International Journal of Mineral Processing, 11 (1983) 255--265 255

Elsevier Science Publishers B.V., Amsterdam -- Printed in The Netherlands

COMPUTER-AIDED DESIGN OF SAMPLING SCHEMES

J.A. FREW
Division of Mineral Engineering, C.S.I.R. O., P.O. Box 312, Clayton, Vic. 3168
(Australia)
(Received September 24, 1982; revised and accepted March 14, 1983)

ABSTRACT

Frew, J.A., 1983. Computer-aided design of sampling schemes. Int. J. Miner. Process.,
11 : 255--265.

A procedure is described that examines the structure of mineral dressing systems

to determine the minimum sampling requirements to enable a material balance to be
calculated. The method is illustrated by examples taken from industrial practice. These
examples show that in some cases, even where assays are measured in all the physically
available streams, it is necessary to measure the flowrates of certain streams to obtain
a material balance.
The procedure can be readily automated on a computer.

INTRODUCTION

Sampling of mineral processing systems at steady state continues to

be a powerful to ol for assessing plant p e r f o r m a n c e (Kelsall et al., 1974),
for mo d el building ( L ove da y and Marchant, 1972) and for assessing the
influence of c o n t r o l variables (Frew, 1982). T he data obtained will nor-
really contain errors and will have t o be adjusted to obtain material bal-
ances. Th e data adjustment problem has been solved to varying degrees
by several authors, not abl y Wiegel (1972) and Smith and Ichiyen (1973).
The in f o r mati on obtained from sampling usually consists of a metal
assay, a size distribution or t he fraction solids of t he sampled stream.
Sometimes it is possible to measure the total mass flowrate, although such
measurements are usually restricted to streams with small flows or the
main feed stream.
F r e q u e n t l y the mineral processing system to be sampled is com pl ex
and some o f th e streams are unavailable for sampling. Thus it is o f t e n dif-
ficult to judge a priori w h e t h e r sufficient samples have been collected
to permit a reliable balance t o be made. The design and analysis of sam-
pling experiments using a sensitivity approach has been discussed by Smith
and Frew (1983). T he t o p o l o g y of separation circuits was examined to
d e t er min e what streams should be sampled to obtain a balance and t hen

0301-7516/83/$03.00 © 1983 Elsevier Science Publishers B.V.

256

singular value decomposition techniques were used to suggest the best

sampling campaign to minimize sensitivity to errors.
In this paper the topological investigation is automated to provide the
sampler with an indication of the samples, both of assays and of measured
flows, that must be obtained to perform the mass balance. Application
of the technique is illustrated by examples taken from industrial practice.

CIRCUIT TOPOLOGY

To determine how m a n y streams need to be sampled to calculate a mass

balance for the entire circuit it is necessary to consider the mineral dressing
circuit in terms of simple nodes. A node in a circuit is a point at which
process streams either join or separate. A simple node is a node having
either two inputs and one o u t p u t (a junction) or one input and two out-
puts (a separator).
It has been shown by Smith and Frew (1983) -- see Appendix A -- that
if all the sampled streams are analyzed for the same component and if
no mass flows other than one reference stream are measured, then the
m i n i m u m n u m b e r of streams which must be sampled is:

(Ns)min = 2 (F + S) - 1 (1)
where F is the number of feed streams and S is the number of separators.
The reference stream is usually the main feed stream which is either mea-
sured or set to 100 flow units. However, it may be convenient to refer
the mass flows to any other stream within the circuit.
Each additional mass flow measurement, up to the number of u n k n o w n
flows, reduces (Ns)mia by one provided t h a t no subset of flow measure-
ments (including the reference stream) includes all streams at a node or
group of nodes. Consequently, if the m i n i m u m number of streams that
must be sampled for a balance calculated by eq. 1 exceeds the number
of streams that can be sampled then the difference indicates to the de-
signer how m a n y flows must be measured (for a single-component system).

AUTOMATION OF THE TOPOLOGICAL INVESTIGATION

The determination of the number of simple separators and the number

of feed streams can be done automatically, as a simple check on a count-
up from the flow diagram, and at the same time other features of the cir-
cuit can be checked. Although this is straightforward for simple circuits
some of the circuits that are sampled in practice are complex and thus
the a u t o m a t i o n provides a quicker and more reliable answer than non-
computerized calculations.
The procedure involves the use of the connection matrix M (Cutting,
1976) whose entries take the form:
 257

+ 1 for stream j flowing into the ith node

m#' =
t 1 for stream j flowing out of the ith node
0 for stream j n o t appearing at the ith node
The connection matrix t h a t is used is derived from the nodes that connect
all the streams to be measured. The procedure is most readily understood
by means of a concrete example taken from an industrial copper circuit
of unusual design and awkward construction for sampling. The circuit
is shown in Fig. la. In this circuit it is not possible to sample either the
feed to Cleaner 2 or the feed to Cleaner 3 (i.e. sampling of two junction
nodes cannot be complete). Consequently, the flowsheet must be redrawn
eliminating these two streams. This is shown in Fig. l b . The circuit con-
sists of 16 streams and 8 nodes and the connection matrix is given by eq.
2. It should be noted that the orders chosen for the streams and nodes
do n o t affect the m e t h o d . However, it is essential that the actual nodes
and n o t combinations (such as the overall circuit balance which is usu-
ally used in material balance calculations) be used.
1 -1 0 0 0 1 0 0 0 1 0 0 0 0 0 0
0 1 -1 - 1 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 1 -1 - 1 -1 0 0 0 0 0 0 0 0 0
M = 0 0 0 0 0 0 0 1 -1 - 1 0 0 0 0 0 0 (2)
0 0 1 0 1 0 0 -1 0 0 0 1 0 0 0 0
0 0 0 0 0 0 0 0 1 0 -1 - 1 0 1 0 0
0 0 0 0 0 0 0 0 0 0 1 0 -1 -1 0 1
0 0 0 0 0 0 0 0 0 0 0 0 1 0 -1 - 1
If the contents of each column (which represent the individual streams)
are summed, then the resultant sum can be used to classify the streams:
t+i stream is an external feed
Column Sum = stream is a product
c 0 stream is an internal stream
Other there is a mistake in the connection matrix.
Using this m e t h o d for eq. 2 identifies stream 1 as a feed, streams 7 and
15 as products and the other thirteen streams as internal streams. Thus
for this example F = 1, which is obvious from the flow diagram.
If the elements of each row (which represent the individual nodes) are
examined and it is found that there are np '+1' entries and nrn ' - 1 ' entries
then np and n m can be used to classify the number of simple nodes:
np, nrn >11: np corresponds to n p - 1 simple junctions (J)
(but n o t np = nrn = 1) nrn corresponds to nrn- 1 simple separators (S)
nD = n m = 1 corresponds to an abnormal node (A) such as a ball mill.
np, n m < 1 a mistake in the connection matrix.
Using this m e t h o d for eq. 2 gives the results in Table I.
The procedure is done row-by-row, rather than considering the connec-
tion matrix as a whole, to check for abnormal nodes and for mistakes.
In the c o n t e x t of this paper an abnormal node is one at which no separa-
tion takes place, such as in a ball mill where at steady state, although there
258

6
7
11 CLEANE1L8

14~~ -

(a)

11 14

151 (b)

Fig. 1. a. Industrial copper flotation circuit, b. Sampling flowsheet o f industrial copper

flotation circuit.

is a change in size distribution, there is no change in overall flow or assay

between the input and output stream. It must be stressed that the proceo
dure described in this paper applies only to components that are conserved
throughout the circuit.
Thus in this example J = 6, S = 7 and (Ns)min = 15. Consequently, as
Ns = 16 sufficient samples have been designed to allow a material bal-
 259

TABLE I

Node classification for industrial copper circuit

Node np nm J S

1 3 1 2 0
2 1 2 0 1
3 1 3 0 2
4 1 2 0 1
5 3 1 2 0
6 2 2 1 1
7 2 2 1 1
8 1 2 0 1

6 7

ance to be constructed, without having to measure any extra individual

mass flows. This is not to say that additional mass flow measurements
will not greatly enhance the material balances obtained. In fact for this
circuit flow measurements of streams 5 and 6 have been shown to be highly
desirable (Frew and Davey, 1982).
The construction of the connection matrix, the column sum classifi-
cation and the node classification are all readily programmed in an easy
to use, interactive computer programme.

APPLICATION TO MORE COMPLEX CIRCUITS

To illustrate the usefulness of the procedure, t w o further practical ex-

amples are considered. The first involves a survey of the lead flotation
separation succeeding the copper separation of Fig. la. The circuit is shown
in Fig. 2a, which must include the overall copper separation, and the sam-
pling flowsheet is illustrated in Fig. 2b. The connection matrix for this
flowsheet is:

I-i-I 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0
0 0 1 - 1 1 - 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0
0 0 0 0 - 1 1 - 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 1 0 0 0 0 - 1 0 1 0 0 0 0 1 0 - 1 0 0 0 0
M= 0 0 0 0 0 0 0 0 0 - 1 - 1 0 0 0 0 0 0 1 0 - 1 0 0
0 0 0 0 0 0 0 0 1 1 0 - 1 0 0 0 - 1 1 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 1 - 1 0 0 0 - 1 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 1 - 1 0 0 0 0 - 1 0 0 1
0 0 0 0 0 0 0 - 1 0 0 0 0 0 0 - 1 0 0 0 1 0 0 0

The column s u m identifies streams 1, 21 and 22 as feed streams, streams

2, 7 and 14 as products and the other sixteen streams as internal streams.
Thus F = 3. T h e row analysis is given in Table II which indicates that J =
10 and S = 10 and hence (Ns)min = 25. This is a very significant result as
Ns = 22 and thus three flows in addition to the reference stream must be
260

21 5

1 2 3 6 7 ~

4 ~
15 18
Pb CLE ~NER 1
16

22 Pb CLEANER 3 10

Pb CLEANER 2

(b) 1~
3

Fig. 2. a. I n d u s t r i a l c o p p e r a n d lead f l o t a t i o n circuits, b. S a m p l i n g f l o w s h e e t o f indus-

trial c o p p e r a n d lead f l o t a t i o n circuits.

measured to enable a single-component balance to be derived. This was

not realized at the time of the sampling campaign. The sampling scheme
was designed on the basis of previous experience, which had shown that
normally a balance could be obtained if all possible streams were sampled.
The basis of the present problem has been exacerbated by the existence
of three feed streams, and the significance of streams 21 (spillage) and
22 (on-stream analysis system returns) for circuit balancing was not ap-
preciated; the demonstration of their significance is a most important
aspect of this computerized procedure for specifying sampling schemes.
It was only by chance that the requisite number of flows was measured.
Several bulk concentrate flows could not be sampled at a single point and
consequently it was necessary to take timed lip samples which subsequently
 261

TABLE II

Node classification for industrial copper and lead circuits

Node np nm J 8

1 2 2 1 1
2 4 2 3 1
3 2 2 1 1
4 3 2 2 1
5 1 3 0 2
6 3 2 2 1
7 1 2 0 1
8 2 2 1 1
9 1 2 0 1

10 10

enabled the required flows to be calculated. Had the bulk concentrate

samples been available, insufficient information would have been collected
for a single-component material balance to be constructed.
The availability of more than a single analysis in each sampled stream
would provide additional equations and thus enable a solution to be ob-
tained. However, often these additional analyses contain more noise (or
error) than information (Smith and Frew, 1983) and thus the flows so
obtained may be highly suspect.
The second example concerns the sampling of a very complex gravity
circuit on a tin concentrator. The circuit and the sampling flowsheet
are shown in Fig. 3a, b. The connection matrix for this circuit is sized
38 by 17. The column sum identifies stream 38 as the feed, and thus F =
1, streams 25, 30, 33 and 37 are product streams and there are thirty-
three internal streams. The row analysis is given in Table III. Consequently,
(Ns)min = 41 and three mass flows in addition to the reference flows have
to be measured to obtain a balance.
This example indicates the ease with which the automatic m e t h o d handles
a problem t h a t would be extremely tedious and error prone to do by any
non-computerized technique. The need for the analysis is indicated by
(Ns)mi n exceeding Ns. When the survey was performed it was possible to
easily measure five flows and thus a balance could be obtained; in any
sampling scheme it is normal practice to measure any mass flows which
do n o t present excessive problems.

DISCUSSION AND CONCLUSIONS

The examples considered demonstrate the value of the automatic pro-

cedure of analysing a complex mineral dressing system to ensure that suf-
ficient streams will be sampled and adequate ancillary measurements, es-
262

ONDARY
"(CLONE

SCAVENGE~
CYCLONE
'I
23
CAVENGER~
SPIRAL

2S

27 26

.,~-,¢ '~x® \
6 3 5 17 21

~ ///

1
8 15 22

37
Fig. 3. a. Industrial tin gravity circuit, b. Sampling flowsheet of industrial tin gravity
circuit.

pecially mass flowrates, will be made to enable a material balance to be

calculated.
 263

TABLE III

Node classification for industrial tin circuits

Node np nm J S

1 1 2 0 1
2 1 3 0 2
3 2 2 1 1
4 1 3 0 2
5 5 2 4 1
6 1 3 0 2
7 2 2 1 1
8 1 3 0 2
9 2 1 1 0
10 5 2 4 1
11 1 2 0 1
12 2 2 1 1
13 1 3 0 2
14 1 2 0 1
15 2 2 1 1
16 1 2 0 1
17 5 1 4 0

17 20

In the case o f simple circuits, the main value o f the p r o c e d u r e p r o b a b l y

lies in confirming t hat conventional sampling schemes will provide suf-
ficient numbers of samples. However, in t he case o f c o m p l e x circuits it
has been shown t hat conventional sampling schemes can be deficient. T he
p r o c e d u r e will provide a check t hat the correct connect i on matrix has
been devised and it will indicate the n u m b e r o f streams which must be
sampled and the n u m b e r o f mass flows which must be measured to obtain
a circuit balance.
The calculation relating to the lead flotation example has indicated
t h a t sampling problems are exacerbated by systems with multiple feeds
and the c o m p u t a t i o n is especially valuable in these circumstances.
Th e m e t h o d is readily i m pl em e nt e d on a digital c o m p u t e r and this ap-
proach is r e c o m m e n d e d f or complex systems. However, the procedure
can be used in the absence of a c o m p u t e r by writing dow n t he connec-
tion matrix and pe r f or m i ng the column and row procedures by hand.

ACKNOWLEDGEMENTS

T h e industrial examples were drawn f rom surveys directed by Dr. A.

J o w e t t and Dr. K.R. Weller. K.J. Davey assisted with the c o m p u t e r pro-
gramming.
264

APPENDIX A: DERIVATION OF THE MINIMUM NUMBER OF STREAMS THAT

MUST BE SAMPLED TO OBTAIN A MASS BALANCE

In the following analysis it is assumed that all streams that are sampled
are analyzed for the same c o m p o n e n t and that the only mass flow that
is k n o w n is t h a t of the reference stream (it may either be measured or
taken to be 100 flow units).
In the actual circuit more than two streams can come together at one
point (called a node) and occasionally more than two streams can leave
a node. In this analysis the actual circuit is represented in terms of simple
nodes, junctions that have two inputs and one o u t p u t and separators t h a t
have one !nput and two outputs. Thus a node in an actual circuit where
three streams join is represented by two junctions with a hypothetical
stream t h a t is n o t sampled joining t h e m .
Each simple junction generates one new stream, while each simple sep-
erator generates two. Thus the total number of streams in a simple nodal
representation of the flowsheet containing F feed streams, J simple junc-
tions and S simple separators is:

N s = F + J + 2S

The mass flows of streams entering a junction from other parts of a

circuit are assumed known; thus junctions give rise to no new mass flows
while a separator gives rise to one u n k n o w n mass flow at its o u t p u t . Thus,
allowing for the one reference stream, the number of independent u n k n o w n
mass flows to be determined is:

Nu=F+S - 1

An independent mass balance can be written for each node, thus the
number of independent mass balance equations available for determina-
tion of the u n k n o w n mass flows is:

Ne = J + S

Where a stream is n o t sampled the number of unknowns is increased by

one, thus if Nn streams are n o t sampled:

Nu=F+S- l+Nn

The minimum number of streams t h a t must be sampled for a mass balance

to be calculated is such that the number of equations available equals the
number of unknowns. So:

J + S = F + S - 1 + (Nn)ma x
 265

or

(Nn)max = J - F + 1

where

(Nn)max + (Ns)min = hrs.

Thus:

(Ns)min = Ns- (Nn)max

=F+J+2S- (J- F+I)
=2 (F+S)- 1.

REFERENCES

Cutting, G.W., 1976. Estimation of interlocking mass-balances on complex mineral

beneficiation plants. Int. J. Miner. Process., 3: 207--218.
Frew, J.A., 1982. Variation of flotation rate coefficients in zinc cleaning circuits. Int.
J. Miner. Process., 9: 173--189.
Frew, J.A. and Davey, K.J., 1982. Mass balancing aspects of sampling surveys at the
Woodlawn concentrator. C.S.I.R.O., Division of Mineral Engineering. Restricted
Report.
Kelsall, D.F., Stewart, P.S.B. and Trahar, W.J., 1974. Diagnostic metallurgy - a system-
atic method of plant optimization. Symposium on Optimization and Control o f
Mineral Processing Plants, Brisbane. A.M.I.R.A., Parkville, pp. 53--65.
Loveday, B.K. and Marchant. G.R., 1972. Simulation of multieomponent flotation
plants. J.S. Aft. Inst. Min. Metall., 72: 288--294.
Smith, H.W. and Frew, J.A., 1983. Design and analysis of sampling experiments - - a
sensitivity approach. Int. J. Miner. Process., 11: 267--284.
Smith, H.W. and Ichiyen, N., 1973. Computer adjustment of metallurgical balances.
CIM Bull., 66(737): 97--100.
Wiegel, R.L., 1972. Advances in mineral processing material balances. Can. Metall. Q.,
11 : 4 1 3 - 4 2 4 .