reduce Drawing Size – reduce palette area, to fit the flowsheet into a smaller area.
Box Item To Move – used to box flowsheet areas which can be moved separately
Renumber Controls on this Page – used to renumber controllers in the current section.
Reverse Unit Op – used to reverse unit operation icons around the vertical axis
Change Object size – used to change the unit operation icon size.
Move object – used to move screen objects i.e. Stream routes, unit operation icons, controllers icons.
Move Text – used to move unit operation text descriptions on the screens.
Copy Object Data – used to copy data from one object to another.
Edit Object Data – used to edit data in unit operations, streams and controller data.
Page Down – used to page down through the sections of the flowsheet.
Stop Execution - On activation will immediately stop flowsheet calculations. Used to abort calculations as
determined by the user.
Calculate Unit Operation Range – used to repeat calculations over the range determined by the user
through SC AL .
Calculate All Unit Operations – used to calculate the full flowsheet from any section. Useful for
situations where the user may wish to observe flowsheet changes during simulation.
Unit Operations - used to display the unit operations in the current section.
User Created Objects - used to display the list of User Created Objects.
Display Value Function for Streams - used to create and select value functions to replace stream
number on the flowsheet screen.
Display Section Spreadsheet - used to display data for all streams in the current section according to
the selections made via the D S D O Spreadsheet Items Standard, and D C S I Spreadsheet Items Custom
routines located in the Display drop down menu.
Plot Screen Analysis - used to plot screen analysis data for and selected stream(s).
Plot Dynamic Data - used to plot screen analysis data for and selected stream(s).
The basic calculation philosophy used in METSIM is to take the feed streams to a unit operation module
and have a mechanism to handle the inputs and to output according to the module.
Most unit operation modules mix the feed streams then the mechanism is applied. That mechanism can
be preceded by chemical reactions or a phase change and if the result required is not achieved then the
mechanism or chemical reaction can be changed or a control applied as a feed forward or feedback loop.
It is possible therefore because of the structure of the program, to add chemistry to any unit operation and
then add controls to simulate any type of reactor without having a specific reactor model.
The calculation sequence for a typical unit operation is according to the following procedure:
- calculate reactions
If an output stream parameter is to be controlled, a feedback controller must be added to sample the
output and adjust an input stream, a reaction extent or another unit operation parameter to achieve the
desired results.
Logic, PID, flowrate, Feedforward and density controllers may be used to adjust streams and parameters
prior to calling the unit operation module.
METSIM was originally developed to calculate mass and energy balances around any type of flowsheet in
a timely manner. To facilitate this task several generic unit operation modules were used. Chemistry and
heat balance data may be added to any of these units. They are:
RCY - Recycled Stream Links is used to facilitate convergence of multiple recycle streams in flowsheets.
MIX - Stream Mixer mixes all of the input streams and has a single output stream. Can be used to
simulate tanks, sumps, bins, mills, reactors, pumps and conveyors.
SLS - Solid/Liquid Separator simulates solid/liquid separations classifiers, thickeners, filters, ponds
S U B - Stream Distributor allows streams to be closed for water balance, Controlled at different flowrates
and totaled as for reagents.
SPC - Component Splitter allows components to be split differently in output streams. Can be used to
simulate flotation cells, gravity concentrators and recovery plants.
Phase Splitter allows phases to be split differently in output streams. Can be used to simulate solvent
extraction, CIP/CIL and furnaces.
Stream Splitter is used to split one or more input streams into two to six output streams.
12
GENERAL Unit Operations
Section Pump, Sump
Stream Pump, Vacuum
Recycle Stream Links Pipe
Stream Mixer Pipe Connection
Sloid/Liquid Separator Pipe Header
Stream Distributor Tank - agitated tank with internal coils for heating or cooling
Component Splitter Tank - agitated tank with external jackets for heating or cooling
Phase Splitter Tank - agitated storage tank
Stream Splitter Tank - with internal coils for heating or cooling
Sump Tank - with external jackets for heating or cooling
Launder Tank - simulates a storage tank
Pump, Tank - decant tank for separating organic from aqueous
Centrifugal Tank - electrolyte or compartmented tank
Pump, Positive Displacement Tank - process tank with agitation
Pump, Verticle Tank - storage tank without agitation or heating
Pump, Metering
MINING Unit Operations
ORE from mine Train
ORE Tonnes & Grade Dredge
Shovel Clam Shell
Front End Loader Barge
Haul Truck Ship, Container
Truck, Container Ship, Tanker
Truck, Tanker
MATERIALS
HANDLING Conveyor, Bucket Elevator
Unit Operations Conveyor, Apron Feeder
Stockpile, Conveyor, Pneumatic
Blended Conveyor, Reclaim
Stockpile, by the LIFO, FIFO or MIXO method Conveyor, Screw
Stockpile, Reclaim Conveyor, Stacker
Static Screen Bin Conveyor, Transfer
Screen Grizzly, Static Agglomerator
Screen Grizzly, Vibrating Heap Leach Column
Chute/Hopper Heap Leach Test Heap
Bin Heap Dump
Silo Heap Leach
Hopper Heap Leach Extension
Chute, Drop Box Heap Leach Drainage
Splitter, Flop Gate
COMMINUTION
Conveyor, Belt Unit Operations
Crusher,
Conveyor, Cone
Chain/Drag Mill, Rod
Crusher, Gyratory Mill, Ball
Crusher, Impact Mill, Roller
Crusher, Jaw Rock Scrubber
Crusher, MMD Sizer Hydrocyclone
Crusher, Roll Classifer, Screw
High Pressure Grinding Classifer, Hydro
Screen, DMS/Banana Classifer
Screen, Derrick Centrifuge, Decantor
Screen, Vibrating Centrifuge, Separator
Screen, Trommel Compactor
Mill, SAG
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BENEFITICATION Unit Operations
Flotation, Column Coal Spiral
Flotation, Jameson Cell Dense Media, Bath
Flotation, Cell Dense Media, Cyclone
Gravity Separator, Cone Dense Media, Drum
Gravity Separator, Jig Dense Media, Sump
Gravity Separator, Mosley Dense Media, General
Gravity Separator, Spiral Dense Media, Screen
Gravity Separator, Table Dense Media, Vessel
Gravity Separator, General Screen Desliming
Dry Magnetic Separator Water Only Cyclone
Wet Magnetic Separator
There are two mechanisms for controlling the dynamic operation of a flowsheet: firstly, by providing a
schedule; or secondly, by using logic controllers. Each mechanism has its merits, and we hope that future
versions of METSIM will incorporate a combination of the two.
Most straightforwardly, a schedule may be provided for the entire flowsheet, specifying what action is
taken for each, fixed period of time. This works best for single batch operations, such as a Pierce-Smith
converter, when the charging, blowing, skimming and transfer periods last for a fixed time, and are
accompanied by a specific action. The most serious drawback with this mechanism is that it is not possible
to specify a logical condition determining the end of the period. For example, if a furnace is to be emptied,
it is not possible to specify that its contents should be transferred at a specific rate until the furnace is
empty. Instead, the rate must be calculated in order that the transfer takes a specific length of time. A
schedule may be constructed most easily from an existing plant: in this case, the actual operating parameters
of the plant may be used, and the various unknown reaction rates and extents may be varied to ensure
a good match. Having constrained the chemistry in this way, various hypothetical schedules may be
tested against the original.
Alternatively, the entire operation of the plant may be dictated solely by logical if…then statements. It is
a considerable undertaking to design logic controllers to describe the appropriate action for every state in
which the flowsheet may exist. All the logical if conditions, obviously, are queried on every pass through
the flowsheet (that is, on every time step), and each must evaluate either true or false, triggering an
appropriate action. It is surprising how quickly such a scheme becomes unmanageable. This mechanism
has, however, been used successfully in at least one case.
Once the schedule or logic program has been completed, the other details of a dynamic simulation are
exactly as for steady-state simulations, with the exception of feedback controllers. In a steady-state
simulation, the role played by feedback controllers is not strictly analogous to that played by feedback
controllers on a physical plant. These steady-state model feedback controllers are used primarily to
automatically calculate parameters (such as the mass of coal that must be burnt to dry a given quantity of
wet feed) that the modeler would otherwise have to calculate by repeated trial and error. This makes
calculations of the effects of changing, for example, concentrate grade, far simpler and faster. In a dynamic
model, however, (as in a real plant) the effects of changing a variable used previously in the flowsheet are
not felt until the next time step, and the controller must wait to determine whether the change made was
sufficient, or whether further corrections are needed. The algorithms necessary to calculate the change to
be made to the controlled variable, from the error in the measured variable, are well established by the
manufacturers of control equipment, and METSIM incorporates the two most popular. The tuning
parameters (the proportional gain, etc.) needed for the model should therefore be the same as for the PID
controller in the real plant.
Costing Module
Operating costs are generated as a spreadsheet, with the cost items listed in rows and the costs in
columns. The spreadsheet is set up by defining the cost areas, then the items in each area with their
costs and then their types.
METSIM operating costs module is designed to enable the user to use the data generated by the
flowsheet model to generate tables of operating costs. Costs are output in spreadsheet format and can
be itemized by flowsheet section, unit operation, and cost types. A series of routines are provided in a
menu structure for input, calculation, editing and output. Operating costs can be determined, at any
time following the calculation of a model.
Costs can be incurred in different currencies and assembled in a single currency. The menu structure is
designed to enable the user to input data by classification, such as labor, materials etc. for each unit
operation and plant section as appropriate, and output itemized costs for display, printing and export.
15
Operating Costs
16
Stream Data
When activated the input data screen is displayed. A series of spreadsheets are displayed to allow
stream data to be entered or edited as described below.
On exiting the stream data screen, the program returns to the palette and the edited stream number and
route will change to the color of the predominant phase. For phase colors see ‘Select Object Colors‘.
Stream data is displayed along the top of the screen above a series of data entry spreadsheets.
The top line is used for text entry e.g. stream description. The second and third lines are for stream data
variables
Data Field Output Level Input Field Design Factor Input Field Maximum Flow
Input Field Box Number Input Field Input Field Input Field Variables 1 2 3
Input Field for Output Level. Stream data is used to switch on/off the stream display. If the stream
output level matches the display level as defined in DVAL Display Value Functions for Streams. The
stream data is displayed. This can be either the stream number, a stream value function or a stream
box as defined in ISBX Design Stream Graphics Boxes.
17
Input Fields for Design Factor, Maximum Flow and Variables 1 2 and 3 are not used at present.
Input Filed for Box Number is used to replace data as defined in DVAL above by a graphics box as defined
in ISBX. Box types are listed in ISBX.
- the upper is for the stream name or description, initially defaults to flowsheet stream number.
-The lower is for the stream label, which is generally an alphanumeric P and I D flowsheet identifiers.
Initially it defaults to flowsheet stream number.
Quick Access buttons are displayed to the left of the above. Only the buttons for the phases present in
the flowsheet are displayed.
- Mass and volumetric flow rates, temperatures, pressures and operating time
- Phase compositions by component
- Phase elemental composition
- Stream particle size distribution (which is activated through the SSA button)
- Stream component size data (which is entered through the SSM button).
- Stream washability or gravity separation data (which is entered through the WAS button).
The suggested method for entering stream data for the first time is to first enter the Mass for each phase,
which will be in the units defined in the column header. Exact values are required for input streams
estimates for controlled input and recycle streams.
As each phase field is activated, components and elemental composition spreadsheets will appear, with the
components and their elements according to and in the order of the component list. If there are no
components listed for a phase no spreadsheet will appear. The phase buttons can also be used for data
entry. The mass flow of the phase is entered, by moving the mouse pointer to the relevant field PL. A blue
border highlights the field. Enter the flow PL. The first component listed for the phase will be allocated all
of the material and its assay will change to 1 i.e. the phase is 100% of that component. Individual component
assays are entered as weight fractions or mole. fractions. As each assay is entered the phase composition
is recalculated and the assay of the first component will be adjusted to ensure the total assay is always
equal to 1 (100%).
Aqueous phase components are often referred can be entered as weight fraction or grams per liter (gpl).
Similarly as with other phases the assay of the first component is balanced with each entry to maintain
the composition to 1.
Hence by choosing the first component in each phase to be either the inert or bulk material, the phase
assay is always balanced with a component, which will not cause major errors in chemistry through error
in input. In the aqueous water is always the first aqueous component as every other component is dissolved
in water.
The elements spreadsheet is designed similarly to that for components, with columns for weight fraction
and gpl entries. In cases where elemental data is available, element composition can be entered. In this
case METSIM will recalculate the component assay for that element composition. This is achieved by
setting up simultaneous equations. However where the chosen element is in several components, there
may be several solutions, METSIM will be unable to arrive at a solution. In this case the user will have to
make judgment, on which data is the best for the material.
The above procedure is repeated for each phase present in the stream.
For solid flows such as ores, the ore and adhering moisture flow generally relate to a measurement from a
weighing device. In this case first enter an estimated flow of solids and aqueous phases to match the total
flow. METSIM will calculate the total flow and the percent solids. The percent solids are next adjusted to
the required value. METSIM will re-adjust the aqueous flow to match that value. Finally the desired total
flow is entered and the program will recalculate both solids and aqueous flows to give the total entered
18
whilst maintaining the desired percent solids.
If the flow of a stream is normally measured volumetrically e.g. gaseous streams, a mass flow estimate is
entered and the composition fixed. Then the required volumetric flow is entered using the flow functions
in the spreadsheet. The mass flow will be recalculated to match the volumetric flow.
Stream temperatures are entered if the heat balance switch (in ICAS) is on. Temperatures can be entered
in Celsius or Fahrenheit. METSIM uses degrees Celsius in all calculations.
Similarly stream pressures can be entered in Kilo Pascal’s (kPa) or Pounds per square inch (psi)
Note: Exact compositions are required for input streams; estimates may be entered for controlled input
and recycle streams.
Quick Access buttons, located at the top center of the screen appear for the phases present in the
component list. These can be used for entry of phase assay data:
SI - Solids Inorganic
SO - Solids Organic
LI - Liquids Inorganic
LO - Liquids Organic
M1 - Molten Metal
M2 - Molten Oxides,
slag
M3 - Molten
Sulfides/Halides
GC - Gaseous
SSM –
Multicomponent size
analysis
WAS – Washability or
specific gravity
NOTE 1: If the SCM option has been chosen, solids inorganic component data must be entered using the
SSM button. This takes president over SSA screen size analysis. The latter array data is derived from
SSM.
The total solids inorganic mass flowrate is calculated on each entry in SSM and the assay of the first solids
inorganic component is set to unity. ON entry of other solids component assays the assay of the first solids
inorganic component at the top of the component list is recalculated to ensure the total is always 1, as with
normal assay entry.
On completion, solids component assays may be adjusted in the normal manner, and the assays will be re-
proportioned in SSM to match the total component assay in the stream array STR.
This section describes the different ways that chemical reactions may be written in METSIM. Chemical reactions
are at the heart of the success or failure of many METSIM models. The way in which they are written, their order,
and their extents can be a prime determinant of the quality of results, and the benefit obtained from the model.
They dictate the amounts of new compounds, whether valuable or hazardous, formed throughout the process, and
the consumption of raw material fed to the process.
Chemical reactions must be specified for a particular unit operation, and will then occur only within that unit
operation. If a chemical reaction occurs in many unit operations, it must be specified for each of them individually
The unit operation ‘Reactions’ page contains input data screen for entering reactions. When activated a list screen
is displayed. Reactions are entered in the order in which they will be performed. Individual reactions are input or
edited using the edit button.
The editing screen provides a list of the abbreviated chemical names (CNM) of all components in the model accord-
ing to the major phase type they exist in i.e. solids, liquids, melts and gases. The chemical reaction is entered, by
selecting the first reacting component from the list by placing the mouse pointer over the chosen reactant and PL.
The reactant CNM will appear in the reaction equation display field. Repeat for the remaining reactants. A plus
sign will be inserted between each selection. On completion, activate PL the + Prod button and select the first
product component. An = sign followed by the CNM of the selected component will appear in the reaction equation
display field. As each subsequent component is selected, + sign will appear followed by the component CNM.
On completion activate the Balance button and METSIM will balance the equation. METSIM uses simultaneous
equations to calculate the reaction balance. If the reactants and products of the chemical reaction balance,
METSIM will rewrite the equation with the number of molecules of each component in the equation. If the equa-
tion does do not balance, or there is no single solution to the chemical reaction METSIM will warn, “ REACTION
DOES NOT BALANCE “. The unbalance equation must be evaluated to determine whether it is incorrect and
corrected. Reactants and products components can be removed or added to the equation by activating the + or –
reactants or + or – products buttons, and highlighting the appropriate components in the component list PL. If
desired the complete reaction can be cleared and re-input. Upon completion, the new reaction must be re-balanced.
If the reaction cannot balance the User button will open an input screen whereby the stochiometry can be input
directly. Once input the balance button will confirm the user-input reaction does balance.
Process Controls
Constraints may be applied to the process flowsheet in addition to those parameters specified in the unit
operation modules through the use of process controls. These controls function similarly to those in oper-
ating plants. During development of METSIM, it was found that numerous alternatives were possible in
fixing or setting process parameters. METSIM was developed by choosing the most common set of con-
straints and programming them into the calculation code. The process model is developed using these
standard constraints, and then the control module is used to release the constraints that are not applica-
ble and to impose those that are desired. Thus they can also be used to simulate process control loops and
evaluate control strategies.
In addition to controls instruments (INS) and totalizers (TOT) can be included in the flowsheet to measure
parameters in streams and unit operations, similar to transducers in real life.
The type of control, which can be applied, will depend on whether the model is used for steady state or
dynamic simulation. The distinction between each mode is:
-In steady state simulation the material balance is achieved by ensuring that there is a balance
between inputs and outputs for all unit operations i.e. matter is neither created nor destroyed. There are
no process inventories
-In dynamic simulation, process inventories are used to balance inputs and outputs. The latter are con-
trolled and the balance between inputs and outputs is achieved by varying the unit operation contents or
inventory.
In steady state simulation constraints are applied using either feedforward or feedback control. Feedforward
type controls apply prior to the calculations for a unit operation and consist of:
FBC – Feedback controls are used to adjust parameters or stream(s) flow(s) to achieve a set point value at
the output of a unit operation. Control is applied after a unit operation calculation routine has been
completed. The controller calculation routine is iterative and the set point is achieved when it is within a
convergence tolerance. The tolerance is set to 10 to ¯10.
Note: Flowsheets converge faster when feed forward controls are used rather than feedback controls.
Each feedback control loop adds flowsheet convergence time due to the controller iterations and also does
not give an exact value, due to the convergence tolerance. It is good practice to keep feedback controls to
a minimum.
In steady-state simulations, process control is used to determine an appropriate value for, e.g. a flow rate
of natural gas to a burner, but can also be used to control variables which it may not be possible to control
in practice, e.g. the extent of a chemical reaction in a furnace to ensure that a slag has a compatible copper
content to the matte. This type of feedback control can best be thought of as simply imposing additional
constraints on the process.
21
In dynamic simulation, the feed forward controllers can used to control
Unit operation inventory will vary dependent upon the difference between input and output and existing
inventory.
Feedback control cannot be used in dynamic simulation and must be replaced by an appropriate P and I D
control (PID ). The same controller module can be used and in this case the controlled variable is modified
for the calculation of the next time step on the basis of the effect of the last change. The feedback control-
ler in P and ID mode should be used to control the variable, which would actually be controlled in practice.
Typically the P and I D controller would use a flowrate controller as the adjusted variable.
METSIM has several alternative P and ID algorithms, which are used in most commercial controllers.
INS – Process controls instruments are used on streams and unit operations to measure operating param-
eters similar to transducers and instruments on process plants. Instruments are used in steady state
calculations to monitor critical parameters during whilst the model calculations are in progress. In dy-
namic simulation instruments are used to plot and record data for each time interval during the calcula-
tion of the flowsheet.
Controls can be accessed either directly from the flowsheet using the ‘Object Editor’ or via the ‘ICTL
Process Controls’ in the Input drop down menu.
Controllers loop numbers, location, set point parameters and values, and controlled variable values can be
view vie the ‘OCTL - Print Controls' routine located in the Output drop down menu.
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METSIM MECHANICS
The Mechanics of entering data into METSIM have certain guidelines which should be followed in order to ease data
entry and avoid errors.
BLANK - METSIM was designed to use the blank as a delimiter between numeric data elements of the same type.
COMMA - The comma will act as a delimiter in place of a blank, however, its main use is to join variables or vari-
ables and numeric data into one vector of data.
DECIMALS - Irrespective of the use of the word percent in the prompts, all data must be entered as decimal
fractions.
ENTER - Pressing the enter key without any data entry will cause METSIM to continue execution of the program in
progess.
Y or N ? - Inputs requiring a yes or no response, will default to no (N or n) for any entry other than a yes (Y or y).“
APL CHARACTERS
METSIM requires some common but special characters in generating APL expressions for process controls and
various output forms. For those not familiar with the APL characters set, the following keystrokes are provided.
Fortran APL Keyboard
Negative number sign - negative sign Alt 2
Subtraction sign - - -
Addition sign + + Shift =
Multiplication sign * x Alt -
Division sign / Alt =
Power sign ** asterisk Shift 8
Assign sign = Alt [
Array subscripts X(,) X[;] X[;]
Equation hierarchy () () ()
Plus reduction N.A. + +/
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APL executes an expression from right to left with no symbol hierarchy. Since all symbols
are treated equally, parentheses are used to alter the calculation sequence. The plus reduction adds
all values to the right of the +/ symbols, this is handy for summing multiple stream data in
controller expressions.
3×4-2
3×4-2
3×2
6
12 - 3 + 3 × 8 ÷ 2 + 2
3
12 - 3 + 3 × 8 ÷ 2 + 2
12 - 3 + 3 × 8 ÷ 4
12 - 3 + 3 × 2
12 - 3 + 6
12 - 9
3
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VALUE FUNCTIONS OVERVIEW
Value functions are used by METSIM to recall or evaluate stream data in a manner analogous to
that
in which instrumentation is used to monitor an operating process. These functions are used in
three ways.
1.The feedback and feedforward controllers use value functions to provide current data for
process control. This is analogous to the input signal to process controllers.
2.The value functions can be called by the METSIM user during data entry and
program interrupts to provide current data as an aid to debugging or model building. This is
analogous to a control room operator checking instrumentation readouts to guide the
process during startup or upset conditions.
3.The value functions are used by the data display and output report programs to
convert stored stream data to the desired output variables.
Value functions require data in their accessing statements consisting of stream, phase, component,
or element atomic numbers. They must also return a value. Value functions can be of two forms,
monadic and dyadic.
form, V*** sS
EXAMPLE: VGPM s15 calls for the gallons per minute in stream 15.
Dyadic functions require two data items. The preceding variable usually are component(s),
phase(p), or element atomic number(s). The trailing variable is a stream number(s). They are of
the form,
cC V*** sS
EXAMPLE: c12 VGPL s10 returns the grams per liter of component 12 in stream
10.
In the following table, the abbreviations for S, P, C, E, and M are to be replaced with the
S Stream number(s) from the process.
following numbers:
P One or more phase numbers, 1 through 8 representing the phase.
C One or more component numbers or a variable containing the component
numbers such as SI, SO, SC, LI, LO, LC, M1, M3, or GC.
E Element(s) represented by their atomic number(s).
M Particle size in microns.
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VALUE FUNCTIONS
Density and Specific Gravity Value Functions
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Mass/Molar Flowrate Value Functions Not-Adjusted for Operating Time
The following flowrates are in the units specified in ICAS.
E Vgle S ;Grams per liter of element E in stream S in total liquor (at 25C).
E Vglea S ;Grams per liter of element E in stream S in aqueous only (at 25C).
E
C Vgleo
VGPL SS ;Grams per liter of element E in
components stream
C in S in
stream organic
S in totalonly (at 25C).
liquor.
C VGPLa S ;Grams per liter of components C in stream S in aqueous only.
C VGPLo S ;Grams per liter of components C in stream S in organic only.
C Vgpl S ;Grams per liter of components C in stream S in total liquor (at 25C).
C Vgpla S ;Grams per liter of components C in stream S in aqueous only (at 25C).
C Vgplo S ;Grams per liter of components C in stream S in organic only (at 25C).
VGLS S ;Grams per liter of solids in stream S.
C VFE2 S ;Grams per liter of Fe+2 in components C in stream S.
C Vfe2 S ;Grams per liter of Fe+2 in components C in stream S (at 25C).
C VFE3 S ;Grams per liter of Fe+3 in components C in stream S.
C Vfe3 S ;Grams per liter of Fe+3 in components C in stream S (at 25C).
V2O5 S ;Grams per liter of Vanadium in stream S reported as gpl V2O5.
E VMLE S ;Moles per liter of element E in stream S.
E Vmle S ;Moles per liter of element E in stream S (at 25C).
C VMPL S ;Moles per liter of components C in stream S.
C Vmpl S ;Moles per liter of components C in stream S (at 25C).
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Special Value Functions
V VFLS U ;Returns value of variable V from unit operation U. Format: 'RM' VFLS u10
VHRD S ;Value of water hardness of stream S in ppm calcium carbonate.
VLAB S ;Returns the short label for stream S.
VSNM S ;Returns the long label for stream S.
VTMP S ;Returns the control temperature for stream S in degrees C.
VAPK S ;Surface area in M3/kilogram of solids in stream S.
VBVP S ;Estimated vapor pressure of brine in streams S.
VLOI S ;Loss on ignition of stream S.
VTMP S ;Control temperature of stream S in degrees C.
Heap Leach Value Functions
VHEP B ;Places data from HEP into STR in an unused stream number and returns
the stream number, used in conjunction with other value functions.
e.g. C VGPL VHEP 3 VHLG ib
Returns the grams per liter of component C in all of the blocks
in the cell containing block ib
VHEP0 B ;Places data from HEP0 into STR in an unused stream number and returns
the stream number, used in conjunction with other value functions.
30