jksimmet 20v6 intro 2bsim1 140403001229 phpapp02 gs
TRANSCRIPT
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JKSimMet
OVERVIEW
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JKSimMet Overview
• JKSimMet is a package developed by the JKMRC/JKTech
for the modelling and simulation of comminution circuits.
• It includes models for crushers, autogenous mills, ballmills, rod mills, screens, and hydrocyclones.
• It is a closed package: you can not add your own
process models.
• There is detailed information on the models included
with JKSimMet in the user manual.
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JKSimMet Overview
Mass Balance
Model Fit
Simulate
Flowsheet Design
Data Input
Model Fitting
Simulation
Mass Balancing
Results Analysis
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JKSimMet References
JKSimMet V6 Help Files
(HELP FILE)
JKSimMet V6 User Manual
(PDF)
Mineral Comminution Circuits: Their Operation and Optimisation
(Published by JKTech)
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JKSimMet User Manual
• Part I – Overview
• Part II – Changes from Version 5
• Part III – Installing JKSimMet
• Part IV – Learning JKSimMet
• Part V – Using JKSimMet
• Part VI – Mass Balancing
• Part VII – Model Fitting
• Part VIII – Model Descriptions
Read Once
JKSimMet 101
MODELS REFERENCE
JKSimMet Reference
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JKSimMet Help File
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JK Blue Book
CONTENTS
Ch 1 Introduction
Ch 2 Models of Comminution Processes
Ch 3 Mineral LiberationCh 4 Rock Testing
Ch 5 Surveying Comminution Circuits
Ch 6 Crushers
Ch 7 AG and SAG Mills
Ch 8 Rod MillsCh 9 Ball Mills
Ch 12 Screens & Hydrocyclones
Ch 13 Optimisation of Comminution Circuits
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Steps to Building a Circuit Simulation
5. Review results.
1. Draw the flowsheet.3. Setup the models.
2. Setup the feed.
4. Run the simulation.
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JKSimMet
FLOWSHEETING
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Starting with JKSimMet
• 1. Create a new ‘Project’ and save it.
• 2. Press No when prompted about V5 icons
• 3. Should now have a blank project on screen:
V5 used bitmap icons;
V6 uses vector images.Can’t mix so need tomake a decision. Best just to go with ‘No’.
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JKSimMet Flowsheeting
Flowsheet drawing area
List of Flowsheets in project
List of models available
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Ex F1: Sandbox Flowsheet
Experiment with:
1. Adding models to the drawing area by dragging anddropping;
2. Connect models using streams (red ports are outputs,blue ports are inputs – connect red to blue);
3. Adjust stream lines to be aesthetically pleasing (rightclick ‘Add/Remove stream node’).
4. Name the flowsheet ‘Ex F1: Sandbox’
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SAVE
• Save, and save often.• JKSimMet can often crash seemingly right when you
have significant unsaved changes.
• Network licenses can cause increased frequency of
crashes (compared to a local dongle).• Become OCD about saving!
• CTRL + S does not work. Must use the disk icon.
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Ex F2: Ball Mill Circuit
Experiment with:
1. Adding nodes to streams
(right click ‘Add node to stream’)
1. Resizing units
(drag and drop) 2. Changing unit orientations
3. Naming streams and equipment
(double click on unit/stream) 4. Adding autolabels
5. Adding water feeders where
appropriate for this circuit
NOTE:
A JKSimMet flowsheet must have atleast one ‘feed’ unit and one ‘finalproduct’
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Ex F2: Ball Mill Circuit
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Ex F3: SABC Circuit
Draw the following circuit:
• Ore is fed into a SAG mill.
• SAG mill has a pebble crusher (closed with a
screen on SAG Discharge).
• SAG Discharge screen U/S feeds a cyclone
cluster.
• Cyclone underflow feeds a ball mill in closedcircuit.
• There are water additions to the SAG feed,
Cyclone Feed, and Ball Mill Feed.
Experiment with
adding Info Blocks to
your flowsheet
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Ex F3: SABC Circuit
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JKSimMet
SIMULATE I
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Steps to Building a Circuit Simulation
5. Review results.
1. Draw the flowsheet.3. Setup the models.
2. Setup the feed.
4. Run the simulation.
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Clone your Ex F3: Flowsheet Layout Design
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
Required Feed Size Distribution:
Screen Aperture WEIGHT
mm %
190 0.0
165 0.0
140 4.1
125 4.3
100 23.9
63.0 23.6
45.0 12.231.5 3.0
25.0 0.5
19.0 2.2
13.2 8.4
9.50 4.7
6.70 3.0
4.75 2.0
3.35 1.2
2.36 1.1
1.70 0.8
1.18 0.80.850 0.5
0.600 0.5
0.425 0.4
0.300 0.3
0.212 0.3
0.150 0.2
0.106 0.2
0.075 0.2
0.053 0.2
0.038 0.1
-0.038 1.3
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
Setting the Ore Feed Rate
Set to 500 tph
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
Feed Sieve Series
• JKSimMet uses one master sieve series for
the entire simulation.
• However survey data from the lab will use
different sieves for different streams.
• JKSimMet allows each stream can have a
custom sieve series.
• JKSimMet will then convert all streams to
the master series by interpolation.
JKSi M V6
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
The Root 2 button is a quick
way to set a sieve series.
Add sieve series here
Specify which serieseach stream is to use
here
TIP: Entering a size of 0 will delete all size fractions below.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
PRESS Transfer to perform theconversion to master sieve
series.
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Ball MillHydrocyclonesWater addition
Need to specify models for:
SAG MillSAG Discharge ScreenPebble Crusher
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Water Feeders
Use a simple model to set a specified % solids in thedownstream unit.
Parameter SAG Ball Mill Cyclone
Req. %S 65 70 30
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Ex SIM1: Simple ModelsSAG, BALL, PEBBLE CRUSHER
Simple model that creates a product PSD by movingit sideways on a Cum % Passing vs size plot to give auser specified product P80.
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
SAG, BALL, PEBBLE CRUSHER
Simple model that creates a product PSD by movingit sideways on a Cum % Passing vs size plot to give auser specified product P80.
Parameter SAG Pebble Ball Mill
Req P80 (mm) 10.0 5.00 0.500
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
SAG Discharge Screen, Hydrocyclone
Efficiency (partition) curve that describes whatfraction of a particular particle size reports to theproduct stream.
• The underflow and overflow curves
are complementary.
• Traditionally the underflow curve is
used for efficiency curves
• JKSimMet uses the overflow curve
given that this is the product
stream in a grinding circuit
classifier.
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Ex SIM1: Simple Models1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
SAG Discharge Screen, Hydrocyclone
Efficiency (partition) curve that describes whatfraction of a particular particle size reports to theproduct stream.
Efficiency Curve:
0
50= .
+ ⋅ ∗ ⋅ 50
⋅ −
⋅∗⋅
+ −
Parameters• Sharpness of Efficient Curve – α• Initial Dip in Efficient Curve –
• Water Split to Fine Product (%) -
• Corrected d50c (mm) – 50(∗is calculated internally and is not a parameter)
For more on Efficiency curves see:
1. JKSimMet Manual – pp. 346
2. JK Blue Book – pp. 276
Alpha Beta
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Ex SIM1: Simple Models1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
SAG Discharge Screen, Hydrocyclone
Parameter SAG DischScreen
Cyclones
Alpha 1.5 2.5
Beta 0 0
C (%) 90 75
d50c (mm) 10 0.10
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Ex SIM1: Simple Models1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
PRESS START TORUN SIMULATION
PRESS THESIMULATE ICON
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Ex SIM1: Simple Models1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
DO NOT TRUST A BLACK BOXThis is where you use your subject matter knowledge to reviewand interpret the results.
• Do they make sense?• Are they realistic?• What needs to be improved/changed/corrected?
JKSimMet Tools:1. Data Blocks2. Graphing3. Reports (Export to Excel)
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Ex SIM1: Simple Models1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Data Blocks:• What is the final product P80?
• What is the circulating load in the ball mill circuit?
• What are the reduction ratios for each comminution
machine?
• Are there any concerning numbers?
(HINT: Pebble crusher tph, ball mill % solids)
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Ex SIM1: Simple Models1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Graphs:
• Can’t print from JKSimMet, can copy toclipboard and paste into Word, Excel,PowerPoint etc.
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Ex SIM1: Simple Models1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Graphs:• Plot all the feed/products for comminution machines (SAG,
Ball, Pebble)
• Plot Feed/US/OS for Cyclone
• Plot Fresh Feed – SAG Screen US
• Plot SAG Screen US – Final Product
• Plot Fresh Feed – Final Product
Review Graphs:
• What do these charts tell you?
• Where is the most size reduction taking place?
• Which machines are working harder than others (too hard?)?
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Ex SIM1: Simple Models1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Reports:
• Allows you to export data for analysis in Excel
(Can’t view reports within or print from JKSimMet)
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Ex SIM1: Simple Models1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Baseline Scenario 1 Scenario 3Scenario 2
• This has described the process of running a single simulation.• Having reviewed the results of the model we can then:
1) make appropriate changes to our model parameters, our feed, our circuit configuration;
2) rerun the simulation; and,
3) compare the results.