Chapter 13

PROCESS SIMULATION AND OPTIMIZATION USING METSIM

Mr . John T. Ba r t l e t t
ABSTRACT
Pi ncock, Al l en & Hol t , Inc.
Manager, METSIM Appl i cat i ons
Tucson, Arizona
With more s t r i nge nt envi ronment al and economic
c ons t r a i nt s bei ng pl aced on mining oper at i ons , it
has become necessary t o opt i mi ze each pr ocess t o
minimize energy and raw ma t e r i a l consumption and
reduce waste di scharge. I n most cases, d e t a i l e d
pr ocess anal ys i s is r equi r ed t o d e t e c t
i ne f f i c i e nc i e s and provi de a l t e r n a t i v e s ol ut i ons
f o r process improvement. HETSIM, a microcomputer
process modeling and s i mul at i on system, i s
r out i nel y used t o anal yze communi t i on,
hydromet al l urgi cal , pyr omet al l ur gi cal , and c oa l
pr epar at i on processes. The pr ocess modeling
t echni ques used i n METSIM, i ncl udi ng pr ocess
c ont r ol si mul at i on, w i l l be pr esent ed and
i l l u s t r a t e d usi ng a c t u a l p l a n t processes.
INTRODUCTION
The met al l ur gi cal engi neer i s r equi r ed t o
eval uat e, desi gn, and oper at e complex mi ner al
pr ocessi ng pl ant s. As or e gr ades di mi ni sh,
envi ronment al cont r ol s a r e t i ght ened, and
economics change a t an a c c e l e r a t i ng pace, t h e
engi neer i s requi red t o make f a s t e r and more
accur at e deci si ons. One method t o improve pr ocess
eval uat i on t echni ques i s t o u t i l i z e t h e computer
f o r process si mul at i on.
Process modeling us i ng computers has become
more common pl ace wi t h t h e a v a i l a b i l i t y of lower
c o s t computer hardware, an i nc r e a s e i n t h e number
of computer t r ai ned engi neer s, and t h e advent of
pr ocess si mul at i on systems. Ear l y computer models
were developed f or s p e c i f i c processes. These
models were expensive because t hey o f t e n r equi r ed
formul at i on and t e s t i n g of new c a l c ul a t i on
t echni ques; were programmed i n t edi ous computer
l anguages; were run on non- i nt er act i ve main frame
computers; and were cr eat ed by engi neer s wi t h
l i t t l e p r i o r experi ence. Today, t he r e a r e pr ocess
si mul at i on packages a v a i l a b l e which reduce t he
t i me and c o s t of c r e a t i ng a pr ocess model. Some
of t hese systems a r e pr opr i e t a r y t o l a r ge mining
companies, but ot her s a r e a va i l a bl e f o r gener al
use. No at t empt is made i n t h i s paper t o compare
a l l of t he avai l abl e programs o r t he many
va r i a t i ons i n si mul at i on t echni ques. Thi s paper
w i l l des cr i be t he f e a t ur e s t h a t a r e a va i l a bl e i n
t h e METSIM process s i mul at i on package.
PROCESS SIMULATION
Process si mul at i on is an a n a l y t i c a l t echni que
whereby mat hemat i cal equat i ons a r e used t o
de s c r i be t h e mechanisms of a c t u a l pr ocessi ng
oper at i ons. When t he s e equat i ons a r e r i gor ous l y
sol ved, t hey w i l l a c c ur a t e l y pr e di c t t he outcome
of t he process. Some of t h e a r e a s i n which
pr ocess si mul at i on i s p a r t i c u l a r l y us ef ul a r e :
Anal ysi s of p i l o t p l a n t dat a
Fe a s i b i l i t y s t u d i e s
Det ai l ed pr ocess des i gn
Operat or t r a i n i n g
Pr ocess opt i mi zat i on
Cont r ol syst em a n a l y s i s
Energy a u d i t s
One advant age of pr ocess si mul at i on is t h a t it
i s l e s s c o s t l y i n t i me and money t o s i mul at e a
proposed pr ocess t han t o ope r a t e a p i l o t pl ant . A
second advant age i s t h a t hazardous and hi gh c o s t
pr ocesses can be "experi ment ed wi t h" a t a l ower
r i s k t o t he envi ronment and f i nances. Si de
b e n e f i t s a r e t h a t t h e model r e qui r e s t he engi neer
t o devel op a d e t a i l e d under st andi ng of t h e
pr ocess, and it pr ovi des a s t r uc t ur e d format f o r
e va l ua t i ng pr ocess c r i t e r i a .
The compl exi t y of pr ocess models is dependent
upon t he purpose of t he computer si mul at i on and
t h e i ngenui t y of t h e pr oces s engi neer. There a r e
t h r e e l e v e l s of computer modeling as s oci at ed wi t h
pr oces s si mul at i on.
1 ) Mass and energy bal ance programs c a l c u l a t e
s t eady- s t at e bal ances based upon user -
s pe c i f i e d performance a t each s t e p of t h e
pr ocess and do not respond t o changes i n
equipment o r oper at i ng paramet ers.
2 ) St eady- st at e s i mul at i on programs u t i l i z e
models devel oped f o r s p e c i f i c pi e c e s of
equipment and ge ne r a l l y respond t o changes
i n oper at i ng paramet ers.
3) Non-st eady-st at e o r dynamic s i mul at or s
MINERAL RESOURCE MANAGEMENT BY PERSONAL COMPUTER
i ncor por at e t i me dependent paramet ers
which f a c i l i t a t e t he si mul at i on of pr ocess
response t o cont r ol s , f eedst ock
va r i a t i ons , and ot her per t ur bat i ons .
For a pr ocess si mul at i on syst em t o be
s a t i s f a c t o r y , it shoul d be a bl e t o anal yze si mpl e
o r complex f l owsheet s s o t h a t i t can be used e a r l y
i n pr ocess development t o model a s kel et on
fl owsheet and can t hen grow a s pr ocess d e t a i l s a r e
devel oped. I t must be capabl e of anal yzi ng
pr ocesses wi t h a l a r ge number of u n i t oper at i ons
and fl ow st r eams and be abl e t o t r a c k and r e p o r t
as s ays on many compounds and el ement s. A pr ocess
si mul at i on syst em must r e a di l y accept cust omi zed
modules t h a t p r e d i c t pr ocess behavi or based on
t e s t dat a. One t echni que i s t o u t i l i z e st epwi se
mul t i pl e r egr es s i on of t e s t da t a t o gener at e
pr e di c t i ve equat i ons. Another f e a t u r e t h a t i s
ext remel y us e f ul f o r d e t a i l e d pr ocess a na l ys i s i s
t h e a b i l i t y t o i ncor por at e dynami cal l y accur at e
pr ocess c ont r ol s t o a i d i n i de nt i f yi ng d i f f i c u l t
o r unst abl e c ont r ol s t r a t e gi e s . I nva l i d c ont r ol
schemes a r e o f t e n a cause of pr ocess mal funct i on.
When appl yi ng pr ocess si mul at i on t echni ques
c e r t a i n d i f f i c u l t i e s and p i t f a l l s need t o be
recogni zed and e f f o r t s made t o underst and and
avoi d them. Det ermi ni ng t he proper c o n s t r a i n t s on
t h e system r e qui r e s a c e r t a i n amount of " f e e l " f o r
t h e f l owsheet i n quest i on. When devel opi ng a
pr oces s model, d a t a e nt r y e r r o r s and l o g i c e r r o r s
a r e of t e n encount ered. I f t he pr ocess si mul at i on
program responds i n a manner s i mi l a r t o an a c t u a l
p l a n t , oper at i ng exper i ence can gi ve i n s i g h t i n t o
pr ocess modeling problems. When s e t t i n g up a
model, appr opr i at e chemical and phys i cal pr ocess
mechanisms shoul d be s e l e c t e d t o minimize
compl exi t y whi l e st i l l pr ovi di ng t h e r equi r ed
accuracy i n t h e model out put . The per son c r e a t i ng
a si mul at i on model shoul d c ont i nua l l y e va l ua t e t h e
ul t i ma t e accur acy and a p p l i c a b i l i t y of t h e model
i n r e l a t i o n s h i p t o t h e t i me, money, and e f f o r t
expended. The s i mpl es t mechanisms may be used
whi l e debuggi ng t h e o v e r a l l pr ocess f l owsheet and
t hen r e f i ne d u n t i l t h e de s i r e d accur acy and
response i s achi eved. The us er must a l s o be aware
t h a t c e r t a i n non-l i near equat i on combi nat i ons may
have mul t i pl e v a l i d mat hemat i cal s o l u t i o n s but
onl y one r e l e va nt pr ocess s ol ut i on. Again,
p r a c t i c a l exper i ence i s c a l l e d upon t o provi de
gui dance f o r development of t h e model.
Process s i mul at i on i s not a repl acement f o r ,
b u t a suppl ement t o , sound engi neer i ng p r a c t i c e s
and judgement. The program us er shoul d be a
pr oces s engi neer and have compl et e c ont r ol over
and r e s p o n s i b i l i t y f o r t he accuracy and
a p p l i c a b i l i t y of t h e c a l c ul a t i ons . Pr ocess
s i mul at i on i s no except i on t o t h e t r i t e
expr essi on: Garbage I n - Garbage Out.
METSIM
METSIM or i gi na t e d a s a me t a l l ur gi c a l pr ocess
e f f i c i e nc y of t he deci si on making process t hat i t
was expanded t o i ncl ude det ai l ed heat bal ances,
chemi cal r eact i ons , u n i t operat i on modules f or
pr ocess si mul at i on, process cont r ol si mul at i ons,
and equipment s i z i n g capabi l i t es . METSIM i s t he
t h i r d such program developed by t he aut hor and
i ncor por at es many of t he l a t e s t modeling
t echni ques avai l abl e. Current development i s
di r e c t e d toward t h e ar eas of enhanced graphi cs,
c a p i t a l and oper at i ng c os t est i mat i on, and dynamic
pr ocess si mul at i on.
METSIM i s a hi ghl y st r uct ur ed and modularized
syst em of s ubr out i nes wr i t t en i n APL. I t i s
desi gned t o f u l l y u t i l i z e t he work space
c h a r a c t e r i s t i c s , i nt e r a c t i ve c a pa bi l i t i e s , and
f unct i onal power of APL. The combination of
METSIM and APL ha s generat ed a si mul at i on language
wi t h t h e power of t he l ar ges t computers whi l e only
moderat el y more compl i cat ed t han t h e el ect r oni c
cal cul at or . The need f or complicated job cont r ol
l anguage, f i l e handl i ng, t e x t edi t i ng, and
debugging programs has been el i mi nat ed. Ut i l i zi ng
t h e al phanumeri c e di t i ng power of APL and a
st andar di zed nomenclature system, METSIM can
e a s i l y be amended t o i ncorporat e s peci al i zed
c a l c ul a t i ons procedures as demanded by t he user.
The s ucces s f ul appl i cat i on of t he METSIM
syst em of programs i nvol ves more t han simply
e nt e r i ng a f i xe d number of d i g i t s on st andardi zed
i nput d a t a s heet s . Due t o t he wide var i at i on i n
mi ner al pr ocessi ng t echni ques and avai l abl e dat a,
t h e development of process models i s an much of an
a r t a s it i s a sci ence. The user must be f ami l i ar
wi t h pr ocess engi neer i ng mass and energy bal ance
c a l c ul a t i ons . Fami l i ar i t y wi t h mathematical
modeling, numeri cal anal ys i s , and process cont r ol
t heor y i s most he l pf ul when at t empt i ng t o model
ext remel y complex processes. Sources f o r
a d d i t i o n a l i nf or mat i on on computer modeling and
numeri cal a na l ys i s a r e gi ven i n t he reference l i st
a t t he end of t h i s a r t i c l e .
Program St r uc t ur e
The compl et e s t r uc t ur e of METSIM revol ves
around i nf or mat i on cont ai ned i n st ream da t a ar r ays
and vect or s. Dat a r e l a t i v e t o flowstreams a r e
cont ai ned i n t he s e var i abl es and a l l u n i t
oper at i on modules, out put f unct i ons, and val ue
f unct i ons oper at e on t hese var i abl es. Array STR
cont ai ns st r eam mass fl owrat es correspondi ng t o
each component. Array SSA cont ai ns s o l i d
component s cr een s i z e anal ysi s. Array WAS
cont ai ns t h e washabi l i t y d a t a f o r each st ream i n a
g r a v i t y s epar at i on/ coal pr epar at i on process. WAS
i s a four-di mensi onal ar r ay cont ai ni ng dat a st or ed
by st r eams, s c r e e n s i z e , s pe c i f i c gr avi t y, and
c oa l component. Vect ors TIM, TEM, SPR, and SHC
cont ai n st r eam oper at i ng t i mes, t emperat ures,
pr es s ur es , and ent hal py fl owrat es.
A l l program, subr out i ne, and const ant names
used by METSIM have been i ncorporat ed i n t o a
s i mul at i on program wr i t t e n t o perform mass s t andar di zed nomenclature system. For example,
bal ances around t h e major u n i t oper at i ons of t h e f i r s t c ha r a c t e r i n t he f unct i on name denot es
var i ous pr ocess fl owsheet s. Appl i cat i on of t h e t h e fol l owi ng:
program proved s o s uc c e s s f ul i n i nc r e a s i ng t h e
PROCESS SIMULATION AND OPTIMIZATION USING METSIM
C - Cal cul at i on programs
D - Di spl ay programs
F - Function subr out i nes
G - Graphics proqrams
H - Help screens
I - Input programs
M - Menus
0 - Output proqrams
P - Pr i nt e r cont r ol proqrams
T - Telecommunication programs
U - Ut i l i t y programs
V - Value f unct i ons
METSIM i s menu dr i ven and f e a t ur e s on- l i ne
hel p scr eens t o a s s i s t t he us er i n t h e oper at i on
of t he system. Mul t i pl e menu i t ems may be
s el ect ed by ent er i ng t he correspondi ng numbers o r
proqram names. For example, t he main r o o t menu
is:
CONF - Machine Confi gurat i on Program
HELP - On Line Help Menu.
MINP - Input Data Menu
MDIS - Input Data Di spl ay Menu
MCAL - Cal cul at i on Menu
MSTR - Stream Data Di spl ay Menu
MOUT - Output Resul t s Menu
FILE - St or e o r Ret r i eve Model Program
Once user s become experi enced wi t h a proqram,
menus of t en become more of a hi ndrance t han a he l p
t o e f f i c i e n t problem sol vi ng. METSIM can be run
wi t hout t he menus by si mpl y e nt e r i ng t he
appr opr i at e commands. The us er may r e e n t e r t h e
menu system a t any l e v e l si mpl y by e nt e r i ng t h e
submenu name. These and ot he r commands f ol l ow t h e
st andar di zed nomenclature which i s s e l f t aught v i a
t h e menu system.
Value Functions
One f eat ur e of METSIM t h a t enhances us e r
i nt e r a c t i on i s t he val ue f unct i on. Value
f unct i ons a r e used t o r e c a l l o r eval uat e st ream
d a t a i n a manner anal ogous t o i ns t r ument at i on
bei ng used t o monitor an oper at i ng pr ocess.
These f unct i ons a r e used i n t hr e e ways:
1 ) Feedback and f eedf orward c o n t r o l l e r s use
val ue f unct i ons t o provi de c u r r e n t d a t a
f o r process c ont r ol by s i mul at i ng i nput
s i gna l s from pr ocess i nst r ument at i on.
2) Value f unct i ons a r e used dur i nq d a t a
e nt r y and program i n t e r r u p t s t o pr ovi de
c ur r e nt s t a t u s f o r model t e s t i n g s i mi l a r
t o a cont r ol room oper at or checki ng panel
i nst rument s dur i nq s t a r t u p o r upset s.
3) Data di s pl ay and out put r e p o r t proqrams
use val ue f unct i ons t o conver t s t o r e d
st ream dat a t o t he de s i r e d out put format .
Model Bui l di ng
The development of a METSIM based computer
model f o r a gi ven pr ocess can t ake any o f s e v e r a l
forms. The model can range from a si mpl e "bl ack
box" t o a complex de t a i l e d dynamic model of t he
process. The "bl ack box" model r e ve a l s l i t t l e
about t he i n t e r n a l s of t he pr ocess, b u t can be
used t o es t i mat e t h e e f f e c t of maj or paramet ers on
pr ocess behavi or. The dynamic model can be used
t o desi qn and eval uat e process oper at i on and
c ont r ol s t r a t e g i e s f o r pr ocess opt i mi zat i on.
Experi ence has shown t h a t t he most us e f ul and
c o s t e f f e c t i v e method of pr ocess modeling i s t o
s t a r t wi t h development of t he model e a r l y i n t h e
f e a s i b i l i t y s t a ge and t o modify and r e f i n e t he
model a s more d e t a i l e d dat a a r e made a va i l a bl e and
more s p e c i f i c r e s u l t s a r e r equi r ed. In t h e "bl ack
boxn approach, f o r example, t he l eachi ng
e f f i c i e n c y of a u n i t oper at i on would be f i xed a t
an average val ue based upon pr el i mi nar y t e s t
r e s u l t s . The d e t a i l e d model would c a l c u l a t e t h e
l eachi ng e f f i c i e nc y a s a f unct i on of t emperat ure
and r es i dence time. Cont r ol s i n t h e "bl ack box"
approach would be minimal o r nonexi st ent . A
d e t a i l e d model would i ncor por at e r e l e va nt pr ocess
c ont r ol s a nt i c i pa t e d f o r t he oper at i ng pl ant .
The normal sequence f o r pr ocess s i mul at i on
model cons t r uct i on fol l ows t he o u t l i n e below.
Due t o t he wide v a r i a t i o n i n me t a l l ur gi c a l and
chemi cal pr ocesses, purposes of models, and
a v a i l a b i l i t y of da t a , i ndi vi dua l judgement must be
made a s t o t he amount of t i me and d e t a i l gi ven t o
each s t e p.
1 ) Develop a compl et e f l owsheet which
i ncl udes a l l u n i t oper at i ons and st r eams
t o be i ncor por at ed i n t h e si mul at i on.
2 ) Compile a l i st of components based on
f eed ma t e r i a l s and chemi cal r e a c t i ons .
3) S e l e c t u n i t oper at i on modules f o r each
a c t u a l u n i t oper at i on and det ermi ne
equipment paramet ers f o r each.
4) Determine f l owrat es and composi t i ons f o r
a l l f eed st reams al ong wi t h e s t i ma t e s f o r
c r i t i c a l r ecycl e st reams.
5 ) Add pr ocess c ont r ol s and oper at i ng and
des i gn c ons t r a i nt s .
Ul t i mat el y, t h e d e t a i l e d model would be
r e f i ne d i n t o one encompassing mass and energy
bal ances as s oci at ed wi t h a l l u n i t pr ocesses; a l l
chemi cal r e a c t i ons , phase chemi st ry, and phys i c a l
changes and s epar at i ons made by t he oper at i ng
pl a nt ; a l l minor pr ocess st reams such a s pump
gl and wat er, ve nt of f gas es , and r eagent s ; and a l l
h e a t l os s es , pr ocess c ont r ol s , and ot he r f a c t o r s
which a f f e c t pr ocess performance i n any way.
I nput Dat a
The r equi r ed i nput d a t a i ncl ude a f l owsheet
de s c r i pt i on, pr ocess oper at i ng condi t i ons , u n i t
oper at i on paramet ers, and component, phase, and
st r eam dat a. Thi s i nput i s ge ne r a l l y der i ved from
pr oces s des i gn c r i t e r i a , t h e o r e t i c a l and e mpi r i c a l
d a t a from t e c hni c a l r ef er ences , a s we l l a s
l abor at or y, p i l o t pl a nt , and f u l l s c a l e p l a n t
oper at i ons .
MINERAL RESOURCE MANAGEMENT BY PERSONAL COMPUTER
Dat a i nput i n t o METSIM f a l l s i n t o t h e gener al Cal cul at i ons
c a t e gor i e s t abul at ed below:
Case Def i ni t i on
Component Data
Fl owsheet Data
Uni t Operat i on Data
Chemical Equi l i bri um Data
Heat Balance Data
Process Cont r ol s
Stream Fl owrat es and Compositions
Stream Names
Chemical Equi l i bri um Data
Pr ocesses i nvol vi ng mass t r a n s f e r oper at i ons
c a n be a c c ur a t e l y modeled by i ncl udi ng any of f our
secondary chemi cal equi l i br i um modules. These
modules can be used by any of t he pri mary u n i t
oper at i ons . The chemi cal equi l i br i um modules a r e
capabl e of t r a ns f e r r i ng ma t e r i a l between
components and phases by s peci f yi ng t h e sour ce
components and t he de s t i na t i on components and by
s e t t i n g c ons t r a i nt s on t h e magnitude of t h e
t r a n s f e r . Data can def i ne si mpl e mass t r a n s f e r
wi t hout r ef er ence t o chemi cal r e a c t i ons , o r
complex t r a n s f e r r e s u l t i n g from chemi cal r e a c t i ons
and i nvol vi ng mul t i pl e components and phase
changes. Combined wi t h t he pr ocess c o n t r o l
modules, t he chemi cal equi l i br i um modules al l ow
f o r accur at e modeling of i n t r i c a t e l y d e t a i l e d
pr ocesses. The f ol l owi ng chemi cal equi l i br i um
modules a r e avai l abl e:
SOL - Sol ut i on and phase changes.
REX - Chemical r eact i ons .
CON - So l u b i l i t y and concent r at i on cont r ol .
EQU - Mul t i phase chemi cal equi l i br i um.
Pr oces s Cont r ol s
I n a ddi t i on t o t hose paramet ers s pe c i f i e d i n
METSIM uses an assort ment of computational
methods i ncl udi ng t he sequent i al modular approach
and si mul t aneous equat i ons t o e f f e c t an optimum
bl end of compl exi t y, user time, and computer
r esour ce usage. The sequent i al modular approach
i s t h e pri mary method used because of i t s
programming el egance and i t s amenabi l i t y t o
s i mpl i f i c a t i on of di ver s e and complex fl owsheet s.
Furt hermore, t he system can e a s i l y be expanded t o
encompass new met al l ur gi cal processes and
t echni ques. An addi t i onal advantage t o usi ng t he
s e que nt i a l modular approach is t h a t i nt ermedi at e
r e s u l t s may be obt ai ned from any s t age of t he
pr ocess i n an i n t e l l i g i b l e form. However, under
some ci rcumst ance, t h i s approach c r e a t e s a l ar ge
number of r ecycl e st reams r e s ul t i ng i n r e l a t i ve l y
sl ow convergence. I n c e r t a i n cases, METSIM uses
si mul t aneous equat i ons t o sol ve p a r t s of t he
fl owsheet . Thi s opt i on i s t r ans par ent t o t he
us er .
I n conformance wi t h t he s equent i al modular
approach, METSIM u t i l i z e s modules cont ai ni ng
s ubs e t s of equat i ons descr i bi ng t he desi gn --
s pe c i f i c a t i ons and performance c ha r a c t e r i s t i c s f or
each r e l e va nt met al l ur gi cal o r mechanical process.
The system s ol ves t h e equat i on s ubs et f or each
module, al l owi ng f o r an i ndi vi dual anal ys i s of
each pr ocess i n t h e flowsheet. Given dat a on
des i gn var i abl es and i nput st ream composition,
each module subr out i ne cal cul at es uni quel y defi ned
val ues f o r a l l out put stream var i abl es which can
t hen be used a s i nput stream val ues f o r t he next
pr ocess st ep. The us er may suppl y a c t ua l dat a
obt ai ned from oper at i ng pl a nt s o r p i l o t pl ant s ,
from oper at i ons usi ng s i mi l ar processes, o r from
es t i mat es suppl i ed by t he engi neer.
METSIM al gor i t hms el i mi nat e t h e need f or user
i nvol vement i n r ecycl e st ream t e a r i ng and mul t i pl e
t h e u n i t oper at i on modules, ot he r c o n s t r a i n t s may st ream numbers a r e not requi red. The user i s
be appl i ed t o t he pr ocess f l owsheet t hrough t h e r equi r ed t o provi de i n i t i a l est i mat es of onl y
us e of feedback, feedf,orward, and st ream c r i t i c a l r ecycl e st reams. The Wegstein
t emper at ur e cont r ol s . These c ont r ol s f unct i on i n convergence a c c e l e r a t or i s employed t o f a c i l i t a t e
a manner s i mi l a r t o t hose i n oper at i ng pl a nt s . r a pi d convergence of r ecycl e st ream val ues. Thi s
t echni que al most always r e s u l t s i n r ecycl e stream
Feedforward c o n t r o l l e r s a r e used t o mai nt ai n convergence i n fewer i t e r a t i o n s t han a r e requi red
c e r t a i n st ream r a t i o s such a s a i r t o f u e l , l i q u i d by t h e d i r e c t s ubs t i t ut i on method. I f r ecycl e
t o s o l i d s , o r r eagent consumptions. The st r eam nonconvergence i s det ect ed, t he program
feedforward c ont r ol s t i e st ream f l owr at es t oget her aut omat i cal l y swi t ches t o vari ous backup
s o t h a t a s one fl ow va r i e s , t h e ot he r i s var i ed convergence r out i nes i ncl udi ng d i r e c t
pr opor t i onal l y. subs ti t ut i on.
Feedback c o n t r o l l e r s a d j u s t s pe c i f i e d st ream, Upon compl et i on of da t a i nput , t he main
u n i t oper at i on, pr ocess c ont r ol , o r equipment c a l c u l a t i o n program, CALC, can be run
va r i a bl e s , wi t hi n a def i ned range, t o a desi gnat ed i n t e r a c t i v e l y , per mi t t i ng t he user t o s e l e c t t he
s e t poi nt . The c o n t r o l l e r i t e r a t i v e l y modi f i es t h e accuracy. Thi s f e a t u r e i s us ef ul when s t a r t i n g up
i ndependent var i abl e and f eeds t h e i nf or mat i on t o a new model i n much t he same manner a s wi t h act ual
t h e u n i t oper at i on u n t i l t h e de s i r e d s e t p o i n t i s p l a n t s t a r t u p , t h a t i s, s t a r t i n g up one pl a nt
a t t a i n e d . s e c t i o n o r pi ece of equipment a t a time.
Two h e a t bal ance c ont r ol methods a r e a va i l a bl e Program Out put
t o t h e METSIM user . Stream t emper at ur e c ont r ol s
f i x o u t l e t st ream t emperat ures and may be appl i ed Screen di s pl a y f unct i ons per mi t t he user t o
t o any st ream e x i t i n g a u n i t oper at i on module. examine u n i t oper at i on and st ream da t a duri ng a l l
Heat i nput and h e a t l o s s c ont r ol s s i mul at e var i ous phases of model bui l di ng and t es t i ng. Thi s
t ype s of he a t t r a ns f e r . enabl es t he us er t o r eadi l y d e t e c t i nput and
c o n t r o l e r r o r s and a i d i n model r e f i ne me nt . The
s c r e e n d i s p l a y f unc t i ons a l s o e na bl e t h e u s e r t o
obt a i n, v i a t h e PRINT opt i on, a ha r d copy o f d a t a
i n b r i e f f or mat f o r h i s t o r i c a l , di s c us s i on, or
a n a l y t i c a l purposes.
METSIM o f f e r s a v a r i e t y of o u t p u t f or ma t s ,
i nc l udi ng u s e r cust omi zed r e por t s . The nor mal
METSIM out put c ont a i ns s t r e a m d a t a i n c l u d i n g mass,
vol umet r i c, and ener gy f l owr a t e s , s p e c i f i c
g r a v i t i e s , t emper at ur es , s c r e e n a na l ys e s ,
c onc e nt r a t i ons , and a s s a ys . A h e a t ba l a nc e ar ound
e a c h u n i t ope r a t i on i s o u t p u t a l ong wi t h a summary
of t he h e a t s of r e a c t i on. P a r t i c l e s i z e a n a l y s i s
and wa s ha bi l i t y d a t a c a n be o u t p u t i n e i t h e r
t a b u l a r o r gr a phi c f or mat . The o u t p u t r e p o r t menu
c ont a i ns t h e f ol l owi ng i t e m s :
Spe c i a l Repor t Writer
I nput Data Echo
Equi pnent Si z e s
Heat Bal ance Summary
Desi gn Flow Ra t e s
St r eam Component Assays
St r eam El ement al Assays
St r eam Scr een Ana l ys i s
Scr een Anal ys i s P l o t s
De t a i l e d Was habi l i t y Dat a
3-D Was habi l i t y Dat a P l o t s
Coal m a l i t y Repor t
Hardware Requi rement s
METSIM w i l l run on most comput er s ys t em ha vi ng
t h e APL l anguage and 512- ki l obyt es of memory. I n
a d d i t i o n t o IBM, DEC, and CDC mai nf r ames, METSIM
c a n be r un on I n t e l 8088/80386 machi nes s uc h as
t h e IBM PC/XT/AT and compat i bl es , and Mot or ol a
68000 machi nes such a s t h e Wi cat , At a r i , Amiga,
and Macintosh.
APPLICATIONS
Dur i ng t h e l a s t e l e ve n ye a r s , METSIM and i t s
two pr e de c e s s or programs have been us ed t o model
ove r e i ght y d i f f e r e n t pr oc e s s e s t hr oughout t h e
wor l d. These have been us ed f o r f e a s i b i l i t y
s t u d i e s , d e t a i l e d p l a n t de s i gn, and t r o u b l e
s hoot i ng of ope r a t i ng p l a n t s .
Comminution Appl i c a t i ons
METSIM ha s been us ed on c r us hi ng pr oc e s s e s t o
e v a l u a t e t h e e f f e c t of f e e d r a t e , r ock ha r dne s s ,
f e e d si ze d i s t r i b u t i o n , o p e r a t i n g t i m e , c r u s h e r
t ype , c r us he r s e t t i n g , and s c r e e n t y p e s and s i z e s
on pr oduc t s i z e d i s t r i b u t i o n . One model i s o l a t e d
c r us he r gap s e t t i n g s a s t h e c a us e of ma t e r i a l
ha ndl i ng probl ems i n a r ock qua r r y.
METSIM ha s a l s o been us ed e x t e n s i v e l y on many
t ype of gr i ndi ng c i r c u i t s . b d e l s have been
devel oped f o r semi -aut ogenous, r od, and b a l l m i l l s
a s we l l a s f i n e s c r e e ns , hydr ocycl ones , and s p i r a l
and r a ke c l a s s i f i e r s . One s i mul a t i on model
demos t r at ed t h a t t he hydr ocycl one v o r t e x s i z e s
wer e i n c o r r e c t f o r t h e pr ope r c o n t r o l of a SAG and
b a l l m i l l c i r c u i t . P l a n t o p e r a t o r s had been
t r y i n g t o ga i n c o n t r o l of t h e c i r c u i t by c ha ngi ng
t h e number of o p e r a t i n g cycl ones . Anot her
s i mul a t i on was us e d t o e v a l u a t e t h e p i l o t p l a n t
t est d a t a f o r a new SAG and b a l l m i l l c i r c u i t .
The d a t a appear ed i n c o n s i s t e n t u n t i l t h e
s i mul a t i on model s d e t e c t e d mal f unct i oni ng
c l a s s i f i e r s and worn t est m i l l di s c ha r ge g r a t e s .
I t i s now recommend t h a t a pr oc e s s s i mul a t i on
model be r un c o n c u r r e n t l y wi t h p i l o t p l a n t t est
programs i n o r d e r t o d e t e c t que s t i ona bl e , f a u l t y ,
a nd r edundant d a t a i n t i m e t o modi fy test
pr oc e dur e s t o i mprove t h e r emai ni ng test program.
Base Met al Appl i c a t i ons
METSIM ha s been a p p l i e d s u c c e s s f u l l y on
s e v e r a l a s p e c t s of copper , molybdenum, l e a d, and
z i n c pr oc e s s i ng i n c l u d i n g comminution and
f l o t a t i o n c i r c u i t s , c o n c e n t r a t e r oa s t i ng,
l e a c hi ng, and dr yi ng, and t a i l i n g s di s pos a l . A
t a i l i n g s d i s p o s a l s ys t em model i nvol ve d a c yc l one
s t a t i o n and two p i p e l i n e s f o r s a nds and slimes.
The s i mul a t i on i s o l a t e d s e n s i t i v e a r e a s and
prompt ed changes i n t h e de s i gn phi l osophy. The
s ys t em was b u i l t a nd s t a r t e d up wi t h a minimum of
probl ems.
Pr e c i ous Metal Gol d/ Si l ve r Appl i c a t i ons
Pr e c i ous me t a l p r o c e s s s i mul a t i ons have
i nc l ude d commi nut i on, g r a v i t y c onc e nt r a t i on,
c ya ni da t i on, f l o t a t i o n , car bon- i n- pul p,
car bon- i n- l each, s me l t i ng, and r e f i n i n g c i r c u i t s .
CIP model i ng h a s been us ed t o opt i mi z e the number
of a ds or pt i on s t a g e s , c a r bon i n v e n t o r i e s , and
o v e r a l l s ys t em hydr a ul i c s . One model was us ed t o
e s t a b l i s h t h e mos t economi c s chedul e, f i r i n g r a t e ,
and c ha r gi ng r a t e f o r a gol d p r e c i p i t a t e s me l t i n g
f ur na c e . Anot her p r o c e s s i nc l ude d c r us hi ng,
gr i ndi ng, c l a s s i f i c a t i o n , s a nd and s l i m e l e a c h i n g
c i r c u i t s , c ount e r - c ur r e nt de c a nt a t i on, f i l t r a t i o n ,
and Mer r i l l - Cr owe p r e c i p i t a t i o n . The s i mu l a t i o n
pe r mi t t e d t h e o p t i mi z a t i o n o f t h e CCD c i r c u i t ,
mi ni mi zi ng c ya ni de consumpt i on and maxi mi zi ng g o l d
r ecover y. Wi t h equi pment changes, t h e gol d
pr oduc t i on was i n c r e a s e d 22 pe r c e nt . Anot her
s i mul a t i on i nvol ve d a r od m i l l and t h r e e d i f f e r e n t
s i z e d b a l l m i l l s . The model de mos t r a t e d t h a t t h e
b a l l m i l l f e e d s p l i t was c r i t i c a l and t h e m i l l s
wer e under char ged. P r e c i s e c o n t r o l of t h e s p l i t
and a hi ghe r b a l l c ha r ge i nc r e a s e d t h e t hr oughput
by 16 pe r c e nt . A non- s t e a dy- s t a t e model was
devel oped f o r a p r e c i o u s me t a l v a t l e a c h pr oc e s s .
The optimum o p e r a t i n g s c he dul e was det er mi ned i n
o r d e r t o mi ni mi ze pr e gna nt s o l u t i o n f l ow rates and
maxi mi ze g o l d r e c ove r y. Ca p i t a l cost s a v i n g s we r e
a l s o r e a l i z e d a s a r e s u l t of mi ni mi zi ng s t o c k p i l e
and t ankage vol umes.
Uraniumflanadium Appl i c a t i ons
METSIM c o n t a i n s a l l t h e u n i t o p e r a t i o n s
ne c e s s a r y t o e v a l u a t e ur ani um r e c ove r y f l ows he e t s
i n c l u d i n g commi nut i on, a c i d and c a r bona t e
l e a c hi ng, mu l t i s t a g e c o u n t e r c u r r e n t d e c a n t a t i o n ,
b e l t f i l t e r s , c o u n t e r c u r r e n t i o n exchange, s o l v e n t
e x t r a c t i o n , p r e c i p i t a t i o n , dr yi ng, and c a l c i n i n g .
Sevent een ur ani um p r o c e s s e s have been model l ed.
One model was us e d t o i n v e s t i g a t e p l a n t losses of
s o l u b l i z e d urani um. Al t e r n a t i v e s t u d i e s pr oved
MINERAL RESOURCE MANAGEMENT BY PERSONAL COMPUTER
t hat l osses could be reduced from nine t o four
percent by operat i onal changes and another two
percent by equipment addi t i ons. A f i ve percent
improvement was r eal i zed i n pl ant operations.
Chloride Hydrometallurgy
METSIM has been applied t o t hree molybdeni t e
upqrading pl ant s using chl ori de leaching
technology. I t was used ear l y i n one pr oj ect t o
di r e c t t he l aborat ory t e s t work. A f lowsheet was
est abl i shed and a minimal amount of laboratory
t e s t work was performed as a r es ul t . The process
model hi ghl i ght ed ar eas requi ri ng addi t i onal t e s t
work. These addi t i onal t e s t s were performed and
t he procedure was repeated unt i l t he model was
complete. The l engt h of t he laboratory t e s t
program was reduced by sever al months. The model,
which included a dynamic leaching module, was
i ns t al l ed on s i t e and used by operating personnel
t o determine optimum pl ant parameters.
An alumina ext r act i on process model was
developed f or t he hydrochloric aci d leach of cl ays
with subsequent pur i f i cat i on, cr ys t al l i zat i on, and
thermal decomposition. This model, t he f i r s t
i nt egr at ed mass and energy balance of t he complete
process, demonstrated pot ent i al energy savings
over or i gi nal est i mat es and was instrumental i n
t he decision t o p i l o t t he process. The model was
i ns t al l ed on s i t e t o ai d i n s t ar t up and process
operation.
Pyrometallurgical Applications
METSIM has been used t o simulate
pyrometallurgical processes including drying,
r oast i ng, smelting, and converting. The models
i ncorporat e chemical r eact i ons, impurity
const i t uent s, and thermodynamics t o provide
det ai l ed mass and energy balances. Convective,
conductive, and r adi ant heat l osses associ at ed
with t he process were incorporated i nt o t he model.
One pr oj ect involved modeling t hree al t er nat i ve
copper smelting processes including t he f l as h
smel t er, dead r oas t process, and conventional
reverbatory smelting. Use of standard cal cul at i on
methods f a c i l i t a t e d det ect i on of small but
s i gni f i cant di f f er ences i n energy, fl ux, and
reagent consumption. Another model was used t o
cal cul at e heat balances f or t he design of a
multihearth r oas t er f or varying grades of
molybdenum concentrate. Tray t o t r ay balances
were made t o det ect hot spot s and provide f or t he
necessary cooling sprays.
Coal Preparation
METSIM has been used t o model sever al coal
washing and preparat i on pl ant s. Numerous coal
streams, with di f f er ent washabi l i t i es and
compositions, can be blended and product
quant i t i es and qua l i t i e s predicted. Coal
preparat i on uni t operat i ons include crushers,
breakers, screens, dense media bat hs, dense media
cyclones, j i gs , t abl es, water only cyclones,
f l ot at i on c e l l s , and magnetic separat ors. One
model was developed f or a 2000 metric ton per hour
pl ant i n t he United Kingdom i n order t o eval uat e
two al t er nat i ve dense media ci r cui t control
schemes. One cont rol method was shown t o be
unstable when t r yi ng t o reduce the density of the
heavy media, t he process was st ar t ed up
successful l y with t he st abl e control scheme.
Another model was used t o design a coal
preparation pl ant i n China.
EXAMPLE OUTPUT
In order t o i l l us t r a t e the various types of
output dat a avai l abl e t o t he METSIM user, several
sample r epor t s from di f f er ent types of models ar e
[presented i n t he accompanying t abl es and graphs.
For a comminution type flowsheet l i ke the SAG
m i l l and ba l l m i l l c i r c ui t of Figure 1 , the
par t i cl e s i ze anal ysi s i s t he primary concern. In
addi t i on t o t he s ol i d ( SI ) , l i qui d ( LI ) , and t ot a l
(TC) flowrates and speci f i c gr avi t i es as shown i n
Table 1 , the screen analysis can be obtained as a
pl ot , Figure 2, or as tabulated dat a, Table 2.
The anal ysi s of f l ot at i on ci r cui t s , see Figure
3, ar e usually centered around mineralogy and
elemental assays. Typical output reports selected
f or t hese processes ar e t he component assays f or
s ol i ds , i l l us t r a t e d i n Table 3, percent sol i ds and
s peci f i c gr avi t i es , Table 4, and sol i d phase
elemental assays, Table 5. The performance of
hydrometallurgical flowsheets, an example of which
i s t he gold cyanidation c i r c ui t of Figure 4, i s a
function of sol ut i on flows and concentrations. A
sample of t h i s type of output is the aqueous
assays i n grams per l i t e r , Table 6, the flowrates,
Table 7, and t he s ol i d, aqueous, and t ot al gold
assays as grams per metric ton i n Table 8.
Pyrometallugical processes ar e operated under
temperature cont r ol and therefore the energy
balance i s of prime importance. The f l ash smelter
c i r c ui t , i l l us t at ed i n Figure 5, contains several
high temperature uni t operations. The METSIM
out put f or t hi s type of model contains complete
t abul at i ons of stream temperatures and enthalpy
flows as i n Table 9. Also avai l abl e t o the user
i s a complete heat balance around each uni t
operat i on as i n Table 10. This includes the heat
contained i n feed streams, heat s of reactions and
phases changes, heat t ransfer and l osses, heating
and cooling requirements, heat content of e xi t
streams, and t he over al l heat balance error. The
i ndi vi dual heat s of reaction ar e al s o presented t o
t he user. Det ai l ed elemental assays ar e often
chosen a s output from t hi s type of model, see
Table 11.
Coal preparat i on pl ant simulation requires
considerable i nput dat a i n t he form of washability
dat a, ash and s ul f ur anal ysi s, and heat value
dat a. This dat a i s usually presented i n
t abul at ed form s i mi l ar t o t hat i n Table 12. This
dat a form i s somewhat di f f i c ul t t o vi sual i ze,
especi al l y when sever al t abl e a r e needed t o
r epr esent each coal type. METSIM can present the
dat a i n three- dimensional pl ot s, see Figures 6,
7, 8, and 9, f or eas i er i nt erpret at i on. Figures 6
and 7 show t he weight di st r i but i on of two
di f f er ent coal seams. Stream 1 i s r el at i vel y
cl ean coal with mining di l ut i on. Stream 3 i s a
PROCESS SIMULATION AND OPTIMIZATION USING METSIM
d i r t i e r coal wi t h more mi ddl i ngs. Af t er t he two
a r e blended and run t hrough a dense media pl a nt ,
t h e r ef use would look l i k e t h a t i n Fi gure 8 whi l e
t he cl ean coal would have c h a r a c t e r i s t i c s of t h a t
shown i n Fi gure 9. A summary of c oa l q u a l i t y and
product i on can be r e c a l l e d v i a t he coal q u a l i t y
r e por t a s shown i n Tabl e 13.
CONCLUSION
Over t he pa s t decade, pr ocess si mul at i on has
progressed from r e l a t i v e l y si mpl e mass bal anci ng
programs t o e a s i l y used f u l l s c a l e pr ocess
si mul at i on systems. Numerous s i mul at i on models
have been developed wi t h many p l a n t s and pr ocesses
havi ng benef i t ed through reduced c o s t s and/ or
i ncr eased throughput and recovery. Process
desi gn, anal yi s , and opt i mi zat i on can now be
accomplished i n less t i m e and a t lower c o s t t han
ever before. A s t h i s t r end cont i nues,
computerized process a na l ys i s w i l l become one of
t h e major t ool s t o be used t o o f f s e t decl i ni ng or e
grades and enviromen t a l and economic c ons t r a i nt s
which a r e bei ng pl aced on mining oper at i ons.
REFERENCES
Himmelblau, D. M., 1972, APPLIED NONLINEAR
PROGRAMMING McGraw-Hill, New York, N. Y.
Himmelblau, D. M., 1974, BASIC PRINCIPLES AND
CALCULATIONS I N CHEMICAL ENGINEERING,
Prent i ce-Hal l , Englewood Cl i f f s , N. J.
Holland, C. D., 1975, FUNDAMENTALS AND
MODELLING OF SEPARATION PROCESSES,
Prentice- all, Englewood Cl i f f s , N. J.
Kuest er, J. L. and Mize, J. H., 1973,
OPTIMIZATION TECHNIQUES WITH FORTRAN,
McGraw-Hill, New York, N. Y.
Lynch, A. J., 1977, MINERAL CRUSHING AND
GRINDING CIRCUITS, El s evi er S c i e n t i f i c
Publ i shi ng Company, Amsterdam, The Net herl ands.
Mah, R. S. H. and Sei der , W. D. ( Ed i t o r s ) ,
1981, FOUNDATIONS OF COMPUTER-AIDED CHEMICAL
PROCESS DESIGN, Engi neeri ng Foundat i on, New
York, N. Y.
Myers, A. L. and Sei der , W. D., 1976,
INTRODUCTION TO CHEMICAL ENGINEERING AND
COMPUTER CALCULATIONS, Pr ent i ce- Hal l , m g lewood
Cl i f f s , N. J.
Ramani, R. V. ( Edi t or ) , 1977, 14TH INTERNATIONAL
APCOM SYMPOSIUM, Soci et y of Mining Engi neers,
New York, N. Y.
Ramirez, W. F., 1976, PROCESS SIMULATION, D.
C. Heath and Company, Lexi ngt on, Mass.
Seader, J. D., Sei der , W. D., and Paul s, A.
C., 1977, FLOWTRAN SIMULATION - AN
INTRODUCTION, Cache, Cambridge, Mass.
112
MINERAL RESOURCE MANAGEMENT BY PERSONAL COMPUTER
COMMINUTION CIRCUIT I
1
FIGURE 1 . COMMINUTION FLOWSHEET
TABLE 1 . FlOWRATES AND S P ECI F I C GRAVI TI ES
DEBIGN FLOl RL)lES
NO. STREP1 TIRE 871H-51 STI H-LI STIH-TC GPll R1lHR
.....-~~~~~~~~~.*.....--+-~~~~~~..-..--.*.--.---.-......*...-.-.
I RUM OF 111NE 100.000 bb8. 11 21. 86 696. 60 l I I P. 2 5 251. 21
2 B RI I I L I UNDR 100. 000 191. 51 I b. 12 101.90 b55. 19 118.8b
1 8 Rl l 1 L Y OVER 100. 000 211.15 11.55 188. 10 1bl . 85 105.15
4 CRUSHER PROD 100. 000 211.15 11.55 188. 10 1b1.85 105. 15
5 STOCKPILE 100.000 bb8. 11 21.Bb b1b. 60 1111.25 251. 11
b SP6 11LL FEED 100. 000 bb8. 11 11. 8b b1b. 60 1119. 15 151. 11
7 UP6 UPTER 100. 000 . 00 101. 12 101. 12 1205.11 111.11
10 UP1 DSCHR6 L00. 000 819.21 111. 61 l l 98. 11 1101.55 b l l . 5 1
II SCREEN OBl l E IOO.VO0 110. 50 10. 01 200.59 111.Il 15. bb
I 2 SPB RECYCLE 100.000 170.50 10. 01 200. 59 111. 11 15.bb
11 SCREEN UBI I F 100. 000 bb9. 71 329. 59 999.12 2121.18 521.92
L5 SUMP NPTER 100. 000 . 00 119. 15 119. 15 1151.61 101. 61
I b SP6 CYC FEED 100.000 bb8. 11 bbB.11 l111.11 1 b l 1 . 0 1 815.bO
I 7 SPb CIC OVER 100. 000 111.00 111.2b 581. 1b 1111.90 151.09
18 1P8 CIC UNDR 100. 000 515. 11 1l 9. 18 155. 21 I b81. 11 181. 5l
20 BllL DISCHPGE 100. 000 1577.18 11b.10 2121. 11 5158. 51 1211.0b
21 8111 BUHP Ul R 100. 000 . 00 811.18 811.18 1119. 92 151. 01
22 1111 CVC FEED 100. 000 1511.48 1511.18 1151.9b Bbl 8. 1b 1111.09
2 1 B11L CIC UNDR 100. 000 1011. 11 52b. 82 I l b 8 . 5 b 1b71. 10 811. 55
24 BllL CIC OVER 100. 000 515. 11 l 050. bb I 58b. 10 5001. 0b l I 1b. 55
SPECIFIC 8RPIVITlES
NO. STREP* PC5 88- Sl SO-LI 56-TC
...+..-..-..-.-.........,--.....+-..~-...--.....
I RUN OF MINE 9b. 0000 1. b5000 l . 00000 2. 18511
2 0R1111V UNDR 9b. 0000 1.b5OOO I . 00000 2. 18511
1 8R1111V OVER 9b. 0000 2.65000 l . 00000 1. 18511
1 CRUSHER PROD Pb.0000 1. b5000 1. 00000 2. 18591
5 STOCKPILE Pb.0000 2. 65000 1. 00000 1. 18511
b SPB 1111 FEED 9b.0000 2.b5VOO 1.00000 1. 18511
1 818 NITER ,0000 ,00000 1. 00000 1. 00000
LO SP8 DUCHRS 70.0000 2. b5000 1. 00000 L.11158
11 SCREEN 0S11E 85. 0000 2.b5000 1. 00000 2. 11115
I 2 BPI8 RECVCLE 85. 0000 1. b5000 1. 00000 1. 12125
I1 SCREEN US11E bb. 98bI 2. b5000 1. 00000 1. 11551
I 5 1U11P UPITER , 0000 . 00000 1. 00000 1. 00000
I b UP18 CVC FEED 50. 0000 1. b5000 1. 00000 1.15205
I 7 BPI8 CVC OVER 22. 8115 1. b5000 1. 00000 1. 1b581
18 UP18 CIC UMDR 10. 9181 1. b5000 1. 00000 1. 19111
20 8111 DIICHRBE b7. 8811 2.65000 1. 00000 1. 11211
21 1111 BURP NTR . oooo .ooooo 1. 00ooo I . UOOOO
22 EM1 CIC FEED 50. 0000 1. b5000 1. 00000 1. 15105
21 Ell1 CIC UNDR bb. 1111 2. b5000 1. 00000 1. 70509
21 811L CIC OVER 11. 7101 2.b5OOO 1. 00000 1. 2bbl b
SAG n i L L - WLL MILL C! RCLI I T
4/5/1086 - 7840
SCREW M L Y S L S - PERCENT PLlSSlNG
SCREENI OCI '0 no 70 60 50 40 30 20 10 On l CRO*
16. 800 I N 426720
1 1 , 879 I N 30 1737
8. 400 I N 213360
5.9.10 I N 150818
4. 200 I N 1116680
2. 9' 0 I N 75434
2 . 1 0 ~ I N 53340
1. 485 I N 37717
I .US0 I N 26070
:42 I N I 8859
, 525 I N 13335
, 371 I N 9429
3 T I 6130
4 TI 4760
6 T 1 3360
8 T I 2380
I 0 T I I 6 8 0
14 T I 1190
20 T I 84 1
28 T I 595
35 T I 420
48 T I 297
6 5 T I 210
IUO T I 149
150 T I I 0 5
200 T I 14
270 1 Y 53
400 TI 37
600 T I 2 6
800 T I I 9
SCREWI OO 90 no 70 60 JO 40 30 20 10 O U I C R ~
PERCENT PASSING
FIGURE 2. SCREEN ANALYSIS PLOT
TABLE 2. SCREEN ANAt YSI S DATA
SCREEN SIZE PNPILVSIS
1TREhM NO. 18 61REPIN NO. 10 STREPI11 NO. 12
SPI1 CVC UNDR UML DISCHRBE 811L CIC FEED
PBO. (110 P10. (15 PSO. b15
...--.-------.- ------------------.. ....---..----...---- ..-..---....--------
SCREEIIBIIICRDU 1111 PCR PCP e l l ~ PCR r c e STIH PC* PCP
, _ _ _ _ _ _ _ _ . . _ _ _ _ _ +_ _ ~~~~. ~. ~- ~~, ~~~. ~. . ~~~~. ~, . ~~. . ~. . ~~~~~. . . . ~. ~. ~. . ~~~* - - - - - -
,515 I N 11115 21. 111 3.9800 1b.01 .OO , 000 100.00 .OO ,000 100.00
, 171 I N 9129 l b. 171 b. 7521 89.21 1.51 ,097 99. 10 1. 51 .O97 99.10
1 1 1 (710 11.Yb1 7. 1191 81.11 5.b1 .15b 99. 55 5.61 .15b 99.55
1 1" 1 l b 0 11. 772 7.9131 71.11 12.48 , 791 98.7b 11.18 , 791 98.7b
b T I 11bO 1b. 195 8.b710 b1. 11 21.94 1.191 97. 36 21.94 1, 111 11.1b
8 1" 1180 18. 801 7.1411 51.17 11. 11 2.040 95.11 12. 11 2. 040 15.12
LO T I IbUO l b. 111 b.7515 50.72 11. 21 2.801 92.52 11. 21 1. 801 92.52
11 1V 1190 11.9bb b. 52b1 44.19 5b.11 1.59b 88. 91 5b. 11 1. 59b 88. 11
20 TY 111 11.140 b. 11b0 18.01 70.12 1.19b 11.11 10.12 1.116 81.11
18 1" 515 11, 019 b. l b11 11.84 8b.11 5.161 78.97 8b. 11 5. 1bl 78.97
15 1" 120 10. 745 5.1118 1b.10 102.71 b. 511 71.4b 101.74 b. 511 71. U
18 IY 297 18.295 5.181b 10.81 118.b2 7.511 b1.11 118.62 7.519 b1. 11
b5 T I 210 21.bY2 4.5959 I b. 11 121.75 1 . l b l 5b.77 111.75 1 . l b l 5b.71
100 1" l 1 9 18.1b4 1. 5211 11.71 l l l . 1 2 7.112 41.05 111.12 7. 121 11.05
150 T I 105 11.b24 1. 5411 I O. l b 111.80 1.017 1 l . 9 b 111.80 7.087 1l . 1b
100 1" 71 0 5 1 2 8.21 100.51 b. 172 15.59 100.51 b.112 15.51
270 1" 5 1 l 2. 37b 1.1101 5.90 81.40 5.b04 29.99 88.10 5.b01 29.91
100 71 17 11.111 1.7517 1.15 Bb. 51 5. 185 21.50 1b. 51 5. 185 21.50
bOO T I 26 5.612 1.0175 2.10 69.01 1.176 20.11 h9. 03 1. 17b 20.11
100 1" I I 2 5 9 1 0 I b .OO 117.50 20.127 .OO 111. 50 20. 121 .OO
SlREPII NO. 11 SIREPI11 NO. 21
B11L CIC UNDR BllL CVC OVER
PBO. 1009 Y80. 107
------.-------- ..------------..-..- -.-..---.-.--.------
SCREENS MICRON Sl / H PCR PCP S11H PCR PCP
...---___.______.__~~~-,-~...-.---.--,-.----.-----..------
, 171 I N 9129 1. 51 , 117 99.85 .OO .OOO 100.00
1 1 1 b710 S.b2 .540 99.11 .OO . 000100. 00
1 l V 17bO 12. 41 1.198 9 8 . l l .OO , 000 l 00. 00
b I V 11bO 21.91 2. 10b 9b.01 .OO , 000 100.00
8 11 1180 11.19 1. 090 92.92 .OO , 000 100.00
LO T I 1bOO 11. 21 4.244 81.b8 .OO ,000 100.00
I1 l V 1190 5b. 71 5.41b 81.11 .OO ,000 100.00
10 T I 111 70. 91 b.808 1b. 41 .OO , 000 100.00
18 1V 595 8b.11 8.2b9 b8.15 . 00 , 000 100.00
15 11 120 l 01. 70 9. 859 58.19 . 01 , 001 99.99
18 1V 197 117.11 11. 1b1 11.01 1.29 .240 99.75
b5 T I 110 115. 85 11.111 15.91 12.91 2.401 97. 11
100 11 I 1 9 82.19 7.909 18.00 19. 11 7.359 89. 98
150 11 105 51.00 5.Yb1 21.71 57. 00 10.b19 79.15
100 11 71 10. 81 1.917 18.12 59. 72 11.14b b8.10
270 11 51 11. 17 1. 155 15.b7 55. 51 10.1b5 57.81
100 11 17 10. 71 2. 918 12.71 55.82 10.420 41.41
bOO T I l b 11. 91 2. 291 10.41 15.10 8.118 19. 00
800 I V I1 lOB.51 l O. 111 .OO 108.91 18. 995 .OO
PROCESS SIMULATION AND OPTIMIZATION USING METSlM 113
FIGURE 3. FLOTATION FLOWSHEET
TABLE 3. COMPONENT ASSAYS
METSIII FLOTATION EIAMPLE
LEPO ZINC FLOTPTIDN CIRCUIT
4/ 5/ l V84 - 9827
STRERM OATA
SOLID - NEISHT PERCENT
NO. PlREeM IIISC POS INS 1525
................................................
I FLOT FEED 02. 1959 4. 8501 12.9205 , 02117
5 PO RbHR FD 02. 1111 4. 8501 12. 9281 , 01767
4 PB 6CVNS FO 85. 9401 1. 9570 11.0889 , 01352
4 P I RSHR CY 4. 7090 58. 0000 57. 0000 , 29099
7 1 P I CLNR TL 18.0458 27.0459 54. 7594 , 15011
9 1 P I CLNR CN I . 4057 42. 0000 14.0000 , 51427
10 2 P1 CLNR TL 8. 1957 52. 0125 10. 5200 , 11404
I 2 LEPD CDNC .O511 48. 0000 10.0000 .54494
I 4 PO OCVNS CY 41. 6144 54. 0000 20.0000 , 18544
15 CICL FEED 45. 8114 54. 0000 20. 0000 , 18544
I 1 CICL OFLDI 45. 8144 54. 0000 20. 0000 , 10344
17 CICL UFLDN 45. 0144 54. 0000 20.0000 , 18144
I 0 P I RENO DSCH 41. 0111 14. 0000 20.0000 . I 0544
I 9 PO fiCVY8 TL 81. 1294 1. 0075 11.8144 , 00810
21 I N ROHR RO 87. 1294 1. 0075 11.0144 , 00046
22 I N RBHR 1L 95.1127 ,7407 4. 0547 , 00595
24 ZN R6HR CN 15. 9709 50. 0000 54.0000 .O2904
25 I N SCVN8 TL 91. 0545 . l 499 2 . l Vl 9 . 00515
21 I N SCVYI CH 71. 9927 1.0000 27. 0000 , 00719
28 CICL FEED 52. 2171 21. 1900 41. 1700 , 02215
29 CICL UFLDN 52. 2171 21. 5900 44. 1700 . 02215
10 I N REYO DSCY 52. 2175 21.5900 44. 1100 , 02175
51 CICL OFLDl 52. 2175 21. 1900 41.1700 . 02215
52 1 I N CLNR TL 45. 0110 44. 7789 11.4075 , 00104
54 1 1 1 CLYR CY 54. 9715 5. 0000 40.0000 . 02552
55 2 I N CLNR TL 72. 0992 5. 5141 21. 2847 , 00000
17 ZINC CONC 22. 7112 2. 4700 74. 5110 .03980
TABLE 4. PERCENT SOLIDS AND SPECIFIC GRAVITIES
METSIII FLOTPTION EIPIIPLE
LEPD ZINC FLOTATION Cl RCUl l
4t at l 9ob - 9 ~ 2 6
SPECIFIC SRPVl l l ES
YO. STRE&M PC8 58-51 SO-L1 00-1C
.--.---......---.--.----.-.---...-----.-,-----..
I FLOT FEED 50. 0000 2. 82152 1. 00000 1.24011
2 REPBENT8 , 0000 , 00000 1. 00000 1.00000
5 PO R8YR FD 29. 9140 2. 02152 1. 00000 1.21908
4 P I SCVNS FO 29.0014 2. 75141 1. 00000 1.22154
5 LNDR IPTER , 0000 , 00000 1. 00000 L.OOOOO
4 P8 R0HR CN 50. 1811 5. 17102 I . 00000 1 . 1 2 WI
7 I PO CLNR TL l l . l 1 1 2 4. 10001 1. 00000 1. 15001
8 LNDR YPTER . 0000 , 00000 1. 00000 1. 00000
9 I PO CLNR CN 11. 2410 5. 41744 1. 00000 1.34195
I 0 2 PO CLNR TL l l . 1914 4.55210 1. 00000 1.20042
I 1 LNDR IPTER , 0000 . 00000 1. 00000 1.00000
12 LEAD CONC 11. 1121 1. 94192 1. 00000 1. 11111
I1 LNDR YPTER , 0000 , 00000 1. 00000 1. 00000
I 4 PO OCVNS CN 21. 7210 1. 19111 1. 00000 1.20929
I1 CICL PESO 15. 4408 1. 49111 1. 00000 1.14014
I 4 CICL OFLON 21. 7240 5. 49113 1. 00000 1.20929
I 1 CICL UFLOl 10. 0000 1. 49511 1. 00000 2.04329
I 0 PO RONO OSCY 10. 0000 1. 49171 1. 00000 2. 04129
I 9 PO OCVN8 I L 29. 2250 2.71404 1. 00000 1.12110
20 REPIEN18 , 0000 . 00000 1. 00000 1.00000
21 1N RSYR RO 29. 1599 2.71404 1.00000 1. 22101
22 1N RSHR TL 27. 0121 2. 41214 1. 00000 1. 21011
21 LNOR IATER . 0000 . 00000 1. 00000 1. 00000
24 1N )BUR CN 5 l . 1 2 0 1 4. 20061 1. 00000 1. 12143
25 I N BCVNS TL 21. 1112 2. 41409 1. 00000 1.20112
24 LNDR NPTER , 0000 , 00000 1. 00000 1. 00000
27 I N SCVNO CN 20. 4512 2. 90420 1. 00000 1.22949
20 CICL FEEO 42. 4009 1. 14115 1.00000 1.41419
29 CICL UFLOI 10. 0000 1. 14015 1. 00000 2. 01011
50 I N RONO OSCH 70. 0000 1. 74071 1. 00000 2. 01011
11 CICL OFLOl 50. 4997 3. 74015 1. 00000 1.29122
52 I I N CLNR TL 21. 7100 1. 90140 1. 00000 1. 21174
55 LNOR IPTER , 0000 , 00000 1. 00000 1. 00000
14 I I N CLNR CN 27. 7102 3. 41109 1. 00000 1.24404
55 2 I N CLNR I L 20. 1352 2. 92172 1. 00000 1.11792
31 LIIDR YPTER , 0000 , 00000 1. 00000 1. 00000
17 ZINC CONC 50. 1R01 1. 66199 l.OOOOO 1.20111
TABLE 5. ELEMENTAL ASSAYS
IIETSIM FLOl Al l Ol EXAMPLE
LEPU ZINC FLOTPTION Cl RCUl l
4I 5/ 1904 - 9x20
ELEMENTPL PSSPIS
SOLID PHASE
YO. STREPM 5 I N
...*------.........--.--.--~----.
1 FLOT FEED 4. 9074 0. 4742
5 PO R8HR FD 4. 9014 0. 4142
4 PO OCVN8 FO 4. 2419 0. 1110
4 PO R6YR CN 19. 9055 24. 021l
7 I PO CLNR I L 21.4424 14. 7409
9 I P I CLNR CN 20. 1915 24. 1142
10 2 PL CLNR 1L 25. 4101 19. 1290
I 2 LEPD CONC 19. 4000 20. 4452
I 4 PL SCVNB CN 11.1413 11.4190
I 5 CICL FEEO 11. 14I 1 11. 4190
I1 CICL OFLOU 11. 14l 1 11. 4190
17 CICL UFLOI 11. 1411 15. 4190
15 PU RENO DSCH 11. 1411 11, 4190
I 9 PO SCVN6 TL 4. 0340 7. 9111
21 I N R8YR no 4. 0548 7. 9511
22 1N RBYR TL 1.4177 2. 7205 , 00142 , 4457
28 I N RHHR CN 21. 7910 14. 2113 , 02310 23. 9113
25 I N SCVNS TL , 0222 1. 4701 . 00110 , 4494
17 I N SCVNO CN 9. 0191 10. 1114 . 00411 .Ebb0
28 CICL FEED l O. 0004 10. 9117 . 01900 10.1944
29 ClCL UFLUl 10. 0004 10. 9111 . 01900 10.4944
50 I N RENO OSCH l O. 0004 10. 9771 . 01900 10. 4944
51 CICL OFLON 18.0004 10. 9777 . 01910 l B. 4944
52 I I N CLNR TL 9. 7510 1. 4530 . 00140 10. 1110
14 I I N CLNR CII 10. 1400 40. 2570 , 02401 2. 1900
55 2 I N CLNR rL 0. 1717 11. 4242 , 00000 1. 1010
57 Z I NC LONC ~ 4 . 8 0 s ~ rs. vsso . oar as Z. I I VI
MINERAL RESOURCE MANAGEMENT BY PERSONAL COMPUTER
TABLE 7 . STREAM FLOWRATES
OESi [i U FLOU RRTLL
NO STREAh TTME ST/ H-S 5T H-R CT. H- T ; Pi <
. _* _ _ +. . - - - * -.... *
GOLD CYANIDATION CIRCUIT
1 GOLI l ORE
2 CRUSH PROL,
3 SCRN OSI Z E
4 SEC CRS PROD
5 SCRN MI I I S
6 SCRN U S I Z E
7 CLASS OSI Z E
8 CL6SS U S I Z E
9 CYCL UFLU
10 CYCL OFLU
11 THI CK OFLU
12 THICK u r L u
13 CYANI I I E L I ME
14 SLM LEI I CH 185
15 SLM 1 CCD OF
16 SLM 1 CCI l 11F
17 SLM 2 CCD OF
18 SLM 2 CCD UF
19 BARREN unsn
20 UASH UhTER
21 SLM 3 CCU UF
33 SL I ME TAI l . 5
23 M I L L SOLN
24 B MI L L OSCH
25 CLASS OSI Z E
26 CLASS U S I L E
27 2 * MI L L DSCH
28 CYCL SOLN
29 CYCL UFLU
30 CYCL OFLU
31 SANI I THK OF
32 SANI I rl l K UF
33 CYANI DE L I M E
34 SNI I LEACH INS
35 SNU 1 CCD OF
36 l.OAIlEI8 SOLN
37 SND 1 CCU UF
38 SND 3 CCO OF
39 SND 2 CCD UF
40 St411 3 CCI l OF
41 BARREN UASH
42 SND 3 CCD UF
43 BARREN UASH
44 F I L T R A T E
45 SAND T I I I L S
96 Z I NC OUST
47 AU PRECI P
48 WARREN F I L l
49 NEU UATER
50 RU CIII(I-
FIGURE 4. GOLD CYANIDATION FLOWSHEET
TABLE 8. ASSAYS I N GRAMS PER METRIC TON
TABLE 6. ASSAYS I N GRAMS PER LI TER
GRAMS OF GOLn PER METRI C r ON
AQUEOUS - GRAMS PER L I T E R
NO. STREAM UATER L I M E NACN AUCN 2NCN
NO. STREAM G/MT-S LG. MT-A G/ MT-T
* * ...__.. + .._---. + - - -
1 GOLI l ORE 3.831 .OOOOO 3.371
2 CRUSH PRO18 3 831 ,00000 3.371
3 SCRN OSI Z E 3.831 44470 3 289
4 SEC CRS PRO18 3.031 ,44470 3.289
5 SCRN MI I l S 3.831 .44470 3.100
b SCRN U S I Z E 3.831 ,49470 1.331
7 CLASS OS I Z E 3.831 ,44970 3.333
8 CLASS U S I Z E 3.031 44470 1.410
9 CYCL UFLU 3.831 94470 2.815
10 CYCL OFLU 3 831 44470 1.051
11 THI CK OFLU ,000 ,89572 ,896
12 THI CK UFLU 1.762 ,89572 1.199
13 CYANI DE L I M E 000 00000 . 0 0 0
14 s L n LEACH rls ,811 1.32ii~ 1.154
15 SLM 1 CCO OF ,000 ,53261 ,533
16 SLM 1 CC[I UF ,811 ,57237 ,656
17 SLM 2 CC[# OF ,000 ,21845 ,218
18 SLM 2 CC[I U F 811 23261 ,435
19 BARREN UASH 000 05159 ,052
20 UASH UATER ,000 ,00000 ,000
21 s L n 3 CCD UF ,000 ,08561 084
22 S L I ME T A I L S ,811 09002 ,342
23 M I L L SOLN ,000 1.08113 1.081
24 B MI L L DSCH 2,719 2.33075 3.602
25 CLASS OSI Z E 3.719 2.33075 2 541
26 CLASS U S I Z E 2.719 3.33075 2 590
37 2 B MI L L I I SCH 1.787 3. 78397 2.190
28 CYCL SOLN ,000 1.08113 1.081
29 CYCL UF L U 1 787 2 11112 1 .8E1+
30 CYCL OFLU 1 787 2.11 112 1 998
31 SANn THY OF 000 2,11112 2.111
32 SAND THK UF 1.787 2.11113 1.998
33 CYANI UE L I M E ,000 .00000 ,000
34 SNI l LEACH US 381 2.02544 1.978
35 SND 1 CCD OF 000 1.08113 1.ll81
36 LOADEI I SOLN 000 1.08113 1.081
37 SND 1 CCII \IF 381 1.16835 .i90
38 SND 3 CCI l OF ,000 .33149 ,331
39 SNP 3 cca UF ,381 36497 773
40 SNO 3 CCI l OF 000 . 12739 ,127
41 BARREN UASH 000 ,05159 ,052
41 SN[I 3 CCI l UF ,381 . 13437 ,253
43 BARREN UASH 000 ,05159 ,053
44 F I L T R A T E ,000 ,10283 103
45 SANI I T A I L S ,381 ,10283 311
46 Z I NC DUST 000 .00000 000
47 AU PRECI P 99.999 ,05297 1 059
48 BARREN F I L T 000 05297 053
49 NEU UATER ,000 .00000 000
50 AU CAKE 99.R99 ,0528: 99.99'
1 GOLI I ORE 1000.00 ,0000 ,0000 00000 ,000011
2 CRUSH PROD 1900.00 ,0000 ,0000 ,00000 00000
3 SCYN OS I Z E 999.38 23.7200 1 8718 00063 ,00111
9 SEC CRS PROO 999.38 33.7280 1.8718 ,00063 00111
5 SCRN MI I eS 999.38 23.7280 1.0718 ,00063 ,00111
6 SCRN U S I Z E 999.38 23.7380 1.8718 ,00063 00111
7 CLASS OSI Z E 999.38 23.7004 1.8693 00063 00110
8 CLASS U S I Z E 999.38 23.7004 1.8693 ,00063 .0011U
9 CYCL UFLU 999.38 23.7009 1.0693 00063 00110
10 CYCL OFLU 999.38 23.7004 1.8693 ,00063 00110
11 T HI CK OFLU 999.38 23.7004 1 . 8 ~ 9 1 .0012i 00110
12 THI CK UFLU 999.38 23.7009 1.0691 00127 00110
13 CY6 NI DE L I M E 997.09 52.9067 3,9680 00000 00000
19 SLM LE6CH DS 999.29 25.3239 1.9855 .00188 00104
15 SLM 1 CCD OF 999.09 28.89118 1.27& ,00076 O.OlZ8
16 SL H 1 CCI I UF 999.10 28.6720 2.2639 .00081 ,00137
17 SLM 3 CCD OF 999.00 30.2481 2.3949 00031 ,00153
18 SLM 2 CCD UF 999.00 30.1850 2.3897 ,00033 .00151
19 BARREN UASH 999.69 16.5591 1.4756 00007 ,00381
20 U6 SH U6TER 997.13 53.9807 3.9360 00000 00000
21 SL H 3 CCO UF 998.96 30.8U09 2.9W"Z.110012 .00158
22 S L I ME T A I L S 998.96 30.8212 3.9426 ,00013 ,00157
23 H I L L SOLN 999.70 16.1349 1.9696 ,00153 .OD249
24 R M I L L DSCH 999.65 17.4069 1.5114 .00338 .00301
25 CLASS OS I Z E 999.65 17.4069 1.5114 ,00318 ,00301
26 CLASS U S I Z E 999.65 17.4069 1.5114 ,00338 .00?01
27 2 B M I L L DSCH 999.69 16.4903 1.9510 ,00391 00206
28 CYCL SOLN 999.70 16,1349 1.9696 ,00152 .00249
29 CYCL UF L U 999.70 16,1333 1.4391 ,00297 00219
30 CYCL OFLU 999.70 16.1333 1.4391 ,00297 .00219
31 SAND TI I K OF 999.70 16.1333 1.9391 00297 00219
32 SAND THY UF 999.70 16.1333 1.9391 ,00297 .00219
33 CYANI DE L I M E 996.40 53.0000 10,6000 ,00000 ,00000
34 SND LEACH 185 999.68 16.6651 1.5708 ,00397 00216
35 SNI l 1 CCO OF 999.70 16.1349 1.4696 ,00153 00249
36 LOADED SOLN 999.70 16.1344 1.4696 00153 ,00249
37 SND 1 CCD UF 999.70 16.1609 1 9747 .nola4 ,0024-i
38 SND 3 CCI I OF 999.71 15.9065 1.9262 00047 00263
39 SND 2 CCD UF 999.71 15.9166 1.4281 .00051 .00302
90 SND 3 CCD OF 999.71 15.8994 1 9144 00018 ,00267
41 BARREN UASH 999.69 16.5591 1.14756 ,110007 00281
42 SND 3 CCD UF 999.71 15.8966 1.4148 ,00019 .00267
93 BARREN UASH 999.69 16.5591 1.9756 ,00007 ,00181
44 F I L T R A T E 999.71 15.9256 1.4208 .0001U .00269
95 SAND T A I L S 999.71 15.9256 1 93011 ,00011, .00269
97 6 U PRECI P 999.67 17.0127 1.5160 00007 00289
98 BARREN F I L T 999.67 17.11127 1.Z160 ,00007 002119
99 NEU UATER 1000.00 ,0000 0000 ,00000 .00000
50 6 U CAKE 999.67 17 0127 1 5160 ,00007 00289
PROCESS SIMULATION AND OPTIMIZATION USING METSIM
TABLE 10. HEAT BALANCE WITH HEATS OF REACTION
HEPI UPLPNCE SUMMPRI - 1000 BTU/HOUR
FLASH SMELTER CIRCUIT
wh a n mrr .
INPUT HEPI HEPT ENERGY HER1 HEPI OUTPUl
OP PROCESS STEP STREPM REPCT SOLUl INPUT LOSS REORD STREAM TOl l i L
........._______...+......*~.~..~+~.~.......~..+.......------*------.------
I DRYER BURNER 7 2 8 1 7 6 2 1 0 0 - 1101 0 - 1 1 2 5 0 (8
2 CONCENTR4TE DRI R 17005 0 0 0 - 5 1 0 0 - 1 6 1 9 5 0
J Pl RPREHE4 TER 1 5 0 619 0 0 - I 6 0 - 1 7 4 U
I FL PSHFURNPCE 5 1 1 7 I 1 1 V 1 1 0 O - I 3 9 3 6 0.125126 0
5 FURNPCE SETTLER 125126 1 5 0 0 - 10018 0- 115113 0
6 MPSTE HEPT BOI LR 5 1 8 1 1 1 0 1 0 0 0 - 15790 - 16125 0
7 STE4M 7926 0 0 1 4 3 5 9 v 0 - 1 2 2 8 5 i l
0 ESP NO. 1 16285 0 U 0 - l i O i 0 - 1 1 9 8 2 0
V EL ECl Rl C FURNPCE 5 1 6 1 1 0 0 0 - 1157 10V0 - 5 3 5 1 5 <'
10 CONVERTER SLPG 2 3 h 2 1 1 2 2 0 1 0 0 - 1950 I l - 6 l S l b 0
II CONVERTER BLOU 12887 28U50 0 (1 - 2 4 5 6 (8 - 1 8 1 8 1 O
1 2 OFFGPS COOLER 6 7 7 0 1 0 0 0 0 - 3S116 - 1 9 2 9 1 0
I1 ESP NO. 2 2V2V1 0 0 ( 8 - 2 3 1 1 0 - 2 b V 1 0 1' - -
I 1 DUSI RECYCLE 6 0 0 0 t , 0 - 1 3 6 "
H t n l OF REPCTION - 10(10 BTU!HR
110 PROCESS STEP BTU,") .-.--.-----......... RE~CTIO".... - ~ - - - - - - - - ~ - - - -
- ~
I DRIER BURNER I OI B V . l FUEL 1 0 2 CO + H20101
2 DRIER BURNER 7 1 1 1 . 2 CO 6 0 2 C02
1 h I R PREHEhTEP I b P . 7 FUEL + 0 2 CO r HI OI GI - - . .. .
1 PI R PREHE4TER 269. 7 CO + 0 2 CO2
5 FLPSH FURNPCE - 751. 7 CUFES2 FES2 r CU2S + FES
b FL4SH FURN4CE 35931. 8 FEE2 + 0 2 5 0 2 + FES
7 FLPSH FURNPCE 5 6 . 1 P6S * 0 2 PBO 1 SO2
8 FLPSH FURNPCE h 3 5 . 1 I NS ' 0 2 I N 0 5 0 2
9 FL4SH FURN4CE 205. 0 RE251 1 0 2 RE201 + 5 0 2
1 0 FL4SH FURNhCE . o CU2O * FEE CU2S + FEO
II FLPSH FURNPCE
1 2 FL4SH FURN4CE
I1 FLPSH FURNPCE
I 1 FLPSH FURNPCE
I 5 FLLSH FURYPCE
I 6 FL4SH FUFN4CE
I 7 FLPSH FURNPCE
I 8 FL4SH FURN4CE
I V FURNPCE SETTLER
20 FURYPCE SETTLER
21 YPSTE HEPl BOI LR
22 H4 Sl E HE41 BOl LR
2 1 M451E HER1 6Ol LR
FEO +
PUSI Oj
2112510
FEO 1 5 1 0 2
FEO 0 2
FUEL 1 0 2
CO . 0 2
FES t 0 2
P8 5 1 0 1 PBO
1N:sIo I N0
FEO *
5 1 0 2
5 1 0 2
5 1 0 2
5 1 0 2
E l 0 2
5 1 0 2
c n s l o :
P L ~ S I O
21 Y4STE HER1 BOl LR
25 MPSI E HE41 801LR
26 YPSTE HE41 8Ol LR
27 N4STE HER1 BOl LR
2B COMYERTER SLl i G
2 v CONVERTER s L n b
FE2510 FEO
CPO * 5 1 0 1
PL203 * 5 1 0 2
FEE 1 0 2
FEO I E l 0 2
CU2S 0 2
FEO 1 0 2
CU2S I 0;
FEO +
FE2SI O
CU .
FE304
CU .
1 5 CONVERIER BLOW
FIGURE 5. FLASH SMELTER FLOWSHEET
TABLE 9. STREAM TEMPERATURES AND ENTHALPY FLOWS
STREPM TEMPERPTURES 4ND ENI HPLPI ES
NO. STREPM IEMP-C TEMP-F KC4LI HR BTU!HR
TABLE 1 1 . ELEMENTAL ASSAYS
ELEMENTPL n s s n v s
G4SEOUS PHPSE
YO. SI REPI 5 FE CU 111 PS
- - - *.--- ..______*_..~.~.*---......---...+...~~~~+---....+
1 2 SHLFT 1 7 . 7 9 5 2 . 00000 .OOOOO , 0 0 3 1 1 , 0 0 0 1 3
15 FURN4CE OFF8 37. 7757 , 0 0 0 0 0 , 00000 . 00111 , 0 0 0 7 1
1 9 BOI LER OFF86 17. 8502 . 0 0 0 0 0 . 0 0 0 0 0 . 0 0 0 0 J . 0 0 0 0 1
21 EBP OFFBPS 1 7 . 8 5 0 2 , 0 0 0 0 0 , 0 0 0 0 0 . 0 0 0 0 1 . 0 0 0 0 1
26 CONVERT OFF6 7 . 2 0 3 2 , 0 0 0 0 0 , 0 0 0 0 0 , 00000 . 00000
3 1 CONVERT OFF8 10. 2062 , 0 0 0 0 0 , 0 0 0 0 0 , 0 0 0 0 0 , 0 0 0 0 0
1 5 COOLER OFF65 8 . 2 8 1 2 , 0 0 0 0 0 , 0 0 0 0 0 , 0 0 0 0 0 , 0 0 0 0 0
3 6 ESP OFFOP8 8 . 2 8 1 2 , 0 0 0 0 0 . 0 0 0 0 0 , 00000 , 0 0 0 0 0
TOTPL STRE4M LESS MPTER
NO. STREPM 5 FE CU 111 n s
- - - *------
I COYCENTR4TE 12. 4000 28. 6110 1 0 . 1 0 0 0 . I 7 0 0 0 , 0 1 0 0 0
2 FLU1 1 . 5 7 0 0 5 . 0 1 2 4 . I 0 0 0 , 0 0 0 0 0 . 0 0 0 0 0
6 DRIER OFFSPS , 0 0 9 1 , 0 0 8 1 .OOBb , 00005 , 0 0 0 0 1
7 DRY CONC 28. 9221 25. 9777 2 6 . 7 I 5 7 , 1 5 0 8 2 . 0154V
12 SH4FT 22. 1575 2 0 . 0 5 7 7 2 1 . 1 1 2 5 . I 1 7 1 6 . 0 2 7 6 1
I 5 FURNPCE OFF0 1 l . 7 7 0 0 , 6 0 7 6 , 6 4 0 5 , 0 0 6 V1 , 0 0 1 6 1
1 8 BOILER DUST 7. V2hV 10. 1821 1 l . 1 l b V . 1 1 6 6 7 , 0 8 1 5 7
I V BOI LER OFF8S 1 2 . 1 8 8 3 . Ob l V , 0 7 8 1 , 0 0 0 7 1 . 0 0 0 1 1
20 ESP DUST 7.1VB1 2 8 . 1 1 8 6 1 5 . V8 1 8 , 1 2 1 5 1 , 0 7 6 1 1
21 ESP OFFG4S 1 2 . 1 5 h 9 , 0 0 6 2 , 0 0 7 8 . 0 0 0 1 1 , 0 0 0 0 2
22 FURM4CE SLPS , 6 1 0 1 11. h718 1. 6015 . 1 1 8 V1 , 08210
2 1 F U R N ~ C E m n r i 2 1 . ~ ~ 2 2 1h. 0061 6 o . o o o o . o o o o o . o o o o o
26 CONVERT OFF5 7 . 3 1 I 1 , 0 1 5 1 , 1 6 4 8 , 00001 , 0 0 0 0 0
27 CONVERT SLPQ , 2 8 1 8 51. 2112 1 . 1 8 6 5 , 0 1 1 0 2 .OO25V
1 0 BLRREN SLLS , 2 2 1 1 46. 6983 , 6 1 5 3 . 2 7 l I 1 . Obl SO
1 1 EL FURY MPTT I J . B b 1 1 2 7 . l 7 1 l 3 7 . 1 5 6 5 . I 1 1 1 5 , 0 2 6 1 5
1 2 C OY V E R T mn i r I V. 6217 , 0 1 1 2 80. 3527 . o o o o o . o o o o o
1 1 CONVERT OFF6 10. 2517 . 0 0 0 0 I . OI V 6 , 0 0 0 0 0 , 0 0 0 0 0
1 5 COOLER OFFGS 8 . 3 7 0 6 , 0 2 0 1 , 5 9 4 6 , 0 0 0 0 0 , 0 0 0 0 0
1 6 ESP OFFGPS 8. 4015 , 0 0 2 0 . 05VB , 0 0 0 0 0 , 0 0 0 0 0
1 7 ESP DUST 2 . 7 6 h 1 1 . l l V b V l . 1 6 1 l , 0 0 0 6 3 , 0 0 0 1 5
3 0 TOT4L DUST 5 . 1 8 1 2 1 7 . 5 5 1 I 5V. 7V2V . I S 1 1 1 , 0 1 1 1 1
1V BLI STER CU , 0 0 0 0 , 0 1 1 2 VV. 8456 , 0 0 0 0 0 , 0 0 0 0 0
I CONCENTRPTE 21. 00 7 0 . 0 0 - 53522 - 2 1 2 1 9 1
2 FLUX 2 1 . 0 0 7 0 . 0 0 - 8 1 9 9 - 1 2 5 1 6
3 DRYER FUEL 2 1 1 0 0 70. 00 7 - 1 0 1 9
4 OIR 2 1 . 0 0 70. 00 1 8 1 I 1 8 71071V
5 BURNER OFFGS 7 0 0 . 0 0 12V2. 00 1116917 1 7 2 5 0 0 8 1
6 Uh I t R UFt GPi 115. 00 275. 00 1 6 1 1 2 1 5 11409905
7 DRY CONC 6 7 . 0 0 152. 00 5 2 5 1 3 5 2OB5OV1
B Yl R 25. 00 1 7 . 0 0 1 7 B6 1 I 5 0 2 5 1
9 FUEL 25. 00 7 7 . 0 0 0 0
1 0 PREHEPI 4 1 1 I I 5 . UU 3 1 7 . 0 0 191VVV 771817
I 1 OXYGEN 200. 00 1 V2 . 0 0 617V57 2 1 5 2 2 5 1
11 SUPFl l 1 6 1 . 0 0 2 6 6 l . 0 0 l l h i l b h V 5 1 2 5 1 2 5 5 0 1
II SETTLER FUEL 2 5 . 0 0 77. 00 0 0
I 4 SEI I I ER U1R 25. ( 10 7 7 . 0 0 I 4 8 5 8 9
I 5 FURHPCE OFFG 1 1 5 2 . 0 0 2 6 1 6 . 0 0 I 3 0 5 h 9 7 1 5 1 8 1 1 2 5 5
l o UOl l l R NUTER 115. 00 2V3. 00 1997112 7 9 2 6 1 8 8
I' BOILER SIEPM 271. 00 5 2 0 . 0 0 I 0 6 5 5 6 5 2 1 2 2 8 5 0 4 1
21 ESP OFF6115 2 9 7 . 0 0 566. 00 1 7 7 1 2 0 6
2: FURIPCC SLOG 1 2 9 0 . 0 0 2 1 5 1 . 0 0 1 0 1 0 5 0 8 2
23 FURNPCE 8PTT 1200. 00 2 1 V2 . 0 0 5 7 2 6 6 8 1 - ~ ~
21 CONVERT FLUS 2 5 . 0 0 7 7 . 0 0 I 1
25 CONVERT l i l R .OO . 0 0 0
26 CONVERT DFt G 96B. 00 1771. 00 9 7 2 1 5 0 2
21 COHYERI SLPG 1 1 7 1 . 0 0 2 1 5 1 . 0 0 2 9 5 7 1 1 5
28 t i &URN dI R 21. 00 7 0 . 0 0 1 5 5 8
1 9 EL FURN OFF0 5 0 0 . 0 0 9 1 2 . 0 0 5 8 0 9 1 2
1~ I ~ R R E N sLn6 1210. 00 2216. 00 1 2 6 8 5 1 2 0
:I EL FURH nPTl 1200. 00 21V2. 00 226112
1; C0HYEhI I P I T 96B.(1U 1 7 7 4 . 0 0 2 V l O6 5 I
3 : CONVERT AI R 21. 00 7 0 . ~ 0 31687V I 1 1 6 8 1 1
$ 4 CONYERI OI t D 633. OI I I I 7 I . I I 0 6 7 5 h 5 2 1 2 6 8 1 2 0 5 1
- 5 LOOIER OFF65 545. 00 61I . OO 7 3 8 1 2 9 0 2 1 2 9 1 1 2 6
i a LSI 0 1 t ~ i i s 116. ( 80 601. 0( 1 h 7 6 7 7 1 1 2 6 8 5 6 5 1 5
" &SF DUST 119.' 10 300. 00 2 1 0 5 1 V1185
18 O l u L UUSI 15(1.0[1 J 0 1 . 0 0 1 1 1 1 5 1 3 6 2 5 2
Y CLI SI EX C U 1110.411 2118. Ul l 2110517 l l b h V 0 1 5
116 MINERAL RESOURCE MANAGEMENT BY PERSONAL COMPUTER
[CClfiL CJTREfiI.1 1 WE1 GHT
o f i L T m E 1 ,,/,/,'"\ D I ~ T R I BUTI 01.1
/'
CORL STREAM 11
REFUSE h
WEI GHT
DI STRI BUTI ON
FIGURE 6. WASHABILITY DATA FOR COAL STREAM 1 FIGURE 8. WASHABILITY DATA FOR REFUSE
COAL STREAM 3
COAL FEED 3
WE I GHT
DI STRI BUTI ON
COAL STREAM 23
WASHED COAL
WE I GHT
DISTRIBUTION
FIGURE 7. WASHABILITY DATA FOR COAL STREAM 3
TABLE 12. TABULATED WASHABILITY DATA
Sr nEnn II - TOTLL S T R E L ~
PCl . COPL PCI . PCT. CUI . tun. CUM.
SP.GR.RLNBE 0181. S11H LEH SULF S l i H PEH SULF
ETRELM 21 - TOTLL E l R t L n
PC1. COLL PCT. PCT. CUM. CUM. CUM.
5P.GR.RLNOE OI ST. 57/11 PSH SULF STI H PSH SULF
FIGURE 9. WASHABILITY DATA FOR WASHED COAL
TABLE ? 3 . COAL QUALITY REPORT
COLL PREP P i n n l
OENSE MEDIP CYCLONE CIRCUIT
I Ol 2 l l 9 8 b - 21121
COAL PUALITY REPORl
no. 81RELn
I COPL f EE0 I
2 conL ~ E E D 2
1 COLL FEED 1
1 COPL FLLO 1
b 6REnl En FEE0
I BI Ehl El l PnoD
8 OESLl l l E COPL
9 0.M.CIC FEED
10 0. I . CI C 81MK
I I REFUSE
1 2 D. I . CI C SLOT
11 11111EO COAL
I1 C E l l R l CDnL
I1 8 L l l l l S
I 7 I.O.CYC OVER
I 0 I.O.CIC UMOR
I 9 8 l t V l UMDR
11I I SMEO CDI L
25 B I H I Wl E n l
1 6 F L OI l IMTERM
1 0 l I I L 8