Jksimmet v6 Manual

Version 6.
User Manual
Steady State Mineral Processing Simulator

JKSimMet - Version 6.0
Steady State Mineral Processing Simulator
by JKTech Pty Ltd
JKSimMet is a powerful tool for the analysis and simulation of mineral processing plant
data. As the program developers do not control data collection, analysis or
interpretation, it is the sole responsibility of the JKSimMet user to verify that the input
data are accurate and that both process unit operating conditions and stream outputs
are reasonable.
In no event will JKTech Pty Ltd be liable for direct, indirect, special, incidental or
consequential damages arising out of the use or inability to use the software or
documentation.
Note: The detailed descriptions of the mathematical models in this manual are provided
for the information of the software licensees. These models are not public domain and
they may not be used in other software without written permission from or a licensing
agreement with JKTech Pty Ltd.
JKTech Pty Ltd

40 Isles Road
Indooroopilly
Brisbane
QLD 4068
AUSTRALIA
telephone: +61 7 3365 5842

facsimile: +61 7 3365 5900
email: info@jk tech.com.au
web: www.jk tech.com.au
JKSimMet V6 Manual
2014 JKTech Pty Ltd
All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the
written permission of the publisher.
Products that are referred to in this document may be either trademarks and/or registered trademarks of the
respective owners. The publisher and the author make no claim to these trademarks.
While every precaution has been taken in the preparation of this document, the publisher and the author
assume no responsibility for errors or omissions, or for damages resulting from the use of information
contained in this document or from the use of programs and source code that may accompany it. In no event
shall the publisher and the author be liable for any loss of profit or any other commercial damage caused or
alleged to have been caused directly or indirectly by this document.
Printed: March 2014 in Brisbane, Qld, Australia.
Special thanks to:

Publisher
JKTech Pty Ltd All of the JKTech and JKMRC staff and students who have
contributed in any way to the preparation of this document.
Managing Editor
Chris Bailey
Technical Advisors
Chris Bailey
Iain Crawford
Chris Keenan
Cover Design
Andrea Evers
Heather Miller
Team Coordinators
Rolf Fandrich
Debbie Gray
Principal Author
Alister Grimes
Assistant Author
Chris Keenan
4 JKSimMet V6 Manual
Table of Contents
Foreword 11
Part I Overview 13
1 About
...................................................................................................................................
JKSimMet V6 13
General Capabilities
.......................................................................................................................................................... 13
How the Program
..........................................................................................................................................................
Works 14
JKSim Met..........................................................................................................................................................
Sim ulation 16
JKSim Met..........................................................................................................................................................
Mass Balancing 17
JKSim Met..........................................................................................................................................................
Model Fitting & Analysis 17
2 Hardware
...................................................................................................................................
& Operating System Requirements 17
3 Cautionary
...................................................................................................................................
Tales 18
4 JKSimMet
...................................................................................................................................
Structure 18
5 Available
...................................................................................................................................
Models 18
6 JKSimMet
...................................................................................................................................
Support 19
Part II Changes from Version 5 21

1 Summary
...................................................................................................................................
of Main Changes 21
2 Precautionary
...................................................................................................................................
Notes on Main Changes 21
3 Toolbar
...................................................................................................................................
Changes 22
4 Creating
...................................................................................................................................
Projects 23
5 Sieve
...................................................................................................................................
Series and Survey Data Entry 28
6 The
...................................................................................................................................
New Flowsheet Drawer 31
7 System
...................................................................................................................................
Properties 31
8 Accessing
...................................................................................................................................
Models 33
9 Equipment
...................................................................................................................................
Manager 34
10 Viewing
...................................................................................................................................
and Entry of Stream Data 35
11 Configurable
...................................................................................................................................
Stream Overview 36
12 Simulation
...................................................................................................................................
Changes 37
13 Simulation
...................................................................................................................................
Manager 38
14 Changes
...................................................................................................................................
to Reporting 39
15 Changes
...................................................................................................................................
to Graphing 40
16 Changes
...................................................................................................................................
to Info Blocks 41
17 Model
...................................................................................................................................
Fitting Changes 43
18 Mass
...................................................................................................................................
Balancing Changes 44
Part III Installing JKSimMet 47

1 Contents
...................................................................................................................................
of the Package 47
2 JKSimMet
...................................................................................................................................
Installation 47
Part IV Learning JKSimMet 51

1 JKSimMet
...................................................................................................................................
Basics 51
JKSim Met..........................................................................................................................................................
Data Structure 51
Available ..........................................................................................................................................................
Equipm ent Item s and Associated Models 52
2014 JKTech Pty Ltd

Contents 5
Building a..........................................................................................................................................................
Sim ulation Model 56
The Mouse ..........................................................................................................................................................
and Cursor 57
The JKSim ..........................................................................................................................................................
Met Window s 58
2 Building
...................................................................................................................................
a New Project 58
The Steps..........................................................................................................................................................
to Sim ulation 59
JKSim Met..........................................................................................................................................................
Start Up 60
Creating the
..........................................................................................................................................................
New Project 61
Adding Flow
..........................................................................................................................................................
sheet Equipm ent 63
Add Connecting
..........................................................................................................................................................
Stream s 72
Define System
..........................................................................................................................................................
Properties 78
Feeder Equipm
..........................................................................................................................................................
ent Data 81
Select Equipm
..........................................................................................................................................................
ent Models 83
Sim ulation
.......................................................................................................................................................... 87
View ing the
..........................................................................................................................................................
Results 89
View ing Individual
..........................................................................................................................................................
Stream Data 94
View ing Data
..........................................................................................................................................................
for Multiple Stream s 97
Finishing ..........................................................................................................................................................
a JKSim Met Session 99
3 Working
...................................................................................................................................
with an Existing Project 99
Selecting..........................................................................................................................................................
the Flow sheet to Use 100
Working..........................................................................................................................................................
w ith the Sim ulation Manager 101
Using Model
..........................................................................................................................................................
Based Groups for Sim ulations 108
Sim ulating
..........................................................................................................................................................
Changes in Operating Conditions 111
Working..........................................................................................................................................................
w ith Configurable Equipm ent Manager 116
Defining..........................................................................................................................................................
Stream Data Info Blocks 120
Defining..........................................................................................................................................................
Equipm ent Info Blocks 125
4 Summary
................................................................................................................................... 129
Part V Using JKSimMet 131

1 JKSimMet
...................................................................................................................................
Description 131
JKSim Met..........................................................................................................................................................
Model Types 132
JKSim Met..........................................................................................................................................................
Capabilities 134
JKSim Met..........................................................................................................................................................
Constraints 135
JKSim Met..........................................................................................................................................................
Expandability 135
Definition
..........................................................................................................................................................
of Term s Used in JKSim Met 135
2 The
...................................................................................................................................
JKSimMet Menus and Toolbars 137
The Main..........................................................................................................................................................
JKSim Met Menu 138
The File ..........................................................................................................................................................
Menu and Main Toolbar 139
The Edit ..........................................................................................................................................................
Menu 140
The View ..........................................................................................................................................................
Menu 143
The Flow..........................................................................................................................................................
sheet Menu and Toolbar 145
The Balance,
..........................................................................................................................................................
Fitting and Sim ulate Toolbar 149
Draw ing..........................................................................................................................................................
Toolbar 150
The Tools..........................................................................................................................................................
Menu 152
The Help..........................................................................................................................................................
Menu 153
3 JKSimMet
...................................................................................................................................
Windows 153
Configurable
..........................................................................................................................................................
Equipm ent Manager 153
Config Graph
..........................................................................................................................................................
Window 154
Configurable
..........................................................................................................................................................
Stream Overview Window 157
Inform ation
..........................................................................................................................................................
Blocks 158
Model Window
..........................................................................................................................................................
s 159
Property..........................................................................................................................................................
Window s 160
Reporting..........................................................................................................................................................
to Excel Window 162
Sim ulation
..........................................................................................................................................................
Manager Window 163
Sim ulation
..........................................................................................................................................................
Window 164
Stream Window
..........................................................................................................................................................
s 165
The Equipm
..........................................................................................................................................................
ent Window 171
2014 JKTech Pty Ltd

The Session
..........................................................................................................................................................
Window 172
The Sieve
..........................................................................................................................................................
Series Window 175
The Survey
..........................................................................................................................................................
Data Window 175
The System
..........................................................................................................................................................
Properties Window 176
4 Building
...................................................................................................................................
and Manipulating a Flowsheet 177
Loading ..........................................................................................................................................................
an Existing Project 177
Creating..........................................................................................................................................................
a New Project 178
Loading ..........................................................................................................................................................
an Existing Flow sheet 179
Creating..........................................................................................................................................................
a New Flow sheet 180
Defining..........................................................................................................................................................
the Flow sheet Nam e 181
Deleting..........................................................................................................................................................
a Flow sheet 181
Building ..........................................................................................................................................................
the Flow sheet - Equipm ent 182
Building ..........................................................................................................................................................
the Flow sheet - Stream s 184
Annotating
..........................................................................................................................................................
the Flow sheet 187
Inform ation
..........................................................................................................................................................
Blocks 189
5 Editing
...................................................................................................................................
the Flowsheet Data 191
Stream Structure
.......................................................................................................................................................... 191
System Properties
.......................................................................................................................................................... 192
Accessing..........................................................................................................................................................
the Equipm ent and Model Data 193
Editing the
..........................................................................................................................................................
Model Data 194
Editing Equipm
..........................................................................................................................................................
ent Data 195
6 Using
...................................................................................................................................
Simulation 199
Sim ulating
..........................................................................................................................................................
Using the Sim ulation Window 200
Sim ulating
..........................................................................................................................................................
Using the Sim ulation Manager 201
Accessing..........................................................................................................................................................
the Stream Data 210
Water in..........................................................................................................................................................
Sim ulation 212
7 Viewing
...................................................................................................................................
the Data - Summaries & Reports 213
Using the
..........................................................................................................................................................
Configurable Stream Overview 213
Configuring
..........................................................................................................................................................
Colum ns in the Stream Overview 217
Using the
..........................................................................................................................................................
Reporting Feature 226
Part VI Mass Balancing 230

1 Introduction
...................................................................................................................................
to Mass Balancing 230
2 Data
...................................................................................................................................
Collection 230
3 Background
................................................................................................................................... 231
4 How
...................................................................................................................................
the Mass Balancing Program Works 233
5 Learning
...................................................................................................................................
Mass Balancing 235
Model Types
..........................................................................................................................................................
for Mass Balancing 236
Entering..........................................................................................................................................................
the Data 237
The SD Calculation
..........................................................................................................................................................
Window 240
Standard..........................................................................................................................................................
Deviation Calculations 243
Preparation
..........................................................................................................................................................
for Mass Balancing 246
Selecting
..........................................................................................................................................................
Data 247
Selecting
..........................................................................................................................................................
Com ponents 251
Solution..........................................................................................................................................................
Controls 252
Water in..........................................................................................................................................................
Balancing 254
Running..........................................................................................................................................................
the Mass Balance 255
The Mass..........................................................................................................................................................
Balance Engine 259
Checking..........................................................................................................................................................
the Balance 261
6 Presentation
...................................................................................................................................
of Mass Balance Results 262
Configurable
..........................................................................................................................................................
Stream Overview 263
Reports ..........................................................................................................................................................
Function and Printing 263
Plotting Size
..........................................................................................................................................................
Data Graphs 265
7 Problems
...................................................................................................................................
Related to Mass Balancing and Possible Solutions 267
2014 JKTech Pty Ltd

Contents 7
The Middlings
..........................................................................................................................................................
Problem 267
The Infinite
..........................................................................................................................................................
Division Problem 268
8 Metallurgical
...................................................................................................................................
Accounting 268
9 References
................................................................................................................................... 269
Part VII Model Fitting 272

1 Introduction
...................................................................................................................................
to Model Fitting 272
2 Background
...................................................................................................................................
to Model Fitting 273
3 How
...................................................................................................................................
the Model Fitting Program Works 273
4 Model
...................................................................................................................................
Fitting as Applied in JKSimMet 274
5 Preliminary
...................................................................................................................................
Data Setup 275
Creating..........................................................................................................................................................
the Flow sheet 275
System Properties
.......................................................................................................................................................... 275
Stream Specification
.......................................................................................................................................................... 275
Data Input
.......................................................................................................................................................... 276
Mass Balance
..........................................................................................................................................................
Prior to Fitting 276
The Model
..........................................................................................................................................................
Fitting Window 277
Master Slave
..........................................................................................................................................................
Fitting 284
Checking..........................................................................................................................................................
the Fit 286
Presentation
..........................................................................................................................................................
of Model Fitting Results 287
Problem..........................................................................................................................................................
s Related to Model Fitting and Possible Solutions 291
References
.......................................................................................................................................................... 292
Part VIII Model Descriptions 294

1 General
...................................................................................................................................
Models 294
Ore Feeder..........................................................................................................................................................
(1300) 294
Water Feeder
..........................................................................................................................................................
Models (1251 & 1252) 295
Model .........................................................................................................................................................
Description - General 295
Required
.........................................................................................................................................................
% Solids - Standard Model 295
Water .........................................................................................................................................................
Addition - Standard Model 296
Model .........................................................................................................................................................
Limitations 297
References
......................................................................................................................................................... 297
Hydrocyclone
..........................................................................................................................................................
Models (200, 201) 298
Desciption
......................................................................................................................................................... 298
Equations
......................................................................................................................................................... 298
Symbols......................................................................................................................................................... 301
Restrictions
......................................................................................................................................................... 302
Printouts
......................................................................................................................................................... 305
Summary......................................................................................................................................................... 305
Fitting.........................................................................................................................................................
the Cyclone Model (200) 306
Fitting.........................................................................................................................................................
the Nagesw ararao Fines Model (201) 307
References
......................................................................................................................................................... 307
Narasim ha-Mainza
..........................................................................................................................................................
Cyclone Model (221) 308
Description
......................................................................................................................................................... 308
Equations
......................................................................................................................................................... 308
Symbols......................................................................................................................................................... 311
Printout
......................................................................................................................................................... 312
Restrictions
......................................................................................................................................................... 313
Summary......................................................................................................................................................... 315
Fitting.........................................................................................................................................................
the Cyclone Model 221 315
References
......................................................................................................................................................... 317
Screen Models
..........................................................................................................................................................
(215, 230 & 235) 317
Kavetsky
.........................................................................................................................................................
Single Deck Screen Model (230) 317
Model Description......................................................................................................................................... 317
Model Equations ......................................................................................................................................... 319
2014 JKTech Pty Ltd

Single Deck.........................................................................................................................................
Model Printout 321
Symbols ......................................................................................................................................... 321
Know n Restrictions
......................................................................................................................................... 322
Parameter Fitting.........................................................................................................................................
the Screen Model 322
Regression.........................................................................................................................................
Model Parameters 324
References......................................................................................................................................... 325
Double .........................................................................................................................................................
Deck Screen Models (215 & 235) 325
Eff. Curves ..........................................................................................................................................................
(210, 211, 212, 213, 203 & 240) 325
Simple .........................................................................................................................................................
Efficiency Curve (210, 212) 325
Model_Description......................................................................................................................................... 325
Model Equations ......................................................................................................................................... 325
Fitting the Simple
.........................................................................................................................................
Efficiency Curve 326
Simple Efficiency.........................................................................................................................................
Curve Printout 326
Simple .........................................................................................................................................................
Efficiency Curve - Water & Fines (211, 213) 326
Model Description......................................................................................................................................... 326
Model Equations ......................................................................................................................................... 327
Fitting the Simple
.........................................................................................................................................
Efficiency - Water & Fines 327
Simple Efficiency.........................................................................................................................................
Curve (Model 211) Printout 328
Splined.........................................................................................................................................................
Efficiency Curve (Model 203) 328
Splined Efficiency
.........................................................................................................................................
Curve (Model 203) Description 328
Splined Efficiency
.........................................................................................................................................
Curve (Model 203) Equations 328
Fitting the Splined
.........................................................................................................................................
Efficiency Curve (203) 328
Splined Efficiency
.........................................................................................................................................
Curve (Model 203) Printout 329
Symbols for .........................................................................................................................................
Splined Efficiency Curve Model (203) 329
Know n Restrictions
......................................................................................................................................... 329
References
......................................................................................................................................................... 330
Eff. Curve ..........................................................................................................................................................
Variable D50c (Model 251) 330
Model .........................................................................................................................................................
Description 330
Model .........................................................................................................................................................
Equations 330
Efficiency
.........................................................................................................................................................
- Variable d50c (Model 251) Printouts 331
Symbols......................................................................................................................................................... 331
Know.........................................................................................................................................................
n Restrictions 331
Fitting......................................................................................................................................................... 332
References
......................................................................................................................................................... 332
Sim ple Com ..........................................................................................................................................................
biner Model (800) 332
Model .........................................................................................................................................................
Description 332
Symbols......................................................................................................................................................... 334
Model .........................................................................................................................................................
Limitations 334
References
......................................................................................................................................................... 334
2 Way Sim ..........................................................................................................................................................
ple Splitter Model (810) 334
Model .........................................................................................................................................................
Description 334
Symbols......................................................................................................................................................... 336
Model .........................................................................................................................................................
Limitations 336
References
......................................................................................................................................................... 336
2 Way Volum ..........................................................................................................................................................
etric Splitter Model (812) 336
Model .........................................................................................................................................................
Description 336
Symbols......................................................................................................................................................... 338
Model .........................................................................................................................................................
Limitations 338
References
......................................................................................................................................................... 338
Water & ..........................................................................................................................................................
Solids 2-Way Sim ple Splitter (813) 338
Model .........................................................................................................................................................
Description 338
Symbols......................................................................................................................................................... 340
Model .........................................................................................................................................................
Limitations 340
References
......................................................................................................................................................... 340
3 Way Sim ..........................................................................................................................................................
ple Splitter Model (870) 340
Model .........................................................................................................................................................
Description 341
Symbols......................................................................................................................................................... 342
Model .........................................................................................................................................................
Limitations 342
2014 JKTech Pty Ltd

Contents 9
References
......................................................................................................................................................... 342
2 Comminution
...................................................................................................................................
Models 342
Crusher..........................................................................................................................................................
Models (400 and 405) 343
Model .........................................................................................................................................................
Description (Anderson/Aw achie/Whiten) 343
Model .........................................................................................................................................................
Equations 345
Ore Breakage
.........................................................................................................................................................
Characterisation 346
Breakage
.........................................................................................................................................................
Distribution Parameter 346
Breakage
.........................................................................................................................................................
Parameters 348
Crusher.........................................................................................................................................................
Pow er Predictions 348
Crusher.........................................................................................................................................................
Model (400/405) Printout 351
Symbols......................................................................................................................................................... 351
Know.........................................................................................................................................................
n Restrictions 352
Fitting.........................................................................................................................................................
the Crusher Model 352
Regression
.........................................................................................................................................................
Modelling 354
Model .........................................................................................................................................................
Testing 354
References
......................................................................................................................................................... 354
Rod Mill ..........................................................................................................................................................
Model (410) 354
Model .........................................................................................................................................................
Description 355
Model .........................................................................................................................................................
Equations 355
Rod Mill
.........................................................................................................................................................
Model Printout 358
Symbols......................................................................................................................................................... 358
Know.........................................................................................................................................................
n Restrictions 359
Fitting.........................................................................................................................................................
the Rod Mill Model 360
References
......................................................................................................................................................... 360
Perfect Mixing
..........................................................................................................................................................
Ball Mill (Model 420) 360
Model .........................................................................................................................................................
Description 361
Model .........................................................................................................................................................
Equations 362
Ball Mill
.........................................................................................................................................................
Model Printout 365
Symbols......................................................................................................................................................... 365
Know.........................................................................................................................................................
n Restrictions 366
Fitting.........................................................................................................................................................
the Perfect Mixing Ball Mill Model 367
Table.........................................................................................................................................................
of Appearance Functions 367
References
......................................................................................................................................................... 369
SAG Mill..........................................................................................................................................................
(Model 430) 370
Model .........................................................................................................................................................
Description 370
Equations
.........................................................................................................................................................
- Particle Breakage 371
Equations
.........................................................................................................................................................
- Mass Transfer and Discharge 374
Prediction
.........................................................................................................................................................
of AG/SAG Mill Pow er Draw 376
SAG.........................................................................................................................................................
Mill Printout 380
Symbols......................................................................................................................................................... 381
Know.........................................................................................................................................................
n Restrictions 382
Fitting.........................................................................................................................................................
the Autogenous & SAG Mill Models 383
References
......................................................................................................................................................... 385
Size Converter
..........................................................................................................................................................
Model (490) 385
Introduction
......................................................................................................................................................... 385
Model .........................................................................................................................................................
Details 385
Fitting.........................................................................................................................................................
the Size Converter 385
Know.........................................................................................................................................................
n Restrictions 386
Variable ..........................................................................................................................................................
Rates SAG Model (435) 386
Introduction
......................................................................................................................................................... 386
Scaling.........................................................................................................................................................
Approach 386
Slurry .........................................................................................................................................................
Holdup Model 387
Variable
.........................................................................................................................................................
Rates Model 387
Effect .........................................................................................................................................................
of Key Parameters 390
Parameter
.........................................................................................................................................................
Fitting - Variable Rates Model 396
Variable
.........................................................................................................................................................
Rates for Simulation & Design 398
Know.........................................................................................................................................................
n Restrictions 399
Variable
.........................................................................................................................................................
Rates SAG Model Printout 401
2014 JKTech Pty Ltd

References
......................................................................................................................................................... 402
High Pressure
..........................................................................................................................................................
Grinding Rolls (Model 402) 403
Introduction
......................................................................................................................................................... 403
Model .........................................................................................................................................................
Structure 404
Breakage
.........................................................................................................................................................
Processes 405
Compressed
.........................................................................................................................................................
Bed Breakage Function 407
Throughput
......................................................................................................................................................... 407
Pow er .........................................................................................................................................................
Draw 410
HPGR .........................................................................................................................................................
Model Printout 413
Fitting.........................................................................................................................................................
the HPGR Model 414
Scaling.........................................................................................................................................................
the HPGR Model 415
Know.........................................................................................................................................................
n Restrictions 417
Nomenclature
......................................................................................................................................................... 417
Acknow .........................................................................................................................................................
ledgements 418
References
......................................................................................................................................................... 418
Size Degradation
..........................................................................................................................................................
(Model 480) 419
Introduction
......................................................................................................................................................... 419
Model .........................................................................................................................................................
Structure 419
Degredation
.........................................................................................................................................................
Model Printout 421
Fitting.........................................................................................................................................................
the Degredation Model 421
Know.........................................................................................................................................................
n Restrictions 421
Index 422
2014 JKTech Pty Ltd

Foreword 11
JKSimMet V6.0
Steady State Simulation Software for Comminution and

Classification Operations in the Mineral Processing Industry
2014 JKTech Pty Ltd

Part
I
Overview 13
1 Overview
Overview This section provides a broad overview of the JKSimMet program and its
capabilities. It includes a chapter on the hardware and operating system
requirements plus some information about program structure and the
included process models.
1.1 About JKSimMet V6
About this This chapter covers some of the more general information relating to
Program JKSimMet V6.
1.1.1 General Capabilities
General JKSimMet V6.0.1 is a comminution circuit simulator that runs on the Intel
Capabilities Pentium family of computers under Windows 8, Windows 7, Vista or XP. It
gives engineers the ability to design and simulate comminution circuits. More
specifically, it allows engineers to:
create a circuit using a graphics based interface;
enter model and stream feed data;
simulate the circuit;
view the results.
Main Features JKSimMet is intended for use by plant engineers not necessarily skilled in
either modelling or simulation. For that reason, it has been written to operate
in a user-friendly manner. The user selects options from menus or lists and
builds flowsheets on the screen. This removes the need for specialized
computer skills while maintaining flexibility.
The main features of JKSimMet are:
graphical user interface;
flowsheet specified interactively on the graphics screen;
a wide range of models that can be selected from the built-in library;
JKSimMet will also in the future have the ability to add new user-
defined comminution circuit models to the program;
model parameters that can be fitted by the user;
simple data transfer between JKSimMet and other programs such as
MS Excel for data preparation and manipulation.
JKSimMet has been designed primarily as a powerful aid to engineers. The
principal application of JKSimMet for many users will be to carry out process
analysis and optimization of existing circuits.
JKSimMet is also extremely useful for conducting conceptual design studies,
where the purpose is to assess the suitability of different flowsheets to achieve
a desired performance objective.
Version 6.0.1 - March 2014

1.1.2 How the Program Works
About JKSimMet JKSimMet is a general-purpose computer software package for the analysis
and simulation of mineral processing operations. The package is designed to
service the diverse needs of plant and development metallurgists, who need
modern process analysis techniques to characterise plant behaviour and
design engineers, who require accurate process simulation models to facilitate
the evaluation of various plant designs.
JKSimMet integrates all tasks associated with optimisation, design and
simulation, including the storage and manipulation of models, data and
results, within one package. It is fully interactive and operates with high-
resolution colour graphics capabilities. These graphics facilitate the display of
detailed plant flowsheets and accompanying information.
Building a The engineer using JKSimMet proceeds through a series of tasks:
Simulation building a flowsheet diagram of the processing plant on the computer
Model screen
assigning characteristics to the various process units and material flows
of the simulation model
simulating the flow of materials through the simulated plant (or a
subsection of the plant).
reviewing and presenting the results.
Once a model has been built, the engineer can alter the design and change the
parameters as required until a satisfactory design has been achieved, or an
optimum operating condition is arrived at, in the case of an existing plant.
The results may be graphed, printed in summary form and stored on hard
disk or archived to a CD or DVD. The results can also be transferred to other
suitable programs via the clipboard.
Simulation is based on the ability to build a model that is representative of a
real system. The behavior or characteristics of the model must be similar to the
characteristics of the real system. In order to build the model the engineer
must analyze the overall plant and break it down into a number of sections
(circuits), in such a way that these circuits are easily understandable and
identifiable. The circuits are interconnected to form the total system.
The data structure within JKSimMet V6.0.1 consists of the following:
Project A project is the container in which the user stores all of the data related to a
particular body of work. The project contains one or more flowsheets (circuits)
and the associated equipment units and stream data.
Flowsheet A flowsheet is a graphical representation of a complete processing plant or a
discrete section of that plant. The flowsheet can have internal recirculating
streams. However, if a stream recirculates to a previous section of the plant
that has been represented using a separate flowsheet, then this stream would
be treated as an output stream from the current flowsheet.
A flowsheet may be increased in size to represent a large, complex circuit.
Either the complete flowsheet or selected sections of it may be simulated, mass
balanced or model fitted.
Note that this capability to select items for inclusion in simulation, modelling
or mass-balancing replaces the circuit-oriented flowsheets required by the
About JKSimMet V6 Version 6.0.1 - March 2014

Overview 15
DOS versions of JKSimMet.

Equipment and Version 5 introduced a new concept. Each flowsheet equipment icon
Ports represents a discrete processing stage in your flowsheet. It can represent a
single equipment item or several identical items in parallel. Each icon (or
equipment unit) will have a single combiner or feed port plus one or more
product ports. These feed and product ports facilitate the connections (by
means of streams) between the various equipment icons on your flowsheet.
The reason for this change in structure was to allow for the future
development of a dynamic simulator. This approach also allows for pipes and
conveyors to be modelled as pieces of equipment.
Units and Streams still provide a convenient way of thinking about
flowsheets and for practical purposes, the terms equipment and ports can be
used interchangeably with units and streams.
Units A unit is any type of unit process such as a ball mill or a hydrocyclone
(Equipment classifier. JKSimMet allows you to select the appropriate unit from an
Items) extensive list of processing unit types 18 and to display their pictorial
representations (icons) on the screen. These units are identified within the
system by a name, which is specified by the user. You can also specify the
orientation of the units (i.e. whether the feed port is to the left and product
port(s) to the right or vice versa) and the position of units on the flowsheet
diagram.
Streams A stream is a description of any flow of material. The description is usually in

(Connectors terms of solids flow rate, water flow rate and particle size distributions (plus
between Ports) assays for mass balancing, if required). The stream connections between units
are made by drawing lines connecting the appropriate feed and product ports
on the units. JKSimMet automatically checks to ensure that the stream
connections are valid. Each stream or port is named by JKSimMet as a
combination of its equipment name and port name. The user can edit the
equipment names as required but the port names for each piece of equipment
are fixed.
Specifying Once the flowsheet has been drawn the engineer must provide data for each
Flowsheet Data process unit and also provide raw data in the form of flows and size
distributions for the streams in the circuit. This is done by stepping through
the process units and the streams one-by-one, adding circuit data and
building up an annotated description of the modelled processing circuit on
the screen. The unit data for the process equipment may come from previous
experience, from a design database or they may be derived from plant data.
The sizing component of the stream data can be entered in one of three size
distribution formats, depending on the preferences of the user. The engineer
can review or correct these data at any time after making the initial entries.
Flowsheet Once the flowsheet has been specified and the required unit and stream data
Simulation have been entered, the simulation can be run. The results of the simulation are
stored and can be displayed on the screen or printed as required. The
following options are available for examining the results:
view the detailed data in the equipment and port data windows,
view summary data for equipment and ports via data information
blocks,
view summary data in overview tables,
Version 6.0.1 - March 2014 About JKSimMet V6

view the size distribution data plotted as graphs on the screen,

generate configurable reports at summary or detailed level for export to
MS Excel or the clipboard,
copy-and-paste the data into other programs (eg. MS Excel) via the
clipboard
print the flowsheet to a Windows compatible printer or to a file.
Recorded data include:
flow rates of solids and water
percentage solids
pulp densities
full particle size distributions.
After analysis of the results, the user can alter the flowsheet, adjust the
equipment parameters or port data and repeat the simulation process until a
satisfactory result is obtained.
Flowsheet A new capability that was introduced with V5 is that a subset of the flowsheet
Selection may also be selected for simulation, mass balancing or model fitting.
1.1.3 JKSimMet Simulation
Available JKSimMet performs steady state simulation of comminution and related

Process Models operations. Process models of the following units are available:
particle size reduction devices e.g. crushers, SAG mills, ball mills;
particle size classification devices e.g. hydrocyclones and screens
separators e.g. 2 and 3 product splitters;
combiners e.g. pump, pump sump, sump;
stream source e.g. feeder, water feeder;
stream sink e.g. final product.
New process models can readily be incorporated into JKSimMet by JKTech.
This is done by defining their characteristics as steady state models and
creating an icon for each to represent them on the screen.
Simulation It is important at the outset to understand what JKSimMet will and will not
Limits do. JKSimMet will predict the performance of a circuit within the limitations of
the data and the models selected. JKSimMet will not determine of its own
accord the best circuit, the best operating conditions or the changes that are
required to ensure that a circuit operates efficiently. JKSimMet does not allow
process constraints to be specified.
Provided that the data used in the process models are relevant to the ore being
studied, JKSimMet can be used to generate detailed design information. Until
experience is gained in detailed design studies using JKSimMet, it is
recommended that design tasks be carried out in consultation with JKTech.
Simulation The operator has an essential role in deciding the conditions to be simulated
Constraints and in critically assessing the simulation predictions. This is a deliberate
result of the design philosophy of JKSimMet, which places considerable
About JKSimMet V6 Version 6.0.1 - March 2014

Overview 17
emphasis on the process experience and knowledge of the operator.
This point is amplified later under the topic JKSimMet Constraints 135 , and
the reader is strongly advised to keep these points in mind when using the
system for simulation analysis.
1.1.4 JKSimMet Mass Balancing
JKSimMet enables users to mass balance comminution circuits on both a size

and assay basis simultaneously. It allows engineers to:
create a circuit using a graphics based interface;
enter stream data and calculate appropriate standard deviations;
mass balance the circuit;
view the results.
Mass Balancing JKSimMet will mass balance experimental data to produce a consistent data
Limitations set. It will not make bad data better, but will show the quality of the data and
where more care is needed in collecting the data.
1.1.5 JKSimMet Model Fitting & Analysis
JKSimMet allows users to perform many areas of data analysis within the
program itself, rather than using external spreadsheet based applications. A
combination of these data templates enables fitting of various model
parameters to be performed.
Model Fitting JKSimMet will model fit balanced or experimental data to produce a set of
Limitations model parameters. It will not tell the user if these values are in typical ranges
or whether the values are realistic. Such judgements rely on the experience of
the user, or on communications with specialists at JKTech.
1.2 Hardware & Operating System Requirements

Successful operation of JKSimMet requires the following:
Computer Intel Pentium PC (or other fully compatible computer) with all of the
System following:
Processor speed 1 Ghz recommended;
512 MB memory minimum 1 GB recommended;
CD-ROM Drive;
2 GB or larger fixed disk drive (with 100 MB free space);
A SVGA or fully compatible equivalent graphics controller
(minimum) Recommended an XGA graphics controller;
A suitable monitor - 15 inch minimum, 17 or 22 inch recommended.
Printer An MS Windows 7, Vista or XP compatible printer.
Version 6.0.1 - March 2014 About JKSimMet V6

Operating MS Windows 7, Vista or XP

System
Keyboard Standard keyboard.
Pointing Device Microsoft Mouse or functional equivalent.
Equipment A wide range of equipment combinations have been successfully tested, but if
Tested in doubt JKTech will be pleased to comment on a particular combination.
1.3 Cautionary Tales
Backup It is recommended that a backup copy of the files be made to CD. If the
JKSimMet JKSimMet CD-ROM is damaged, a new CD-ROM can be acquired from JKTech
Installer by notifying them and quoting the version number of the copy of JKSimMet.
Learn by JKSimMet is a program that is rich in capabilities and easy to operate. The
Example simplest way to become familiar with the techniques of using JKSimMet and
its capabilities is to follow a structured example. Such an example is provided
with the package. This example assumes no experience with JKSimFloat and
leads the user through a session exploring flowsheet creation, data input and
the use of the simulation features of the program.
It is recommended that some time be spent working through the example
provided (starting with the topic Building a New Project 59 ), until the user is
confident that JKSimMet can be applied to different problems. More detailed
reference information on all aspects of the program is outlined under the
section Using 131 JKSimMet .
Backup Work Remember to save the work to the hard disk regularly, for example as each
section of data (say a flowsheet or a data set) is entered. Usually earlier
versions will be overwritten. If this is done regularly, then when (not if), there
is a power failure or other mishap, the work up to the last save will be on the
hard disk; it will not have been irretrievably lost. There is an auto save
function incorporated in the program that runs every 3 minutes, however
regular manual saving is also recommended.
1.4 JKSimMet Structure
Program JKSimMet consists of the following software modules:

Structure Main Program;
Supporting DLLs;
Program Database;
Project Databases.
1.5 Available Models

The unit models currently available for simulation include the following:
Available Feeder Single deck screen
Models Stockpile Double deck screen
Bin Autogenous mill
Hardware & Operating System Requirements Version 6.0.1 - March 2014

Overview 19
Pump sump Semi-autogenous mill

Sump Rod mill
Splitters (2 way & 3 Ball mill
way)
DSM Screen
Gyratory crusher
Hydrocyclone
Two rolls crusher
Spiral classifier
Jaw crusher
Rake classifier
HPGR crusher
Thickener
Degradation model
Custom Models JKTech can be contacted to add other models to JKSimMet.
1.6 JKSimMet Support
Documentation Three levels of documentation are supplied:

User manual.
Help files.
Model instructions (these are included as the final section in both the
manual and the help files)
Courses JKTech offers regular courses in simulation technology at various locations
around the world. Contact JKTech for details.
Extended Continuing support is provided by JKTech either through a Maintenance
Support Agreement, telephone or facsimile contact, or through visits by JKTech to your
site.
E-mail Help JKSimMet project files can be sent electronically to JKTech via the Internet for
assistance. Send files to help@jktech.com.au.
Updates Updates and bug fixes will be supplied for one year from date of installation/
supply and are available under a maintenance agreement thereafter.
Restrictions A standard licence for the use of JKSimMet permits operation of the software
on a single workstation only. Extension of the licence for additional
workstations at a single site is available for a fee.
Distribution of copies of JKSimMet to other company sites is not permitted.
Additional copies for other sites are available at reduced cost.
Hardware Key JKSimMet will not operate without a hardware key (also called a dongle). The
(Dongle) standard key is suitable for a USB port. One working key and one spare key
are supplied with each software licence.
Version 6.0.1 - March 2014 Available Models

Part
II
Changes from Version 5 21
2 Changes from Version 5
JKSimMet V6 is based on the JKSimFloat architecture and so presents a new

experience and new features to the user, while retaining the underlying
JKSimMet V5 functionality.
2.1 Summary of Main Changes
Main Changes In summary the main differences between version 5 and version 6 are:
Definition of Sieve Series of up to 40 sizes and Survey Data entry 28
Flexible flowsheet drawer 31
Configurable Stream Overview 36 including data entry

Simulation Manager 38 for running simulations in batch mode
User editable Info Blocks 41
Size x Assay mass balancing 44
2.2 Precautionary Notes on Main Changes
Overview JKSimMet Version 6.0 represents a major shift in many respects from version
5. Version 6 is available free of charge to clients who hold maintenance
agreements and will be available to other users for an upgrade fee.
The most significant change is that JKSimMet has been moved from the old
Visual Basic/Fortran platform to the more modern C++ platform that is used
by JKSimFloat. Thus, the look and feel of JKSimMet V6.0 is now quite different
from older versions and is much more like JKSimFloat. This section of the help
file has been adapted from two stand-alone documents that were prepared to
guide users through their early use of the new version.
Increase from 30 Until now, the maximum number of size fractions available was 30. This
to 40 Size limited the range of equipment that could be handled in a single flowsheet.
Fractions The range available in a series was from 2.0 m to 0.086 mm. With the extra
size fractions, that range is now increased to 2.0 m to 0.003 mm or 10 m to
0.014 mm. It is now possible to use as many as 40 size fractions in the
internal series.
Single Master Previous versions of JKSimMet allowed the user to specify different size
Sieve Series distributions for each stream in the flowsheet. Internally, these were all
converted to the same series but this was not easily visible to the user. This
flexibility caused problems in mass balancing, where the same sieve series is
required for all streams and for reporting. These problems have been overcome
by using a single master series for all streams in a flowsheet. The user is first
allowed to specify the master series for the project. Once this is done, survey
sizing data obtained using any other sets of sieves can be entered and the
program will then automatically convert such data into equivalent data for
the master sieve series.

Small The two changes discussed above, 40 Size Fractions and the Master Sieve
Differences in Series may mean that simulation and model fitting could give slightly
Simulation and different results in V6.0 compared with V5.3. Our testing has shown that
Fitting Results these differences are insignificant except for the HPGR model see next
section.
HPGR Model The internal structure of the HPGR model means that the change from 30 to 40
internal size fractions makes significant differences to the simulation results.
Therefore, it is necessary to refit the HPGR model in V6 before conducting any
simulations.
Conversion of V6.0 allows JKSM5 extension files to be opened and converted to JKSMX files.
Files from V5 to The conversion process creates a new file and leaves the old file untouched.
V6 The flowsheets created by the conversion process may require some work to
improve them aesthetically. Extensive testing has shown that the converted
files respond correctly throughout the full range of functions, when used in
V6. However, there is always the possibility of issues that have escaped
detection during testing, so please dont hesitate to contact JKTech if you find
any items that you are concerned about.
Keep in mind that after any conversion process, it is always important to
check the results carefully.
Note that the conversion process does NOT convert component data. This will
be implemented in the next release.
Also, it is not possible to convert .JKSMX files back to .JKSM5 format.
Mass Balancing Apart from the look and feel, one of the major changes is to the mass balance
system. The old JKMBal system previously used could handle only one
dimensional data size distributions or assays. The new JKMultiBal system,
taken from JKSimFloat, is completely new for JKSimMet and uses different
algorithms that can handle size by assay data. However, because the
algorithms are different, the results may be different. If the data are good
quality and require little adjustment, the results of balancing in the two
versions will be close. However, if the data are of lower quality, the results
from the two versions may well be different. There is no right answer in
mass balancing and the results will be heavily influenced by the users choice
of starting estimates and standard deviations. Please note that in JKSimMet
V6.0, a zero value for standard deviation is not permitted. When converting
from V5 files, all 0.0 SD values will be converted to missing.
Installation Installation of JKSimMet V6.0 will uninstall any older JKSimMet versions.
After installation of V6.0, double clicking on a .JKSM5 file will open V6.0 and
instigate the conversion process.
Contacting Please feel free to contact JKTech if you have any questions or problems with
JKTech JKSimMet V6.0. The best contact is via Help@jktech.com.au.
2.3 Toolbar Changes
Main Toolbar A screen grab of the main tool bar is shown below, with annotation to show
the names of the buttons. These names are indicative of their functions and
are in fact the same as the tool-tips that will appear when you hover the
mouse over these buttons.
Note that tool-tips for the buttons will be switched on by default when you
Precautionary Notes on Main Changes Version 6.0.1 - March 2014

first open the program. They can be switched off if required. This is done by
selecting Tools from the main menu, then Customize. For further details on
this, see the Tools Menu topic 152 .
Side Bar As indicated in the annotations to the screen grab above, the three buttons for
entering the main areas of JKSimMet functionality (viz. Balancing, Fitting and
Simulation), were moved after this screen shot was taken. They have now
been transformed into large buttons in a separate toolbar located in the left
panel, just above the flowsheet list. An annotated screen shot of this toolbar is
shown below.
Note that many of the screen shots in this help file were taken before this
change in the toolbar structure took place. These shots have generally not
been updated where the difference was considered irrelevant to the user's
understanding of the topic.
Flowsheet The new version of the flowsheet tool-bar is shown below, again annotated to
Toolbar indicate the names of the buttons.
2.4 Creating Projects

After opening JKSimMet V6 the user may create a new V6 project, open an existing
V6 project or open an existing V5 project from the file menu.
Version 6.0.1 - March 2014 Toolbar Changes

Selecting New Project will open a window in which the user may enter the file
name for the new project and save it (a default file name is supplied).
If the user chooses Open Project they will be presented with a window giving
them the option to open either a V5 or V6 project:
Creating Projects Version 6.0.1 - March 2014

If the user chooses to open a V5 file they will be presented with this prompt:
Version 6.0.1 - March 2014 Creating Projects

Clicking Save will initiate the import process. Note that the process of
converting the V5 file to V6 leaves the V5 file unchanged, it creates a new V6 file
and transfers the flowsheet and data into the new file.
If the V6 file name already exists the user is asked if they wish to overwrite the
existing file. Choosing no will return them to the save prompt screen to enter or
choose another file name.
On return the user will be asked if they wish to use V5 style flowsheet icons:
After clicking save the user will be presented with a window to choose or
modify the sieve series to be used as the initial Master series:

The user is presented with all unique sieve series defined in the V5 flowsheet to
choose from. The default master series is copied from the feed in the V5 project
with material in the coarsest size fraction. The user may modify this series as they
choose. Clicking OK will generate the project and the user is advised that they
may need to re-run simulation:
If the user creates a new project they will be presented with a blank flowsheet:
Version 6.0.1 - March 2014 Creating Projects

If they open a V5 or V6 project the first flowsheet in the project will be opened:
2.5 Sieve Series and Survey Data Entry
Master Sieve A fundamental difference between JKSimMet V5 and V6 is the introduction of the
Series concept of a Master sieve series. In V5 the user could define individual sieve
series for each port for entry of experimental data and viewing of simulated,
fitted and balanced results. In V6 the user defines as many sieve series for
survey data entry as they need, and a single Master series for the entire circuit
to view and edit data thereafter. The user may define up to 40 sizes in each sieve
series in V6, compared with 30 sizes in V5.

The sieve series definition window may be opened from the FlowSheet menu or
the toolbar:
The user clicks the Insert button ( ) to insert a new sieve series. They may
then name it appropriately for the part of the circuit the sieve series relates to.
After this they enter the relevant sieve series, either directly, via copy and paste,
or entering a new top size and generating a new root 2 series by clicking the
Root 2 button ( ). The new series will then be available for selection against
appropriate streams in the Stream section.
Version 6.0.1 - March 2014 Sieve Series and Survey Data Entry
After creating and allocating sieve series against appropriate streams, the user
may open the Survey Data window and enter their experimental data obtained
through plant surveys.
The user may choose to view the streams for the whole circuit (All Sieves) or
for specific parts of the circuit as defined by the specific sieve series selected.
They may then choose to view the stream data as any of the defined sieve series
(View As), but will only be able to edit the data for the streams that have been
assigned that sieve series. In addition they may view the data as % Retained,
Cum % Retained or Cum % Passing, and choose the interpolation method for
translating the survey data into the global Master sieve series.
If the user wishes to create extra sieve series they may click the Edit Sieve
Series button to load the Sieve Series Overview, make their changes then return
to the Survey Data window and re-make their selections. After entering the
survey data and choosing the appropriate interpolation method, the user may
click the Transfer button to translate the survey data into the Master series for
all streams. They will be prompted to confirm the action before proceeding as
existing data will be overwritten:
The survey data is stored so the user may later modify and re-translate the data
into the master series.
Sieve Series and Survey Data Entry Version 6.0.1 - March 2014
2.6 The New Flowsheet Drawer

The new flowsheet drawer works in two modes locked and unlocked. When
the flowsheet is locked adding and removing icons, pasting items, moving items
etc is not possible, but access to the equipment models and stream data
windows is enabled by double clicking the appropriate icon or stream. When
the flowsheet is unlocked the user may create and modify the flowsheet by
selecting equipment icons from the tree view to the left of the flowsheet and drag
and drop them directly on to the flowsheet, then connect them by clicking and
dragging between ports. The new flowsheet drawer is more flexible than the V5
Version, including the ability to route streams exactly as the user wishes, and
have complete control over the placement of icons and setting of display
features (colour, size etc). There is also an automatic labelling feature for units
and streams.
By default the flowsheet drawer works with vector graphic based icons, unlike
the bitmap icons used in V5. However at the point where a new project is being
created, the user may choose to have it use the bitmap icons (V5 style)
throughout all its flowsheets. Note however that once this initial selection has
been made, you will not be able to switch icon styles for the project in question.
For further information on use of the flowsheet drawer, refer to the section
Building and Manipulating a Flowsheet 177 .
2.7 System Properties

The System Properties in V6 serve 2 purposes as a place to set properties that
are global to the project, and to define the elements (components in V5) that
may be used in mass balancing. System Properties are accessed from the
Flowsheet Menu or the toolbar:
Version 6.0.1 - March 2014 The New Flowsheet Drawer

The first selection in the System Properties is the Elements. The user defines the
Elements and display units (% or g/t) used in mass balancing:
The bulk Solids and Liquid SG used in simulation and the default global size
markers used in each stream window are defined in the Miscellaneous System
Property.
System Properties Version 6.0.1 - March 2014

2.8 Accessing Models

In V5 double clicking an icon takes you straight to the selected model
window. In V6 when the user double clicks on an equipment unit they are
first presented with a window that allows them to change model selection for
the unit or open the feed or product stream windows for that unit.
When the user clicks on the arrows next to the model selection they are taken
into the model window, with a display very similar to V5 and identical
parameters.
Version 6.0.1 - March 2014 Accessing Models

2.9 Equipment Manager

In addition to individual model viewing/data entry, V6 provides the
Configurable Equipment Manager that allows the user to construct summary
views for all equipment using a selected model.
This allows flexibility in choosing which parameters to view/edit for a selected
model. To access the Equipment Manager choose from the Flowsheet menu or
the toolbar:
The user may construct an Equipment Overview for each model used in the
circuit, insert columns and define the parameters to be displayed by clicking in
the top cell of the column.
This will invoke the selection box from which they select the parameter for
display, after which they can then view or edit data for this parameter. In
addition the Overview tables can be printed, copied to the clipboard, or
exported to Excel.
For further information on this subject can be found in the topic Configurable
Equipment Manager 153 .
Equipment Manager Version 6.0.1 - March 2014

2.10 Viewing and Entry of Stream Data

JKSimMet V6 replaces the concept of ports with streams. In JKSimMet V6 the
user enters and views stream data by double clicking directly on streams, unlike
V5 where they right click on a unit and choose the port. This displays a familiar
window showing Totals and Sizing data:
The user may choose which data types they view in the columns for all streams by
clicking the Data Type View button.
An additional feature is the SD Calculator, which allows the user to make bulk
changes to SDs for a given stream or multiple streams, and for a single data point
or multiple data points.
Version 6.0.1 - March 2014 Viewing and Entry of Stream Data

Some further information on the SD Calculator is contained in the topic Viewing

Individual Stream Data 94 .
2.11 Configurable Stream Overview

Like V5, JKSimMet V6 provides an Overview window to view summary stream/
port data. Unlike V5, the V6 Overview provides complete flexibility in selection
of data to view, and where the data is user editable (e.g. experimental) it can be
modified in this window. To access the Configurable Stream Overview choose
from the Flowsheet menu or the toolbar:
The user may construct as many Stream Overviews as required, but is provided
with several defaults displaying various data. The user may insert columns and
define the data to be displayed by clicking in the top cell of the column. This will
invoke the selection box from which they make their selection, after which they
can then view or edit the data. In addition the Overview tables can be printed,
copied to the clipboard, or exported to Excel.
Viewing and Entry of Stream Data Version 6.0.1 - March 2014

For further information refer to the topic Configurable Stream Overview Window
157 .
2.12 Simulation Changes

The V6 simulation window may be accessed from the Flowsheet menu or the
toolbar:
The V6 Simulation window largely replicates the functionality V5 implements

in three tabs:
Version 6.0.1 - March 2014 Configurable Stream Overview

V6 has intuitive equipment and stream selection via the check boxes or by
clicking on equipment and streams in the flowsheet, and has the ability to create
multiple select lists which like V5 are available in model fitting. For further
information on Simulation refer to the manual or help files.
2.13 Simulation Manager

The Simulation Manager allows users to run a batch of simulations to observe
the effect of adjusting unit operating parameters in each simulation. The
simulation manager may be accessed from either the FlowSheet menu or the
toolbar:
The method for selecting parameters and calculated results to view is identical
to the Equipment Manager. The user may specify absolute or % change to the
original data values for each simulation.
Simulation Changes Version 6.0.1 - March 2014

For further information on the Simulation Manager refer to the topic Working
with the Simulation Manager 101 .
2.14 Changes to Reporting

The reporting function in V6 is similar to V5, but there is no report preview or
ability to print reports directly from the program. Instead the report is exported
directly to Microsoft Excel and opened for viewing or printing. Reporting may
be accessed from either the FlowSheet menu or the toolbar:
In addition, to avoid the need to modify existing reporting templates when

model selections change, each units data occupies a fixed maximum number of
rows in the Excel worksheet.
Version 6.0.1 - March 2014 Simulation Manager

For further information on the Reporting refer to the topic Using the Reporting
Feature 226 .
2.15 Changes to Graphing

The Configurable graphing function in V6 is similar to V5, but the selection and
graph display are contained in one tabbed window and there is no ability to
print graphs directly from the program. Instead they may be copied to the
clipboard and pasted to other applications for viewing and printing. The
Graphing may be accessed from either the FlowSheet menu or the toolbar:
Changes to Reporting Version 6.0.1 - March 2014

The streams or equipment to display graphs for are selected in the top row. The
graph format options can be set by clicking the Format button. After all
options are set, the user selects the Graph tab to view the generated graph:
The user may also change the format options in this tab, and copy the graph to
clipboard for use in other applications.
For further information on the Graphing refer to the topics Plotting the Size
Data Graphs 265 in the Mass Balancing section and Presentation of Model
Fitting Results 287 in the Model Fitting section..
2.16 Changes to Info Blocks

The Flowsheet Info Blocks function in V6 is an enhanced version of V5. Users
may choose any equipment or stream parameters/data to view in the Info Blocks,
Version 6.0.1 - March 2014 Changes to Graphing

and where the data is user editable (e.g. experimental) it can be modified in the
Info Blocks. The Info Blocks may be accessed from either the Flowsheet menu or
the toolbar:
The user selects the number of parameters then clicks on each cell to define the
parameter or data to be displayed:
Changes to Info Blocks Version 6.0.1 - March 2014

The user then selects the streams or equipment to apply the info blocks to and
clicks Add Info Block. For further information on the Info Blocks refer to the
Information Blocks 158 topic in the section Using JKSimMet .
2.17 Model Fitting Changes

The Model Fitting Window in V6 consolidates the five tabs in the V5 window, but
provides the same functionality. Unlike V5, the parameters available for fitting are
not defined through the jkp database; rather the selection is made within the
Model Fit window. The Model Fitting may be accessed from either the Flowsheet
menu or the toolbar:
Each model fit case is represented by a user defined circuit selection. Unlike V5,
each model fit case in V6 is associated with unique parameter selection lists
they are not shared between model fit cases. Also it is not possible to fit model
parameters for equipment that is not in the selected circuit for the fit case.
Version 6.0.1 - March 2014 Changes to Info Blocks

Master/Slave fitting of multiple data sets is controlled from this window. For
further information on model fitting refer to the Model Fitting 272 section.
2.18 Mass Balancing Changes

The Mass Balance window in V6 is quite different from V5 but provides
essentially the same functionality, including the ability to balance flows, sizes
and assays across the whole circuit or selected parts of the circuit. The Mass
Balance window may be accessed from either the Flowsheet menu or the toolbar:
Model Fitting Changes Version 6.0.1 - March 2014

In addition, V6 provides the ability to balance assays within size classes as well
as total assays and sizes. Unlike V5, the user does not balance everything at
once. The suggested process to balance a whole circuit:
1. Make selections for all required equipment, streams, sizes and elements.
2. Set TPH Solids and Sizes to Adjust and all other components to unused,
then run the balance.
3. Then set the TPH Solids and Sizes to Fixed, the TPH Water to Adjust and
% Solids to Influence and run the balance again.
4. Set the TPH Water back to unused and the Elements to Adjust and run
the balance again.
5. Set the Elements to Fixed and Size x Element to Adjust and run the
balance a final time.
For further information on mass balancing go to the Mass Balancing 230 section.
Version 6.0.1 - March 2014 Mass Balancing Changes

Part
III
Installing JKSimMet 47
3 Installing JKSimMet
Installing This chapter provides installation instructions for JKSimMet V6.

JKSimMet
3.1 Contents of the Package
Package The JKSimMet system comes either as a package containing two HASP keys
Contents or dongles and as a download from the JKTech website. This manual is also
available as a download.
Paper copies of the manual and the JKSimMet pdf file are on CD and can be
supplied on special request.
The manual (and help files) contain information on the installation and
maintenance of the JKSimMet software, a tutorial guide for first-time users and
a comprehensive reference chapter (Using JKSimMet 131 ).
3.2 JKSimMet Installation
Hardware / To be certain of a successful installation and of a system that works efficiently

Software once installed, you should check that your physical system and operating
Requirements system comply with the requirements outlined under the heading Hardware
and Operating System Requirements 17 .
User Privilege As JKSimMet requires several device drivers the user must have full
Required administrator privileges to install or uninstall JKSimMet.
JKSimMet V6 JKSimMet V6 is a standard Windows program. The steps required to install the
Installation program are as follows:
Step 1 If you have an earlier version of JKSimMet on your computer, make a

backup copy of any existing projects
Step 2 If you have JKSimMet V5 installed already on your computer, go to:
Control Panel
Select Add/Remove, and
Select JKSimMet V5
Uninstall
Step 3 Ensure that the hard lock key is installed in a USB port in the
computer as this interferes with the installation of the hard lock
drivers. If you have downloaded the program from the JKTech web
site, double click on the appropriate .exe file. This file will have a
name that is unique for your installation. It may be located in a
Downloads directory or wherever else you may have elected to store
it on your hard drive following the download.
Step 4 If your copy of JKSimMet V6 is on a CD-ROM, insert the disk into
your CD drive. The install program should auto start, alternatively
double click on the installation .exe file. This launches the
InstallShield Wizard. Follow the instructions on the screen. The
install program will guide you through the setup process. If you are

installing from a CD and it does not auto start, go to the Windows

Start Menu, select RUN and then Browse to find the appropriate .exe
on your CD Drive.
Step 5 The default location for the installation of JKSimMet is:
<C:\Program Files(x86)\JKTECH\JKSimMet 6.0> for 32 bit
computers
<C:\Program Files\JKTECH\JKSimMet 6.0> for 64 bit computers
Click on the "Change" button if you wish to install the program in a
different location (see below).
Step 6 Once the installation is complete, you must then plug your
protection key (dongle) into one of the USB ports of your computer or
the parallel printer port (as appropriate), in order to allow operation
of the program. Note that the protection key(s) provided with your
copy of V5.0 or V5.1 will also work with V6.
Note: The install program may also ask to update your HTML help file viewer.
This will allow full use of JKSimMet V6 help.
If the default If the default path is not the desired installation location, click on the Change
path is not button in the InstallShield Wizard and follow the instructions to select a new
chosen for location.
installation
Non-English If a non-English version of windows is installed, the spelling of the install path
Versions of may be different. If this is the case, you must modify the install path to the
Windows correct spelling using the Change button.
Installing As part of the installation process, a shortcut to the program will be placed on
Additional your desktop. In Windows 7 you can also pin a shortcut to your Start Menu or
Shortcuts to your Taskbar at the bottom of the screen. Left-click on the Start button at the
bottom left of the screen, then on Program Files and then on the JKSimMet V6
JKSimMet Installation Version 6.0.1 - March 2014

Installing JKSimMet 49
folder within the Program File sub-menu. Now right-click on the item JKSimMet
V6. When the right-click menu appears it will look similar to the illustration
below.
Making an
accessible
Shortcut
From here you can select to either Pin to Start Menu or Pin to Taskbar. You may
find one of these shortcuts is more convenient, especially if you are going to be
using the program regularly.
Version 6.0.1 - March 2014 JKSimMet Installation

Part
IV
Learning JKSimMet 51
4 Learning JKSimMet
Learning This section (Learning JKSimMet) is designed primarily as a tutorial exercise.

JKSimMet It is anticipated that the first time user of JKSimMet might spend two to three
hours working through this section step by step. In this way the new user
should gain sufficient confidence and knowledge to begin using the system in
earnest.
The first main heading is JKSimMet Basics. This chapter contains a general
description of the procedure for building a simulation model. It also contains
a list of all the available equipment items and the process models 52
associated with each of them. This is followed by some basic instruction on
operating the software under the topics Mouse and Cursor 57 and JKSimMet
Display 58 . The topics that follow then take the user step-by-step through
the procedure for creating a new project in order to build a simulation model
for a flowsheet. Techniques that apply for the manipulation of an existing
project are covered in this section under the main heading Working with an
Existing Project 99 .
Given the nature and design of JKSimMet, the user will very quickly be able to
learn the basic operating techniques. It is assumed that the user already
understands the techniques of mineral processing simulation and also has
some appreciation of the standard features of the MS Windows 7, XP/
NT/2000 interface.
Typical Users of JKSimMet is a general purpose computer software package for the simulation
JKSimMet of comminution plant operations. The package is designed to service the
diverse needs of:
Plant and Development Metallurgists - to apply modern process
analysis techniques to characterize plant behaviour.
Plant Operators - to understand the effect of day to day changes in
circuit operation on metallurgical performance.
Researchers and Academics - to test and evaluate new process
models.
Consultants - to develop and demonstrate process optimization and
design for client operations.
Once familiar with the program, you will be able to use the JKSimMet
simulation engine to determine the metallurgical performance of your
processing circuit under various operating condition scenarios. The ability to
do this is facilitated by the fully interactive nature of the program and it's
flowsheet based graphical interface.
4.1 JKSimMet Basics
Some JKSimMet Before you can begin to build a new project, you need to get familiar with the
Basics basic concepts covered in this chapter.
4.1.1 JKSimMet Data Structure
The data structure within JKSimMet V6.0.1 consists of the following:

Project A project is the container in which the user stores all of the data related to a
particular body of work. The project contains one or more flowsheets and the
associated equipment and stream data.
Flowsheet A flowsheet is a graphical representation of a complete processing plant or a
Section of the plant and consists of an appropriately configured collection of
process units and streams. The flowsheet can have (and usually will have),
internal recirculating streams.
Equipment Each process unit in the flowsheet is represented by an Equipment Unit.
JKSimMet allows the user to select the equipment from a list of processing
plant equipment types and to display their pictorial representations (icons) on
the screen. This equipment is identified within the system by a name that the
user can specify.
The orientation of the equipment and the position of the equipment on the
flowsheet diagram can also be specified. There are a number of choices for the
process models to be used for each equipment unit.
Streams A stream is a description of the flow of material between process units. This
description includes the sizing characteristics, the SG and the water content
of the stream. It contains sufficient information to perform simulations via the
various models that are currently in use and there is virtually unlimited
capacity for developing and testing new models in the future.
The stream connection between two equipment units is made by drawing a
line that connects the appropriate feed and product ends of the equipment
units in question. On simulation, JKSimMet automatically checks to ensure
that all stream connections are valid. The streams are identified within the
system by names that the user can specify.
4.1.2 Available Equipment Items and Associated Models
Equipment Items Below is a listing of the JKSimMet equipment items, showing the associated
menu icon and the process models available for each of them.
Equipment Equipment Menu Available Models (Model ID)

Category Item Icon
Stream Feed (Solids Terminator - Solids Feeder (1300) 294
Source Feeder)
Water Feeder Water Feeder - Required % Solids
(1251) 295
Water Feeder - Water Addition (1252)
295
Crushers Jaw Crusher Crusher - Anderson/Whiten (400) 343
Crusher - Anderson/Whiten - Size

Extended (405) 343
Size Converter (490) 385
Gyratory Crusher - Anderson/Whiten (400) 343
Crusher
Extended (405) 343
JKSimMet Basics Version 6.0.1 - March 2014

Cone Crusher Crusher - Anderson/Whiten (400) 343

Extended (405) 343
Rolls Crusher Crusher - Anderson/Whiten (400) 343

Extended (405) 343
VSI Crusher Crusher - Anderson/Whiten (400) 343

Extended (405) 343
Size Degradation (480) 419
HPGR High Pressure Grinding Rolls (402)

403
Degradation Size Degradation (480) 419
Mills Autogenous Perfect Mixing Ball Mill (420) 360
Mill
Semi-Autogenous Mill - Leung (430)
370
Semi-Autogenous Mill - Sim/Org

Scaling (435) 386
Rod Mill Rod Mill - Lynch/Kavetsky (410) 354
Ball Mill Perfect Mixing Ball Mill (420) 360
Screens Trommel Splined Efficiency Curve (203) 328
Simple Efficiency Curve (210) 325
Efficiency Curve - Water & Fines

(211) 326
2-Way Simple Splitter (810) 334
Single Deck Splined Efficiency Curve (203) 328
Screen

(211) 326
Version 6.0.1 - March 2014 JKSimMet Basics

Single Deck Screen - Kavetsky (230)

317
Double Deck Double Deck Screen Based on

Screen (One Efficiency Curve (215) 325
Under
Double Deck Screen - Kavetsky (235)
Product) 325
DSM Screen Splined Efficiency Curve (203) 328

(211) 326
Efficiency Curve - Variable d50c (251)
330
Water & Solids 2-Way Splitter (813)

336 // wrong
Classifiers Air Classifier Splined Efficiency Curve (203) 328
Hydrocyclone Nagaswararao Cyclone (200) 298
Nagaswararao Fines (201) 298
Splined Efficiency Curve (203) 328

(211) 326

336 // wrong
Narasimha-Mainza (221) 308
Spiral Splined Efficiency Curve (203) 328
Classifier

(211) 326

336 //wrong
Rake Classifier Splined Efficiency Curve (203) 328

(211) 326


336 // wrong
O-Sepa Splined Efficiency Curve (203) 328
Classifier
Splitters 2 Product 2-Way Simple Splitter (810) 334
Splitter
Fixed 2-Way Volume Splitter (812) 336

336 // wrong
3 Product 3-Way Simple Splitter (870) 341
Splitter
Storage/ Bin Size Degradation (480) 419
Transport
Simple Combiner (800) 332
Pump Size Converter (490) 385
Pump Sump Size Converter (490) 385
Sump Size Converter (490) 385
Stockpile Size Degradation (480) 419
Thickener Simple Efficiency Curve (210) 325

(211) 326
Filter Model Controlled by % Solids
to U/F (240) 325
Final Product Terminator (1300)
Separators Flotation Cell Splined Efficiency Curve (203) 328
Efficiency Curve - Flotation (212) 325
Efficiency Curve - Water & Fines -

Flotation (213) 326

336 //wrong

Flotation Splined Efficiency Curve (203) 328
Column
Efficiency Curve - Water & Fines -

Flotation (213) 326

336 //wrong
Spiral Splined Efficiency Curve (203) 328
Separator

(211) 326

336 //wrong
2 Product Splined Efficiency Curve (203) 328
Separator

(211) 326

336 //wrong
3 Product 3-Way Simple Splitter (870) 341
Separator
4.1.3 Building a Simulation Model
What is Simulation is based on the ability to build a model that represents a real
Simulation system. The behavior and characteristics of the model must be similar to those
of the real system. JKSimMet allows the user to draw the flowsheet of a
comminution circuit, input and manipulate the data for a very wide range of
operating conditions and see the predicted results of running the circuit.
Steps to Building The user of JKSimMet proceeds through a series of tasks as outlined below.
a Simulation 1. Building a flowsheet diagram of the comminution plant on the
Model computer screen.
2. Input the feed stream data in the Feeder equipment.
3. Select the models for the equipment and input the required model
data.
4. Run the Simulation of the flowsheet.

5. Review the results of the simulation in the Report window or in the

individual stream data windows.
These tasks are described in more detail under the heading Building a New
Project 59 , which takes the user through each step.
Once a simulation model of a circuit has been built, the metallurgist can use
JKSimMet to assess the impact of altering various plant conditions on
metallurgical performance, until a satisfactory design or an optimum
operating condition for an existing plant is achieved. The results from
JKSimMet can be exported to Excel for printing, graphing and further
analysis. Data can also be transferred to other programs (such as MS Word),
by copying them to the clipboard and pasting into the other program.
Values calculated in a simulation include:
flow rates of solids and water;
pulp densities (percentage solids);
particle size distributions (if size has been chosen as one of the stream
properties);
Solids and water recoveries.
4.1.4 The Mouse and Cursor
The Mouse The standard two button mouse is used as the pointing device in JKSimMet.
This manual refers to left click and right click, which simply means to press
the left or right hand button on the mouse. Note that if the words left or right
are omitted, the default is always left click.
The manual assumes that the user is familiar with common mouse techniques
such as double clicking and click-and-drag.
Note that when you follow a link (underlined blue italics) which takes you to
another topic and you then wish to return to the original topic, clicking the
back button on your mouse will achieve this. That is of course assuming you
have a mouse that is equipped with forward and back buttons.
The Cursor The cursor is the visual feedback to the user of the current mouse position on
screen. Any click of a mouse button will interact with the image located at that
position. In JKSimMet V6.0.1 the usual form of the cursor is an arrowhead.
When the cursor is over equipment in the flowsheet window and the
flowsheet is unlocked, the cursor will change to show arrows pointing in 4
directions to indicate that the equipment item can now be moved. To achieve
this you can now just hold down the left mouse button and drag the item.
Releasing the mouse button will drop the item into its new location.
Once the left mouse button has been clicked while hovering over an
equipment unit, you will see that the item then has 8 grey squares around its
periphery to indicate it is now selected. If you then double click on the item,
you will bring up the equipment properties dialog box where the attributes of
this equipment can be modified. Alternatively you can right click and select
Properties from the right-click menu.
Cursor When working with a flowsheet in JKSimMet, the mouse provides the means
Movement of moving the cursor around the screen and selecting individual streams or
equipment items as required. In the equipment, stream and model data

windows, the cursor control keys (also known as the arrow keys) may be used
to move the cursor from one data cell to the next. In this case, the movement
will be in the direction of the arrow key used. Otherwise you can still use the
mouse to hover over and click to select, any required data entry cell.
To begin entering data into one of the cells, you can just begin typing once the
cell has been selected. To edit data already existing in a cell, you must first
double-click with the mouse to select the text within that cell. The text in the
cell will then be highlighted with white figures on a blue background. Starting
to type at this point will again just over-type the existing text. If your intention
is to edit the existing text, you need to now single click in the highlighted cell.
You will then see the mouse cursor flashing as a vertical line between the
characters and you can move it to the left or right via the arrow keys.
In summary then, to overwrite existing text, just begin typing once the cell has
been selected. To edit existing text, double-click and then single-click inside
the target cell.
Appearance As with all MS Windows programs, the preferences that the user sets for the
Windows desktop will provide colours and fonts for many of the tools and
menus within JKSimMet.
Keyboard Access Most of the functionality of JKSimMet can also be accessed from the keyboard
using standard MS Windows conventions.
4.1.5 The JKSimMet Windows
The JKSimMet V6.0.1 display uses windows to present the various types of
data on the JKSimMet desktop. These windows include the following:
flowsheet window
equipment and port data windows
graph windows
data overview window
the report window
Users may have as many windows open on the screen as they wish at any
one time. An XGA video card and a large monitor are recommended to
gain full advantage of this capability.
Many of the windows are divided into several distinct areas that are
accessed by selectable tabs. Each area is used to convey specific types of
information.
Note that most windows may be minimized for convenience. However,
some non-critical changes (eg. an equipment name change) may require
that a window be closed before other windows are updated.
4.2 Building a New Project
Building a Having gained an understanding of what JKSimMet does and generally how
Project it works, this section will take you through a series of steps in order to build a
JKSimMet project. A simple flowsheet will be used for learning purposes. In
order to cover as many of the available techniques as possible though, this
tutorial will take a number of diversions along the way during the process of

putting together this simple flowsheet.

In this demonstration we will be assuming that you already have the
necessary parameters for the main equipment items on this flowsheet. Later
on in this help file, you will be shown how to carry out the fitting process in
order to obtains such parameters and also how to perform mass balancing
which is normally performed ahead of any fitting exercise.
4.2.1 The Steps to Simulation
This section contains a step by step tutorial style set of instructions that is
tailored for users who are still becoming familiar with the program. The
following section on Using JKSimMet 131 covers all of the basic operational
features of JKSimMet and is structured as a reference section.
Steps to The stages involved in performing a simulation are outlined below, and the
Simulation sections JKSimMet Start Up 60 through to Viewing Individual Stream Data
94 are designed to guide the user through each stage.
Step 1 Make a backup copy of any existing projects

Step 2 Startup JKSimMet - covered in the topic Start JKSimMet 60
Step 3 Create the flowsheet covered in sections Create a New Project 61

through to Build a New Flowsheet - Add Streams 72 . Note that a
flowsheet must have a Feed equipment unit and all equipment
items (apart from feeders) must have feed streams to be valid.
Step 4 Set the System Properties in the section Flowsheet Data - System
Properties 78 . These are global characteristics that do not change
during simulation. In JKSimMet they consist of only the solids and
the liquid SG values and assays where needed for mass balancing.
Step 5 Input feed stream data into the Feeder equipment item - see section
Flowsheet Data - Feeder Equipment 81 .
Step 6 Select the models for the equipment and input the required model
data section Flowsheet Data - Equipment & Models 83 . The data
for the models will usually be derived from plant or test work data.
Some data may also come from previous experience. The user can
review or correct the data at any time after data entry.
Step 7 Run the Simulation of the flowsheet section Simulation 87 .
Step 8 Review the results of the simulation in the Configurable Stream
Overview section Viewing Data Using Configurable Stream
Overview 89 .
Step 9 Review the results of the simulation in the individual stream data
windows section Viewing Individual Stream Data 94 .
Step 10 From the Configurable Stream Overview, the results of the
simulation can be copied to the clipboard and then exported in a
printer-friendly format to other programs such as MS Excel, as
required. After analysis of the results the circuit configuration can
be altered, the capacity and characteristics of the equipment
changed, the properties of the feed stream adjusted and the
simulation process repeated until a satisfactory result is obtained.
Version 6.0.1 - March 2014 Building a New Project

The section Working with an Existing Project 99 outlines how to

work with an existing project in this manner.
4.2.2 JKSimMet Start Up
JKSimMet Start The instructions for starting JKSimMet V6 are as follows:

Up
Step 1 Plug the JKSimMet protection key into the appropriate place in the
computer.
Step 2 Left click on the Windows Start button at the bottom left hand
corner of the screen to open the Start menu.
Step 3 Move the cursor to select the All Programs sub-menu.
Step 4 Move the cursor to highlight the JKSimMet V6 program from the
list displayed in this sub-menu and left click. You will then see
two items; JKLicenseManager and JKSimMet V6. Left click on the
latter to launch the program. The JKSimMet logo is displayed
while the program is loading.
Step 5 Alternatively, JKSimMet can be started by double clicking on the
JKSimMet icon on your desktop or by clicking on a Taskbar icon in
Windows 7, if you have opted to pin a program shortcut to the
Taskbar.
Having successfully launched the program the main JKSimMet session
window will open as shown below. From here, the next step is typically to
open a previously saved project (see section Working with an Existing Project
99 ), or to enter the data for a new project (see sections Create a New Project
61 through to Flowsheet Data - Equipment & Models 83 ).
Changing Note that the session window can be re-sized using the minimize and
Window Size maximize buttons (top right corner) or by moving the cursor to any edge of the
window. When it is positioned over the border line the cursor will change
from the arrowhead to a line with arrows on each end; left click and drag with
this cursor to change the window size and release the mouse button when the
window size is as required. Note also that the various sections of the session
window can be re-sized in the same manner.
Building a New Project Version 6.0.1 - March 2014

4.2.3 Creating the New Project
Creating a New In this exercise a new project will be created by following the steps outlined
Project below. The project you are about to create will be a simple closed circuit ball
mill flowsheet.
New Project Step 1 After starting JKSimMet click on the New Project icon on the
toolbar or select New Project from the File menu. This will open
the New Project window.
Define Project Step 2 A dialog box will open where you can select a suitable directory
Name (probably somewhere within My Documents would be best) and
also enter a name for the project. Note that you can create a new
sub-directory for this tutorial work by clicking on the icon circled
in the screen grab below.
In this case we will replace the name 'New JKSimMet Project' with
Learner Project. After making this change, click on the Save
button.
You will then be presented with the option to either use the more

realistic icon style familiar to Version 5 users, or the stylised icons

that have been adopted as the default for the Version 6 interface.
Note that once you make this selection, you cannot switch back
again within this same project and you cannot mix icon styles
within a project.
Having made your selection, the new project will open. The name
of the project ('Learner Project' in this case) will be displayed in the
title bar of the main window. The new project will have a default
flowsheet called FlowSheet1, as shown below. It will initially be
empty of any equipment and streams.
Define Step 3 To change the name of the flowsheet, right click on the flowsheet
Flowsheet Name name FlowSheet1 in the left panel and select Properties from the
drop-down menu. Click in the Flowsheet Name text box and type
in the new name; use the name Learner Flowsheet.

4.2.4 Adding Flowsheet Equipment
Adding In this exercise a flowsheet for a comminution plant will be created using the
Equipment to graphics-based flowsheet drawing tools in JKSimMet. Check that the flowsheet
the Flowsheet is not locked before you begin - the Lock button ( ) should not be depressed.
However, the flowsheet should be unlocked by default, after you have just
created a new project.
Save the As with all computer programs, your work should be saved regularly to avoid
Flowsheet loss of data. To save changes to the project, click on the Save Project button or
select Save Project from the File menu.
Select the Step 1 The far left panel contains the list of flowsheets that are contained
Flowsheet from in the current project. In this case, there is only one flowsheet. This
Left Panel is the default flowsheet that was created along with your new
project and has now been re-named as Learner Flowsheet. Note that
the project name and the flowsheet name now appear in the title bar
at the top of the window.
The Learner Flowsheet will be selected by default since there are no others.

The available equipment list is displayed in the centre panel of the session
window. The equipment icons are grouped by equipment functionality,
progressing from the feed end of the plant to the final product. An exception is
that Separators are placed in a group at the end of this list, since they are not so
often required in JKSimMet, this program being primarily a comminution
modelling tool.
To the right of this list is a large blank area where you will be constructing the
new flowsheet.
If your project had more than one flowsheet, to change the flowsheet selection
you would need to double click on the required flowsheet in the left-panel list.
The selected flowsheet's contents would then appear in the right (flowsheet
display) panel.
Create New The new blank flowsheet is now ready for equipment to be added. Note that a
Equipment flowsheet MUST have at least one Feed equipment unit, as it is in the Feed
Units on the equipment unit that the feed stream data are defined. So we will add this first.
Flowsheet
Add Feed Step 2 Double click on the Feeds Folder and then click on the Feed
Equipment equipment icon from the equipment list and then place the cursor
over the flowsheet. The arrow cursor will change to the equipment
placement cursor (a cursor with the equipment icon next to it - see
below).
Move the cursor to the position on the flowsheet where you require
the Feed equipment to be placed and click again. You can move it
later, so there is no need to be precise. If you change your mind
about adding an item you have selected before you have placed it
on the flowsheet, just right-click to cancel the placement.
Add the Ball Step 3 The Ball Mill equipment item should now be added to the flowsheet
Mill in the same manner as the Feed equipment. To do this, open the
Mills folder and click on the ball mill icon in the equipment list,
move the cursor to the required position on the flowsheet and click
again.

Add the Step 4 You now need to add the auxiliary equipment units - namely a
Ancillary cyclone plus the sump/pump to feed it. When you have placed
Equipment these items, your screen should look something like the one
Units illustrated below.
Add Water Step 5 You now need to add two Water Feeder units, which should be
Feeders to the added so that their locations are similar to those shown in the
Flowsheet screen grab below.

Exercise: To add multiple units, press Ctrl when selecting an equipment item from the
Adding list. Instances of the selected unit can then be placed by repeatedly left clicking
Multiple Units on the flowsheet. The process can be discontinued by right clicking anywhere
on the flowsheet, or by clicking on the arrowhead (Select) button in the toolbar (
).
Exercise: If you have multiple units on a flowsheet, some of which you don't require,
Deleting Units deleting the surplus units is simple. Clicking on an individual unit will select
it and you can select multiple units by holding down the Ctrl key for your
subsequent selections. After one or more units have been selected, you can just
hit the Delete key to remove them. Alternatively, you can select Delete from the
Edit drop-down menu. A dialog box (shown below) will then be displayed,
which asks you to confirm the deletion - the purpose of this being to reduce the
chances of accidental deletion.
Note that if you press the Delete key and nothing happens, it will most likely be
because the flowsheet is currently locked. In this case, click on the Lock button (
) and try again.

Add the Final Step 6 Lastly we will add a Final Product equipment icon to the flowsheet.
Product Icon This icon is located under the Storage / Transport heading and is
added in the same manner as any other equipment unit.
The Final Product icon is optional but the stream which feeds it is
essential. This is where the product data are stored.

Copying Multiple units may also be added by placing a single unit on a flowsheet in the
Equipment normal manner, then selecting this equipment item by clicking once on it before
Units copying and pasting to wherever else it is needed on the flowsheet.
There are many alternative ways to achieve the copy and paste operation.
Copying can be done by pressing Ctrl and C or by clicking the Copy button (
) on the toolbar. Alternatively you can select Copy from the Edit menu or
from the right-click menu (with the mouse cursor placed over the equipment
item in question). Multiple units may then be placed on the flowsheet by
performing a paste operation at locations where the extra units are required.
Again this can be achieved in a number of ways; by pressing Ctrl and V, by
clicking the Paste button ( ) on the toolbar or by selecting Paste from the Edit
menu or from the right-click menu.
Another method of copying existing units is to select the unit, hold down both
the left mouse button and the Ctrl key while hovering over the unit and then
with both these held down, drag with the mouse to the location where you
require a copy to be placed. Letting go of the mouse button will then drop a
copy into this position.
Which of these methods you use is a matter of preference.
Position Equipment units may be moved around the flowsheet window, providing that
Equipment the flowsheet is not locked. Simply place the cursor over the equipment to be
moved, click & hold down the left mouse button and drag this equipment to
your preferred location. Now release the mouse button to drop the equipment
into its new position. If there are streams attached to the equipment, they will
remain attached while the equipment is being moved. You may sometimes
need to modify the route taken by the streams associated with equipment you
have moved, for aesthetic reasons or to restore clarity to the flowsheet. The
manipulation of streams on your flowsheet is covered under the next topic.
Change You can also change the appearance of individual equipment items. Double
Equipment click the equipment on the flowsheet or right click and select Properties from
Appearance the right-click menu to bring up the Component Properties window. You can
then use the Line and Fill tabs, to modify how this equipment appears on the
flowsheet. For instance, the fill colour, outline thickness and outline colour
may all be altered using this function. You can click Apply to check the

appearance after your changes while the Component Properties window is still
open.
Name The equipment can be named and labelled for ease of identification. Steps 7
Equipment and 8 detail the procedure for naming and labeling equipment.
Step 7 Ensure the flowsheet is unlocked. Place the cursor over an item of
equipment and double click to open the Component Properties
window for that equipment. The Name field will be activated by
default on opening this window. Type in the new equipment name,
and then click OK. For this exercise, name the equipment items as
shown in the illustration below.
Remember that the Component Properties window may also be
accessed by right-clicking on an equipment unit and selecting
Properties from the pop-up list.
Label the Step 8 Once you have defined the names, click on the Equipment Auto
Equipment Labels button or select the Equipment Auto Label item from the
View menu. The labels will then appear on the flowsheet above the
equipment. To remove these labels click on the Equipment Auto
Labels button again or select this item from the View menu again.
These are equivalent and both act as on-off toggles.
Remove or Re- The labels for individual items of equipment may also be removed if desired by
position an double-clicking on the equipment, selecting the Auto Labels tab and
Equipment unchecking the On/Off check-box. This enables the user to only display
Label selected equipment labels. In the above flowsheet we have disabled the
equipment labels for the two water addition units.
Auto labels may be formatted by selecting Equipment Auto Label Properties
from the Edit pull-down menu. This option allows changes to font size, style
and colour, as well as allowing changes to the background colour and line
thickness and colour of the equipment label itself.
Equipment labels can be moved by double clicking on the unit or the label. In
the resulting Component Properties dialog box, choose the Auto Label tab and
change the position of the labels by selecting from the options under the Auto

Label Position heading.

Change the The orientation of equipment can be changed so that the feed end is facing left
Feed Direction or right, as required. In the next step you will change the feed direction for the
(The Flip ball mill and its pump on your Learner Flowsheet.
Buttons) Step 9 Ensure the flowsheet is unlocked. Place the cursor over the Pump
Sump equipment item and single click to select. Click the Flip
Vertical button on the toolbar to create a mirror image of the
equipment. Repeat this sequence for the Ball Mill.
Note that the Flip Horizontal button would be used less frequently since most
equipment icons are designed to look recognizable in their default orientations.
However, for some icons (e.g. the water feeder), flipping horizontally does not
make them look odd and it may sometimes be useful.
Auto Save The first stage of building the flowsheet is complete and the flowsheet should
Function look similar to the one shown below. Remember to save the project regularly.
Note that JKSimMet has an auto save function that will save the current project
approximately every 3 minutes. This is done in the background and the user
should not notice it happening. If for some reason the program crashes, the
auto saved project can then be opened on re-starting the program and saved
with the appropriate file name.

Tips for Adding The size (and proportions) of an equipment item on a flowsheet can be
Equipment changed if required. After clicking on the item to select it, a series of grey
squares will appear around its perimeter. If the cursor is placed over one of
these squares, it will change into a short line with an arrowhead at each end.
When this cursor appears, hold down the left mouse button and drag to
change the size of the item. Note that if you drag one of the corner squares, both
the height and width will be modified simultaneously. Also when you use a
corner square, if you hold down the Shift key while you are dragging the
mouse, then the existing height/width ratio will be maintained.
Matching When equipment has been resized it is possible to match other pieces of
Equipment equipment to the same size. Select the different sized pieces of equipment by
Dimensions holding down Ctrl or Shift and clicking the desired items. Once selection is
completed, there are three buttons on the toolbar that can be used to resize the
equipment. These are the Same width, Same height and Same size buttons.
The selected equipment will all be resized to match the item of equipment
surrounded by the grey squares. This means that the item with the required
dimensions has to be selected last. If selected first or anywhere else in the
sequence, it will not have the grey squares around it. Note however, that if you
forget and select it first, you can simply select it again at the end of the
sequence - without having to start the selection sequence all over again.

Changing Along with the Flip Vertical button and Flip Horizontal buttons discussed
Orientation of earlier, there are a number of other buttons in JKSimMet that can be used to
Equipment change the orientation of a particular piece of equipment. These buttons are
also located on the Draw toolbar and are the 'Rotate', Rotate Left and Rotate
Right buttons. The Rotate Left and Rotate Right buttons will rotate the
selected item anti-clockwise and clockwise respectively, by 90 degrees, each
time you click on them. Intermediate angles of orientation can be achieved
using the Rotate button. When you click on this button and then move the
mouse over the selected item, you will see the cursor shown below. Move this
cursor to one end or one side of the item, hold down the left mouse button and
drag around in the direction of the rotation required.
Aligning If the user wants to ensure that several pieces of equipment on the flowsheet
Equipment are exactly aligned with one another, there are a number of tools for doing this.
Items There are six buttons on the Draw toolbar for aligning equipment tops, middles
(horizontal), bottoms, left sides, centres (vertical) and right sides. To use the
align tools, select the equipment to be aligned by pressing Ctrl while clicking
with the mouse on the desired items. Again, the piece of equipment surrounded
by grey squares is the one to which the rest of the equipment will be aligned
and thus it needs to be selected last. Once your selection is made, press the
desired align button on the toolbar.
Spacing Different pieces of equipment may also be evenly spaced both horizontally and
Equipment vertically from one another. To do this, select multiple pieces of equipment in
Items the usual way and press the Space across or Space down buttons on the
toolbar.

Moving a Group If you wish to move a whole block of equipment items, you need to first select
of Equipment them as a group by dragging your mouse around them with the left button
Items depressed. Each unit inside the area you have delineated will now be
surrounded by squares to indicate selection. The units highlighted in this way
can be moved as a group by clicking and dragging any one of the selected
units.
Adjusting As an alternative to the gross movement of an equipment item that is normally
Equipment achieved through clicking and dragging, very small adjustments to the location
Positioning of an item can be achieved using the Nudge function. Select the item and then
use the appropriate Nudge button on the toolbar to move it a very small
amount in the required direction. This function is particularly useful
immediately after you have added the connecting streams. When first added,
sections of the streams may not be perfectly orthogonal. This can be rectified by
nudging the equipment one or more times as required, in the appropriate
direction.
4.2.5 Add Connecting Streams
Add Streams to The next step is to create streams to join the equipment units that have been
the Flowsheet placed on the flowsheet. Note that for the flowsheet to operate correctly, all
input and output ports must have feed and product streams respectively
connected to them.
The flowsheet must be unlocked in order to add streams.
Add Streams Step 1 To begin the stream connection:
Move the cursor to a position over the feed or product port of the
equipment to which a stream is to be connected, in this case the
product port of the Feeder equipment. Note that product ports are
shown as red dots and feed ports as blue dots. When the stream
cursor changes into a circle containing a cross, click the left mouse
button. One end of your stream will now be attached to this
equipment item.
Step 2 To complete the stream connection:

Move the cursor to the feed inlet or product outlet (as appropriate) of
the equipment item that is to be at the other end of this stream. You
must connect product ports to feed ports (or vice versa). You cannot
connect a feed port to another feed port and the same applies to
product ports. In this case you will move the cursor to the feed inlet
of the pump sump. When the cursor is close enough for a
connection to be made, it will change back into a circle containing a
cross. When this happens you can click the left mouse button again
and the connecting stream will then be drawn on the flowsheet.
Streams may be connected directly from an outlet to an inlet (or vice
versa) in a straight line, as would be the case following the

instructions above. Often however, you will need to make the stream
lines follow a more complex path to avoid drawing them over the
top of other items of equipment or over other stream lines. Also, for a
neater presentation, you will probably want to have your stream
lines generally follow an orthogonal pattern on the flowsheet, rather
than being oriented at many different angles.
This is easily achieved as follows:
Stream Once you have connected one end of a stream, you can insert points
Inflexion Points of inflexion to control the route that the stream takes to its
destination item of equipment. To do this you simply click the left
mouse button at intermediate locations where you wish to have the
steam change direction. Each time you do this, the stream will be
anchored at the current cursor position and you can then move the
mouse in a new direction, either to make further points of inflexion
(as required), or else to the connection port on the target equipment
item.
You can later move the points of inflexion, if required. When you
hover the mouse cursor over an inflexion point, you will see that it
changes to a little square with tiny arrow heads pointing away from
each side of the square ( ). You can now hold down the left mouse
button and drag to the required new location.
Further points of inflexion can also be added after the stream is
completed. Start by selecting the stream and then hovering the
mouse cursor over the straight line part of a stream where you wish
to place the new point of inflexion. The cursor will initially have the
symbol that indicates the stream can now be moved ( ). However,
when you hold down the Control key, the cursor will change to
indicate a new point of inflexion can be inserted ( ). Now to
complete the insertion, just left- click the mouse.
You can delete points of inflexion if you have added more than you
need. This is achieved by first selecting the stream and then holding
down the Control key as you hover your mouse over the point you
wish to delete. When close to an inflexion point, the cursor will
change to a cross ( ) and you can then left-click to complete the
deletion. The stream will revert to a straight line joining the points
on either side of the one deleted.
Step 3 Repeat steps 1 and 2 to continue connecting the streams in the
flowsheet until the flowsheet looks similar to the one shown below.
For the Cyc O/F stream, follow the normal procedure but simply
double left click when the end of the stream is where you want it.

Tips for Stream Feed ports can have multiple streams connected to them. The
Connection maximum number of feed streams able to be connected to any
equipment unit in JKSimMet is currently 50.
Product ports can only have one stream connection. If a product
port already has a stream attached and you are attempting to
connect another, you will find that the cursor does not change to
give it's normal "connection available" signal as you approach this
port. Clicking the mouse over this port will not make another
connection.
If you have changed the location of a unit or a stream node and you
then find that a vertical section of stream is no longer quite vertical,
you can usually fix this by moving the equipment that it comes from
slightly. The Nudge buttons 72 have been provided to make it
easier to achieve this. If moving the equipment slightly doesn't
correct the problem, a small adjustment to its size probably will.
To connect to a unit, a stream must go all the way to the relevant
product or feed port. You cannot connect a stream into another
stream that is already connected to the required port. However, new
streams may partially follow the same path to that port, giving the
appearance of a stream to stream connection.
Errors in JKSimMet will not allow connecting streams to be drawn that could not exist in
Connecting a real plant. For example, JKSimMet does not allow streams to be drawn from
Streams one product outlet to another.
Redraw Note that streams will remain attached if equipment units are moved after they
have been connected by streams. Be aware however that this may result in an
incomplete stream display upon completion of the move. In this case you can
use the Redraw button on the Flowsheet toolbar to redraw your flowsheet. This
should correct any problems that might have become evident as a result of your
editing.
Naming the When you create new streams on a flowsheet, they will all be allocated names
Streams automatically by the program. However, these names may not be very
meaningful to you. Thus it is recommended that you change the names so that
they will be easily recognised during data analysis and later when they appear
in your reports.
Step 4 Double click on a stream or right click on the stream and select

Properties from the right-click menu. This will open the

Component Properties window. Type in the new stream name then
click OK. Repeat for all streams. Rename the streams as shown in
the screen grab below.
Adding Labels The names that you allocate to the streams can be made to appear on your
to the Streams flowsheet as stream labels (see below). To do this, click on the Stream Auto
Labels button or select Stream Auto Label from the View menu. Note that again,
both the menu item and the button act as toggles, so clicking either again will
make the labels disappear.
The Stream Auto Labels may be formatted by selecting Stream Auto Label
Properties from the Edit pull-down menu. This option allows changes to font
size, style and colour, as well as allowing changes to the background colour
and line thickness plus the colour of the stream label itself. The screen grab
below shows our flowsheet with both the Equipment and Stream Auto Labels
switched on.
Location of a Individual stream labels can be moved to one of several alternative locations
Stream Label relative to the stream line. For instance the Cyc Feed stream label above has
been re-set from the default location so as to be closer to the cyclone.
To change a label location, first double click on the stream or the label to open
the Component Properties dialog box for that stream and then select the
Drawing tab. You can then change the position of the stream label by selecting
from the various options under Auto Label Position.

A further addition that can be made on this tab is to add an arrow head to
indicate the direction of flow of a stream. If you wish to do this, click the On/
Off box in the End Arrow section and click OK after selecting the desired arrow
head length and width.
Hiding Note that on the Drawing tab of this dialog box, there is also the option of not
Individual displaying the stream label for the selected stream. If the On/Off check box to
Stream Labels the left of the position radio buttons is unchecked, then the label for this stream
will no longer appear when the Stream Auto Labels toggle is switched on. If
there are a number of stream labels that you don't wish to have displayed, then
you can arrange this by first doing a multiple selection of the streams
concerned. Then just select Properties from the right click menu and uncheck
the On/Off check box.
Changing Changes can be made to both the thickness and colour of stream lines. Again
Stream Line double click on a stream in the flowsheet and select the Line tab in the
Appearance Component Properties dialog box. If you change the selection for either one of
these properties, you will see that the Apply button will become activated. If you
wish, you can use this button to check the effect of the change you are
proposing to make, without closing the dialog box. Note however that pressing
cancel will not undo this change. If you are not happy with the modified
appearance, then you need to click on the line width or style that was originally
selected, before you pressed the Apply button. Alternatively, if you are confident
that your selection will give the desired result, you can just click on OK to close
and keep your modifications.

Delete a Stream Streams can be deleted in the same manner as equipment. First ensure the
flowsheet is unlocked and single click on a stream. Press the Delete key or
select Delete from the Edit pull-down menu. A dialog box will be displayed
asking you to confirm.
Text Boxes To add labels that are not associated with any streams or equipment, click the
Text button and then move the cursor onto the flowsheet. A single click will
place a text box on the flowsheet. The size of the box can be adjusted by clicking
on and dragging the handles, when the text box is selected. The text within the
box can be altered by double clicking the box and entering the desired text.
Pressing the Enter key completes the text addition.
The appearance of a text box can be changed by right-clicking on the box and
selecting Properties. The resulting Component Properties window allows the
user to change the text font, colour and size, as well as the box fill colour, line
style and line thickness.
Text boxes may be removed in the same manner as equipment single click the
text box to select it and press the Delete key or select Delete from the Edit
pull-down menu. The orientation of text boxes can be changed in the same
manner as equipment by selecting the Rotate of Flip buttons from the toolbar.
Note that if you edit the text from within the Properties window (as opposed to
editing directly in the text box), when you subsequently close the Properties
window, the text box will automatically resize to neatly accommodate the
revised text. You can over-ride this auto sizing however if you wish; just select
the text box and drag on one of the selection handles to modify its size.
Step 5 Now add a text box to your flowsheet and edit the text so that it just
contains the name of this flowsheet (Learner Flowsheet).

The flowsheet required for this exercise is now complete.

At this stage it is advisable to lock the flowsheet by clicking on the Lock button
or by selecting Lock from the Flowsheet sub-menu. When the flowsheet is
locked, adding and removing streams and equipment in the flowsheet is not
possible. Locking a flowsheet also allows users to access the equipment data.
Saving the flowsheet at this point would also be advisable.
4.2.6 Define System Properties
Once your flowsheet has been finalised with all equipment in place and
connected by streams to form a circuit, the data associated with this flowsheet
can be entered. The first step is to define the system property classes required
for a particular flowsheet.
Open System Step 1 Ensure the flowsheet is locked, then click on the System Properties
Properties
button ( ) or select System Properties from the Flowsheet menu.
Note that if the flowsheet has not been locked, then Lock should be
the only available item on the Flowsheet menu. Click on the Lock
item and then select the Flowsheet menu again. The other items
should then be available.
The System Properties window when first opened, should look
similar to the one shown below.

Step 2 You will notice there is a Select property drop-down at the top of
this window. The system properties are divided into two
categories, Elements and Miscellaneous. When the window first
opens, Miscellaneous is selected as the default. With this item
selected, the two parameters to be configured are Solids SG and
Liquid SG. These are required for the comminution modelling
functions in JKSimMet.
Change the Solids SG value to 2.8 and leave the Liquid SG value
on the default setting of 1.0 for water.
Close System Step 3 Click on the Close button to close the window.
Properties
Remember to save your project regularly.
Set the Sieve Step 4 The next step is to set the series of screen sizes that will be used for
Series this project. Again select the Flowsheet menu and the next item
down from System Properties, which is Sieve Series.
A window similar to the one shown below will then open, which
will already have a default sieve series listed.

You would normally need to change this default series into

something more appropriate.
You can make this change by typing in the individual values or you
can copy and paste a series of values. Note that unless you are using
the copy and paste method, you will first need to type a zero in the
Size 1 cell (immediately below top-size), before typing in your new
top-size value; otherwise it will just return to the default of 200 when
you press the Enter button.
To copy in a series of values from a spreadsheet or from another
JKSimMet file, first select the list of values and copy them onto the
clipboard. Then back in JKSimMet, select the Top-size cell and press
the Paste button ( ) or Ctrl V. The program will automatically

place a zero below the last size pasted and will grey-out all sizes
below this.
Another alternative is to type in a top size and then press the root 2
button ( ) located in the toolbar above this list. This will cause the
program to fill in a root 2 series below the entered top size. Note
again that you need to type a zero into the Size 1 position before a
new top-size value can be entered. Once you put in the required top-
size, press the root 2 button and a root 2 sieve series will be inserted.
This will extend right to the bottom of the available aperture
definition rows. To complete the sieve series definition, you will now
need to type a zero below the smallest aperture in your sieve series.
This will once again grey-out all of the fields below this size.
Note that there is space for adding as many as 40 sizes, but it would

be rare to need anything approaching this.

You should now enter the values shown in the screen grab below.
We are just going to use the one sieve series for all streams in this
case. The program does allow for you to use different screen sets for
different streams for data input but the Master sieve series is used
for balancing, fitting and simulating. The two buttons to the left of
the root 2 button are for adding or deleting additional columns of
sieve sizes. Note that you cannot delete the Master sieve sizes
column - there must always be at least one set of sieves for any
project. In cases where you have added an extra column of sizes, the
Stream table to the right allows you to select which of the alternative
sieve series is to be used for the different streams in your flowsheet.
When you press the OK button, you may get a warning like the one
below.
Its purpose is to remind you that if you did have any data already
entered, changing the sieve series being used will result in the
resetting of your entered data to zeros.
4.2.7 Feeder Equipment Data
In JKSimMet the feed stream data are actually entered in the feed equipment
rather than as a feed stream. Note that the system properties have already
been defined via the System Properties window.
In this section, data will be entered for the Feeder equipment

Open Equipment Step 1 Ensure the flowsheet is locked, then double click on the feeder
Window equipment item in the flowsheet to open the Equipment window.
This window will appear similar to the one illustrated by the
screen grab below.
Enter the Totals Step 2 By default the Totals tab is selected when this window opens.
Tab Data Enter the numbers shown in the white cells of this screen grab.
Don't worry about entering any data in the SD or Bal data columns
at this point.
Data Field General Note: There are three different background colours used to indicate
Colour the different categories of data present in the JKSimMet windows:
Conventions
1. White the user is required/permitted to enter data (e.g. feed
tonnage).
2. Light grey these data cannot be changed (e.g. labels).
3. Medium grey user entry is not required but the data will change
depending on a user selection or calculation during simulation (e.g.
TPH water).
Enter the Sizing Step 3 Now click on the Sizing data tab and the window will change to
Data something like the one below; except that all the Exp column
values will be initially set to either zero or 100. Now enter the
experimental values for these sizing data, as shown below. Note
that you can enter these data using the normal Ctrl C for the copy
operation in Excel, followed by Ctrl V for the paste operation in
JKSimMet, once you have selected the top cell of the sizing data
range.
Note however, that in order for the data you enter to be interpreted
correctly, you must ensure the appropriate button is selected on
the main tool bar, so that it matches the form of the sizing data you
are pasting or typing in. The alternatives are % retained ( ),
cumulative % retained ( ) and cumulative % passing ( ). In

this case we are typing in cumulative % passing data, so make
sure the appropriate button ( ) is selected before performing the

paste operation.

For this exercise, there is no requirement to fill in data on the other two tabs.
These tabs are for the entry of assay data and such data are not needed since
here we are carrying out a comminution simulation exercise. Once more you
should save your project at this point.
4.2.8 Select Equipment Models
After the system properties have been defined and the feed stream data has
been entered, the models for each equipment unit should be selected and the
relevant parameters entered. The Equipment and Model windows contain all
of the information about the equipment that JKSimMet requires to perform a
simulation task.
As discussed in the previous section, the Feed equipment unit is a special
form of equipment in which the actual feed stream data are entered.
Open Equipment Step 1 Ensure the flowsheet is locked then click on the Equipment icon on
Window the toolbar or select Equipment from the Flowsheet sub-menu to
open the Equipment window. This window can also be opened
simply by double clicking on any equipment unit in the flowsheet,
in which case the item of equipment you have clicked on will be
selected by default from the Equipment Name drop-down list.

Select the Ball Step 2 Begin by selecting the Ball Mill from the Equipment Name drop-
Mill down list, if it is not already selected.
Select Model for Step 3 Click on the Equipment Model drop-down list to access the model
the Ball Mill choices for the Ball Mill and select the Perfect Mixing Ball Mill
model. See under the Model Descriptions 360 topic for further
details on the way this model works, including a description of the
parameters associated with each tab.
Perfect Mixing Step 4 Click on the double arrow button ( ) located to the right of the
Ball Mill Model Equipment Model drop-down list to access the data for the Perfect
Mixing Ball Mill model.
The Perfect Mixing Ball Mill model data input screen is shown in the screen
grab above. The first tab (which is selected by default when the window
opens), is the Scaling tab. On this tab you enter the dimensions of the mill to be
simulated, its rotational speed (expressed as the fraction of critical speed), the
loading of the mill, the work index of the ore being treated and the ball top
size. Default values are provided for each of these items when this window is
first opened. For this exercise, you should modify the default values to line up
with the values displayed in the white cells of the screen grab above.
On this tab it is possible to scale up (or down) in cases where the parameter
fitting has been done for a different sized mill to the one that is specified in the

current flowsheet. This is the purpose of the right hand table under the
Original Mill heading.
Ball Mill Perfect Step 5 The second tab is the Rate/Discharge Function tab. The values on
Mixing Model - this tab are the fitted parameters for the milling operation we are
Rate/Discharge about to simulate. In this case we will again leave these values at
Function Tab their default settings.
Note that you have to close the equipment and model parameter
windows by just clicking on the cross at the top left corner. There
is no Save button on these windows, but the entered values will
remain in memory and will be saved when you press the Save
button on the main window toolbar or else when you close the file
(provided you elect to save it when prompted).
Water Feeder - Step 6 Double-click now on the water feeder associated with the cyclone
for Ball Mill feed sump. This will bring up the Equipment window for a water
Cyclone Feed Bin feeder. The screen grab below shows this window activated with
the Equipment Model drop-down expanded.
For the model we will select the Required % Solids model. After
you have selected this from the drop-down, click on the double
arrow button beside this list to access the properties of the chosen
model.

For this model, the only value to be entered is the required % solids
value. We will select 58% as the required % solids, which will then
be the pulp density of the feed to the ball mill cyclone. Close the
equipment window for the water feeder.
Water Feeder - Step 7 Now double-click on the Ball Mill Feed water feeder and perform
for Ball Mill Feed the same sequence, this time selecting 73% as the required % solids
Stream value. With this model and this parameter value selected, the
water flow will be adjusted during the simulation so as to achieve
73% solids for the pulp density of the total feed to the mill. Close
the equipment window for this water feeder.
Cyclone - Model Step 8 Finally, we need to select the model and set the operating
Selection parameters for the cyclone. Double click on the cyclone icon on the
flowsheet and you will bring up an equipment window for the
cyclone, as shown below.
From the Equipment Model drop-down, select the Narashima/

Mainza model as the model to be used. Once you have made this
selection, click again on the double-arrow button to set the
parameters for this model. Enter the cyclone dimensions and the
other operating variables on the Operating Condition tab as shown
below.

Cyclone Model -
Setting
Parameters
Then select the Model Parameters tab and enter values as

indicated in the following screen grab.
Once these are entered, close the model parameters window for the
hydrocyclone.
Models have now been selected for all of the equipment and the
flowsheet is ready to be simulated.
Remember to save the project.
4.2.9 Simulation
Now that your flowsheet has been set up with models assigned to all
appropriate equipment items and values have been entered for their relevant
parameters, you can proceed with a Simulation of this circuit.
Open the Step 1 Ensure the flowsheet is locked and then click on the Run
Simulate Simulation icon (large icon in left panel toolbar) or select Run
Window Simulation from the Flowsheet menu to open the Simulate
window. This window together with the main window behind it,
is shown in the screen grab below. All the equipment items and

streams are highlighted in heavy blue to indicate that they are all
initially selected.
You will notice that by default the Simulation Select List drop-
down displays 'Whole Circuit'. Initially this is the only select list
available. You can however add your own select lists if you wish
to simulate certain parts of the circuit in isolation. For this exercise
however, we will be simulating the whole circuit only.
Note that the check boxes for selecting and de-selecting individual
items of equipment and streams can only be modified once you
have defined (and selected from the drop-down), your own partial
circuit for simulation. When defining a partial circuit, you will
notice that as you select streams or equipment items from the list,
they become highlighted on the flowsheet (in heavy blue), to
indicate selection. A partial circuit consisting of the cyclone and
its feed and product streams is shown in the screen grab below.
If you try this, be sure to select the Whole Circuit from the drop
down box before continuing.

Adjust the Step 2 In the Settings region, you will see that the default Convergence
Simulation limit is set at 0.0000001 and the default number of Iterations value
Settings is 1000. Both of these values can be left at their default settings.
The Interpolation can be left as Spline and the Starting Condition
as Experimental.
Run Simulation Step 3 Click on the Start button to start the simulation. It also displays
the convergence value and the number of iterations that the
simulation algorithm has performed to reach convergence, see
below. These values are updated while the simulation is
proceeding.
Completed The iteration count will proceed until either convergence to the defined
Simulation convergence value has been reached, or the maximum number of iterations
has been reached, whichever occurs first. This flowsheet should simulate to
convergence in about 70 or so steps, if set up as described.
Close Simulate Step 4 The simulation of this flowsheet is now complete. To close the
Window Simulate window, click on the cross in the top right hand corner of
the window.
4.2.10 Viewing the Results
The results of the simulation can be viewed in the Configurable Stream Overview
window. This window allows the user to view the stream statistics calculated
during simulation for one or more selected streams. The user can choose which
data and which streams are displayed. However, when you first open this
window, all the streams in your flowsheet will be listed by default. You can
either modify this view of the data or add other alternative views that you can
build to satisfy your own requirements.
Open Step 1 Ensure the flowsheet is locked, then click on the Configurable Stream
Configurable Overview icon or select Configurable Stream Overview from the
Stream Flowsheet menu. The Configurable Stream Overview window will
Overview then open. The window will look something like the screen grab
below. From the Select List drop-down, you can select the type of

data you wish to view. In this case we wish to view the simulated
data, so select 'Stream Data (Sim)' from the drop-down.
Note that the screen grabs below are incorrect in one respect. The
grabs were taken from an earlier test version of the program and the
cells in some of the simulated data columns appear white. In fact all
columns containing simulated data should be grey, to indicate they
cannot be edited.
The Function
Some aspects of this table's layout can be modified. The Lock button ( ) on
of the Lock
this Window's toolbar acts as a toggle that determines the functionality of
Button
certain actions in terms of the table configuration changes that can be achieved.
If the Lock button is down, you can add columns and rows to the table. Also
with the button in this position, clicking on a column header will bring up a
dialog box for setting up the contents of the selected column. If the Lock button is
up, clicking on the column headers does not have the aforementioned affect, but
it will allow you to make changes to the order of the columns and the same for
the rows.
Adding Step 2 In this exercise we are going to add two extra columns. To achieve
Columns and this, the Lock button needs to be in the down or locked position, but
Rows this should already be the case when you first open this window.
First click somewhere within the % Solids column to select this
column. Note; don't click on the title of the column as this will bring
up the dialog for selecting the contents of the column. Now use the
Insert Column toolbar button ( ) to add a column. The new

column will be added to the right of the currently selected column.
Adding a Step 3 Initially, the new column will just have 'No Selection' as its column
Column to header. The next step is to set up this column with the information
Display that you require it to display. Clicking on the column header will
Volume Flow bring up a dialog box where the contents of the new column can be
specified.

In this case we want a column showing the volume flow in each of

the streams. We will leave the Selection Name set on 'Auto Generate'.
Unchecking this check-box allows you to enter your own name for
the column - which may be useful if you have lots of columns to
display and want to make the headers more concise. In this case you
need to select the options as per the above screen grab and then click
on 'OK'.
Adding a Step 4 We will add a further column now to demonstrate another feature of
Column to the Selection Options window. Click within the new volume flow
Show Solids
column to select it, then again use the Insert Column button ( ) to
Amount
add a further column to the right of the one selected. Again click on
Above a the title bar of the new column to bring up the Selection Options
Selected Size window. We will assume that for some reason we want to see how
much of the ore in each stream is coarser than 4.75 mm. Again click
on the header bar for the new column. When the dialog box opens,
select Size for Option 1, and you will find that another dialog box
will appear.

Select 4.75 mm from this dialog. When you press OK after this
selection, the value 4.75 will be displayed in the grey box to the right
of the Option 1 drop-down and Option 2 will become available for
selection.
Select 'View As' from the Option 2 drop-down.
This will bring up another dialog box from which you should select
'Cum % Retained'.

Finally, after you have selected 'Cum % Retained' for Option 2, a

drop-down will become available for Option 3. Here you need to
select 'Simulated' for the data type that will be displayed.
When you OK this selection, the overview will look something like
the one below, with a new column showing the amount of solids that
is coarser than 4.75 mm in each of the streams.

Stream Order Step 5 The order that the stream names appear in this table is the same
and Column order in which their associated equipment items were added to the
Order flowsheet when it was first drawn. To change this order, you need to
Changes first click on the Lock button - so that is in the up or unlocked
position. In this exercise we will just move the Cyc feed Water down
to the bottom of the table.
Now click the left mouse button while hovering your mouse over the
name cell for stream (row) that you wish to move (i.e. in this case the
Cyc feed Water stream).
With the mouse still over this row, hold down the left mouse button
and drag this row to its new location. As you move the mouse,
potential new locations will be marked by a red line. When you are
satisfied with the indicted new position, let go of the mouse button
and the required change will be completed. The same method can be
used to change the relative location of columns in this table.
The screen grab below shows the Cyc feed Water row in the process
of being moved.
Note that you can select multiple adjacent rows or columns by just clicking,
holding down and dragging - provided that the column or row you begin this
process on has not already been selected. Once the required group of rows or
columns has been selected, you can then click, hold-down and drag again and
this time the dragging process will move the selected group into a new position,
as indicated by the red line.
We have now set up an overview to show the results of our simulation. For more
information on the Configurable Stream Overview and its capabilities, go to the
topic Using the Configurable Stream Overview 213 .
In the real world, you would be looking at these simulation results and
assessing whether this circuit is achieving the required results and if not,
considering what changes might be made to improve the situation.
After an analysis of your simulation results, the circuit configuration could be
altered and/or the capacity and characteristics of the equipment items changed
before repeating the simulation process. There may be several iterations of this
sequence required before you are satisfied with the results being obtained.
Finally, don't forget to save your project after a session such as this, to protect
against losing your work in the event of a power outage or other mishap.
4.2.11 Viewing Individual Stream Data
A range of different stream statistics calculated during simulation can be viewed

using the individual stream data windows.

Open Stream
Step 1 Ensure the flowsheet is locked then click on the Stream button ( )
Window
or select Stream from the Flowsheet menu to open the Streams
window. This window can also be opened by right-clicking
anywhere on the flowsheet and selecting Stream from the drop-
down menu.
All streams in the flowsheet can be accessed from the Streams
window. The Streams window also shows the equipment items that
the currently selected stream is flowing from and to.
Select Data to Step 2 The user can, from this point, choose to view the data for any of the
view streams in the active flowsheet by first selecting the required stream
from the Stream Name drop down and then clicking on the double
arrow to the right of this drop-down to open the Stream Data
window.
An alternative method of getting at the Stream Data window for any
individual stream is to double-click directly on the line representing
that stream on the flowsheet. This will open the Stream Data
window for the stream directly, without going first to the Streams
window.
Stream Data The layout of the Stream Data window is the same for every stream. A tabbed
Window interface is used to display the different categories of stream data. The first tab
shows the Total values for the stream, including the TPH Solids, the TPH Water,
% Solids values and others. The other three tabs are labelled Sizing Data,
Elemental assay data and Size by elemental assay data respectively.

Click on any of the four tabs to view the data in the relevant categories. On each
of the tabs, there are columns to show the types of data associated with the
parameters listed on that tab. For example, on the Totals tab is a column for the
SD (standard deviation) data. This is where a reliability estimate is assigned to
the individual parameters that have been measured for this stream. Larger SD
values indicate reduced confidence in the experimental value and allow the
program to move further away from these values during balancing.
Viewing the Step 3 To view the sizing data, click on the second tab of the Stream Data
Sizing Data window. The row labels will now be the screen sizes that have been
previously entered. Note that at any time you can change the way the
sizing data are expressed throughout the program, using the buttons
on the main toolbar.
The sizing data can be expressed as either % Retained ( ), Cum %
Retained ( ) or Cum % Passing ( ).

On the other two tabs are the Elemental Assay Data and the Size by Elemental
Assay Data. On these tabs, the data types displayed are limited to Exp, SD, Mbal
and Error. This is because in JKSimMet, none of the models deal with
predictions of assays and we are not generally dealing with processes that
result in any differentiation in grade.
Copying Data Step 4 To copy data from the tab that is currently chosen, first select the
into Excel required data, then click on the copy button ( ) located at the far
right of the Stream data window toolbar - as shown below.
If you then open MS Excel, you will be able to paste the current data grid into the
active sheet, with your chosen cursor position being the top left hand corner of
the grid.
Close To close the Stream data and Streams windows, click on Close ( ) in the top
Windows right hand corner of the windows.
4.2.12 Viewing Data for Multiple Streams
The Configurable Stream Overview feature allows the user to view the stream
statistics calculated during simulation, mass balancing or fitting for one or more
selected streams. The user can choose which data types and which streams are
to be displayed.
Opening the Step 1 Click on the Configurable Stream Overview button ( ) to open the
Configurable Configurable Stream Overview window. If no overview tables have
Stream been set-up previously, the window when first opened will still
Overview contain a default table with some flow and % solids data and all of
the size fractions that have been entered for the project concerned.
There are a number of pre-configured overviews with different
combinations of data types. The user can select an appropriate one of
these via the Select List drop-down in the upper left-hand corner of
the window. The screen grab below has captured this process, with
the user in the process of making a selection.
If one of the pre-configured overviews does not satisfy your needs,

then there are plenty of tools provided for modifying an existing
overview or for creating a new overview and setting this up precisely
to your requirements.
Creating a Step 2 To create a new Overview, click on the New Stream Overview button
New Stream ( ) which will bring up the Add New Stream Overview dialog.
Overview Type a name for the new Overview here and then click on the OK
button.

The Configurable Stream Overview will then re-open with a default

range of stream statistics as shown below. The user can then add or
delete rows or columns to display only the required data for this
particular overview. Note that data can be entered via the
Configurable Stream Overview, in any cells that have a white
background.
Remove Step 3 For the practice, we will assume that you don't wish to display the
Unwanted data for the Cyc Feed in this overview. To remove it from the display,
Streams click anywhere in this row and then click on the Delete Rows ( )
button.
Add a Data Step 4 To insert an extra column, click in any column of the table and then
Column click on the Insert Column button ( ). This will add a blank
column to the right of the cursor. The new column will just have "No
Selection" as the header and all of its fields will initially be grey; as
illustrated in the screen grab below. Note that you can also add a
new column that is a replica of an existing column. To do this you
click in one of an existing column's cells and then click on the Copy
Column button ( ). When you do this, a replica of the selected
column will be placed immediately to its right. This may be more
efficient if the column being added is to be very similar to an existing
column, but with just the data type changed perhaps or the mode of
display changed - e.g. from % Retained to Cum % Retained.
Define the Step 5 To define the data that is to be shown in the new column (or to
Data Shown in modify what is shown in an existing column), click on the header
a Column row of the new column to open the Select Options dialog box. Select
the required stream statistic from the Option 1 drop-down list. In this
case select "%Solids", then from the Option 2 drop-down list select

"value" and from the Option 3 drop-down list select the type of data
to be displayed (e.g. experimental, simulated etc.).
Export the Step 6 The data presented in the table can be exported to Excel by clicking
Configurable on the Export Overview button ( ), or on the Export All button (
Stream
) if more than one stream overview exists. Alternatively, by
Overview
table clicking on the Copy Grid button ( ), the data can be copied to the
clipboard for pasting into other documents (e.g. a Word document).
Clone the Note that the user is able to create clones of existing tables in the Configurable
Configurable Stream Overview by clicking on the Clone Overview button.
Stream
Overview
table
4.2.13 Finishing a JKSimMet Session
Ending the Step 1 To quit from JKSimMet click on the cross in the top right hand
JKSimMet corner of the session window or select Exit from the File menu. A
Session JKSimMet prompt will ask to save the changes if changes have
been made and not yet saved. Click on "Yes" to save any changes.
Simulation of the simple comminution circuit has been completed and the
simulation data have been examined. In the next exercise the operation of the
circuit will be changed by varying the parameters of some of the components,
and then running simulations to observe the predicted results.
Before doing this, end the JKSimMet session as explained above.
4.3 Working with an Existing Project
About this Now that a simple comminution circuit has been successfully simulated, this
Section exercise will demonstrate how to:

Change some of the input data and flowsheet configuration in an

attempt to improve the performance.
Re-simulate the circuit.
View the results.
The objective is to optimize the performance of the circuit by changing key
parameters. The parameters are those characteristics of the equipment or
streams that can be altered. In a real plant most equipment parameters can be
altered (with varying degrees of difficulty and with varying degrees of
expense!). A few stream parameters such as the mass flow rate can also be
varied. It is however difficult and costly to experiment with real equipment;
simulation using JKSimMet allows the engineer to make a wide range of
changes easily and then view the predicted results. The selection of these
parameters is the engineers job and you may wish to experiment; this section
will take you through the steps for a number of changes.
The general technique is to first decide on the parameter changes you wish to
make, then select the equipment concerned and make the changes, re-simulate
the circuit and finally observe the results. These results can then be accepted
and saved as a permanent record; further changes can be made and the
process of simulating and assessing the results repeated.
4.3.1 Selecting the Flowsheet to Use
The procedures used when working with an existing project are very similar
to those outlined under the heading Building a New Project 59 .
Start JKSimMet Step 1 Start JKSimMet by following steps 1 to 4 under the heading
JKSimMet Start Up 60 .
Load an Existing Step 2 Click on the Open Project icon on the toolbar or select Open
Project Project from the File menu. This will open the Open JKSimMet
Project dialog, which displays the previously saved projects.
Select the Learner Project that was created while working
through the Building a New Project section and then click Open.
Loading a Project JKSimMet closes an open project before opening a different one. If opening a
when Another project is attempted when another project is still open, JKSimMet will prompt
Project is Still to save the open project where changes have been made since the file was last
Open saved.
Step 3 To prevent the Learner Project from being overwritten, select Save
Project As from the File list then type in the new project name; for
example use Learner Project Changed Cyclone Params as the
new name, and click OK.
Note however, that on occasions when you do wish to deal with two different
projects at the same time, you can open a second instance of JKSimMet and
then use this instance to open the second project. It would be wise though to
avoid having the same project open in both instances. This could potentially
result in problems - especially if you go to save data that may have been
changed in both instances.
Working with an Existing Project Version 6.0.1 - March 2014

4.3.2 Working with the Simulation Manager
In this section the cyclone vortex finder diameter will be changed to see how
this affects the size distribution of the final product from the grinding circuit .
While the user can make this type of operating parameter change in the
Equipment window or via the Info Blocks on the screen (see Defining
Equipment Info Blocks 125 ), the Simulation Manager provides a more
convenient means of doing this, particularly when several similar simulations
are to be performed. Note however that with this version of JKSimMet, you
cannot change the feed rate to the circuit from within the Simulation Manager.
This is because the Simulation Manager deals with changes to model
parameters associated with equipment items only. However, it is intended
that in later versions the circuit feed rate will also be made available for
modification via the Simulation Manager interface.
Open the Step 1 Click on the Simulation Manager button on the toolbar to open the
Simulation configuration window for this feature. It will initially be blank as
Manager shown below and the first thing to do is to create a simulation
scenario.
Create a New Step 2 Click on the New Sim Scenario button to create a new simulation
Simulation scenario. Type the name of the scenario into the dialog that
Scenario appears and click on the OK button to access the blank scenario
configuration screen.
When you click on OK, the initial framework for the new
simulation scenario will be set up. This will have a single column,
with "No Selection" as the header.
Configure the Step 3 To begin configuring the new simulation scenario, click on the "No
Simulation Selection" header and a new dialog will open labelled Equipment/
Scenario Tab/Option/Parameter. This dialog appears as shown below.
Version 6.0.1 - March 2014 Working with an Existing Project

Selecting the Step 4 In this case we will select the cyclone from the Equipment/Group
Parameter to be drop-down, then Operating Condition from the Tab drop-down.
Changed The Option drop-down is not relevant in this case and will not be
available. From the Parameter drop-down we will select Vortex
Finder Diameter - Do (m).
Once you have made these selections, click on the Apply button at
the bottom of this dialog. The Simulation Manager window should
look similar to the image below. You will notice that now the
Simulation 1 cell for the cyclone parameter we have selected is
available for data entry.

Selecting the Step 5 The new simulation conditions can now be entered in the Cyclone
Type of Change column. You will see that just above the Original Data label, there
and Specifying is another row labelled "Type of Change". There are two choices
the Amount of here. You can specify the actual value for the parameter or you can
Change specify a percentage change from the original value. In this case
Required we will reduce the vortex finder diameter by 10% for one
simulation and then increase it by 10% for a second simulation.
By default the Type of Change will be set to "Value". Click on the
drop-down and change this to "% Change". Then click in the
Simulation 1 cell for the Cyclone column and enter "-10". This
simulation scenario will be automatically saved under the default
name "Simulation 1".
Adding a Step 6 As we are going to be doing two simulations, we need to add an
Simulation extra row - in addition to the default Simulation 1 row. To do this,
place the cursor anywhere in the Simulation 1 row and press the
Apply Simulation button. An extra row will be added below the
cursor position, with the default name Simulation 2. The new
simulation conditions can now be entered in the Cyclone column -
in this case we will enter the value +10, meaning that we will be
increasing the vortex finder diameter by 10% from its original
value.

Step 7 If you now place the cursor anywhere in the Simulation 1 row,
pressing the Simulate Select button ( ) will run a simulation
using the parameter changes that have been specified in this row.
The same would apply if you placed the cursor in the Simulation 2
row - a simulation would occur with the settings specified in the
Simulation 2 row only.
If you press the Simulate All button ( ), the program will run
simulations consecutively on all of the scenarios you have set up.
Note that only the results from the last one of these simulations
will be available for plotting. Note also that you can press the
Simulate All button from any one of the three tabs. This means that
you can simulate with one of the results tabs active and therefore
immediately see the before and after values.
The results of the simulations just performed can be observed on
the next two tabs, Results - Streams and Results - Equip. You can
set up these tabs to observe any results from the simulation that
you wish to monitor. This is done in a similar fashion to the way
you set up the Simulation Scenario tab
Set up Columns Step 8 Click on the Results - Streams tab, create a new column by clicking
for the Results on the Insert Column button. example of the Results - Streams tab
you wish to is shown below where the user is looking at the effect of the vortex
Monitor finder changes on the solids flow rate in the cyclone underflow
and P80 in the cyclone underflow.

Notice that the buttons for adding and deleting rows from the table
are not available when you are on either of the results tabs. You
need to return to the Simulation Scenario tab if you wish to set up
further scenarios for simulation. The buttons for adding columns
however are available and these can be used to add any
characteristics of the streams or equipment that you would like to
monitor following simulations under the various scenarios. Note
that you do need to repeat the simulations if you add further
columns because the cells in any new columns will be just
populated by zeros until the simulations have been re-run.
Step 9 Now select the Results - Equip tab, add a column and click the top
row of the column to bring up the dialog for selecting the
equipment and equipment parameters for display. Select Cyclone
from the first drop-down, Perform Data from the second and Op
Pressure from the fourth. Notice that the third drop-down (Option)
is de-activated. It is only required for a very limited number of
equipment types.

When you click on the Close button, another dialog box will
appear where you select the types of data that you wish to
display.
Once you have made the selection and closed this dialog, you will
be returned to the Simulation Manager window, which will now
look something like the screen grab below.

Rename the Step 10 You can change the name of the scenario easily by pressing the
Scenario Rename Scenario button. This will bring up a dialog box like the
one shown below. Change the name to something that will be
more suggestive of what the current scenario has been set up to
investigate - in this case perhaps something like "Cyclone Vortex
Finder Changes".
Run a Simulation Step 11 To continue the exercise, now press the Simulate All button to
on the Selected carry out simulations according to the conditions set up for both
Row rows. You will see that the cyclone operating pressure data will
then appear for the two scenarios that have been defined on the
first tab.

4.3.3 Using Model Based Groups for Simulations
Groups - Where you have multiple equipment items that are using the same model, you
Principles of can assign these to a group which can then be selected instead of an individual
Use equipment item. When this is done, any changes in the settings that you make
to the equipment or model parameters for the group will apply to all of the
equipment items assigned to that group. Once you have set up groups, these
will become available as alternatives to just selecting individual equipment
items from the top drop-down list in the Scenario Manager window. Note that
the defining feature of a Group is that all members of the Group will be using
the same model, with the same parameter settings.
Edit Groups Step 1 In the Simulation Manager window, click on the Edit Groups button
Button to bring up the Select Equipment for Groups dialog.
Step 2 Click on the Add Group button at bottom left of this dialog. This will
bring up an Add New Group dialog where you can provide a name
for the new group and then select from all possible models
associated with the types of equipment that exist in your flowsheet.

In this case we do not have multiple equipment items using the same model,
but we will go through the exercise anyway to demonstrate how it works.
Step 3 Enter a name, such as "Perf Mix BM Group". This would be a group
consisting of equipment items on your flowsheet that all use the
perfect mixing ball mill model.
Note that you do not have to assign all of the equipment items that use this
model to this group. Some of them could be left outside the group to be set up
individually for simulations. Alternatively, you might wish to have two
groups. For instance you could have "Perf Mix BM Group 1" and "Perf Mix BM
Group 2". Both groups would necessarily consist of mills that use the perfect
mixing model, but each could be set up with different parameter values within
any given simulation.
Step 4 When you close the Add New Group window, you will see the new
group you have added in the right hand panel of the Select
Equipment for Groups window. This new group will initially
contain no equipment items. When you click on it however, you will
be able to see in the left hand panel, all of the equipment items on
your flowsheet that are currently set up to use the model associated
with the selected group.
Now use Ctrl or Shift click on the equipment items from the left
panel to select all of those that you wish to include in the group and
then click on the transfer button to move these items into the
selected group. In this case there is only one equipment item - the
ball mill. Click on this item and then click on the transfer button to
move it into the "Perf Mix BM Group". Just prior to the transfer, the
window should look similar to the one shown below.

After the transfer, the window will look like the screen grab below,
now with the equipment item that was selected from the left panel,
appearing in the right panel, under the selected group.
Now when you go back to the Simulation Manager window and

click on the top row of the table, you will find that the group you
have just added will be available for selection.

Note that once you have assigned an item of equipment to a group, you will no
longer be able to select this item of equipment individually. This is because by
definition, all members of the group will have the same parameter values.
Similarly, once you have set up a column with a particular parameter selected
for a given item of equipment, you will not be able to set up another column
with the same equipment and parameter selections.
4.3.4 Simulating Changes in Operating Conditions
In this example we will look at the effect of increasing ore hardness and how
JKSimMet might be used to investigate ways to compensate for this and thus
maintain throughput at existing levels.
Open the
Step 1 Click on the Simulation Manager button ( ) to bring up the
Simulation
Simulation Manager window, then click on the Simulation Scenario
Manager
tab.
Window
Step 2 Click on the New Sim Scenario button ( ) to create a new
simulation scenario. In JKSimMet, the term scenario is used to
describe a group of related simulations that have been set up to
investigate the effects of changes in a particular set of model
parameters. The individual sets of parameter values are just referred
to as Simulations.
We will call the new Simulation Scenario in this case "Compensating
for Ore Hardness Changes".

Add a New
Simulation
Scenario
Step 3 Now click on the "No Selection" at the top of the default column that
will be present on the Simulation Scenario tab. This will bring up
the Equipment/Tab/Option/Parameter window. Note that you must
have the Lock button ( ) in the down position for this dialog to
activate. From the Equipment/Group drop-down list, select "Ball
Mill".
Step 4 Select Scaling from the Tab drop-down and then select Ore Work
Index from the Parameter drop-down.
Step 5 When you click on the Close button from the above window, a Select
Properties window will open. Here you should just tick the check-
box for "Sim" since the Org (original) values are only relevant for
when you are fitting - not for simulating.

On closing this window you will find that the Simulation Manager
now looks like the screen grab below.
Simulation 1 will be present because this is a default simulation row

that is added by the system. You can change the name of each
simulation if you wish to something more indicative of the
parameter adjustments that have been applied. To do this, you just
click in the relevant cell of the Simulation Name column and made
the required editing changes.
Add Step 6 Add three more rows to this Simulation Scenario by pressing the
Simulation
Insert Simulation button ( ) three times.
Rows
Add Columns Step 7 Next add two more columns by pressing the Insert Column button (
) twice.
Step 8 Using the same procedure as described above for setting up the first
column, set up the second column for adjusting the fraction of
critical speed that this ball mill is operating at. Similarly, set up the
third column for adjusting the load fraction for the ball load in this
mill.
Step 9 Now change the names of the simulations so that they provide an
abbreviated specification of the parameter changes involved. Also
enter the new parameter values in the columns, as shown in the
screen grab below.
For the first simulation we will just be looking at the effect of harder
ore on throughput when there are no compensatory plant changes
made. We will call this simulation "Harder Ore" and change the Ore
Index value from the original 15.3 to 17.7 kWh/t. For the second
simulation we will increase the mill speed from 74% of critical to
80% of critical and for the third we will increase the mill load from
40% to 45%. Finally, for the last simulation we will increase both the
mill speed and mill load to look at the combined effect. Note that the

higher ore work index should of course be entered for all four
simulations. The Simulation Manager window should now look
similar to the screen grab below.
Step 10 Now go to the Results - Streams tab and set up columns for the
results you wish to observe on running these simulations. Say in
this case we are just interested in the cyclone U/F solids TPH, %
solids and cyclone O/F P80. There will be one column present by
default so you will need to add two more columns. Set these up in
the same way as you have done for the columns on the Simulation
Scenario tab.
Step 11 Once the columns have been set up for the results you wish to
observe, click on the Sim All button ( ) to simulate each of the
plant conditions that you defined back on the Simulation Scenario
tab. The Simulation Manager should now look similar to the one
shown below, with simulated outcomes for each of the sets of
parameter values.

We can see from the values obtained above that with both changes
applied to the mill operating conditions, the simulator is predicting
that production can be returned to the level that existed prior to the
ore hardness change.
Step 12 If we now go to the Results - Equip tab, we can have a look at what
effect our operating parameter changes have had on the power
consumption of the mill. When you click on this tab, there will be a
default column in place - but again it will just have "No Selection" as
the header. Click on this cell and you will again be presented with
the Equipment/Tab/Option/Parameter window.
Step 13 In this window, select "Ball Mill" from the first drop-down and
"Power" from the second. From the Parameter drop-down, select the
total power item for an overflow ball mill.
Step 14 Note that after you have made the selection and closed this window,

the selected parameter identification fields (column headers) back on

the Simulation Scenario window will now be populated. However,
there will be no values filled in for the results of the various
simulations. To see the results, you will now need to run the
simulations again, by pressing the Sim All button ( ). Once the
simulations have been run, your Simulation Manager window will
look like the one below.
So the results from this exercise have indicated that to minimise the
effect of the harder ore and almost restore the circulating load and
product P80 requires an 18% increase in power.
4.3.5 Working with Configurable Equipment Manager
Configurable The Configurable Equipment Manager window displays a summary of selected

Equipment equipment unit parameters. The user can configure multiple summary tables for
Manager display and can edit the values displayed in the tables. This window provides a
simpler and more efficient alternative for reviewing and adjusting equipment
information than using the individual equipment data screens. More information
on the Configurable Equipment Manager is available under the section on
JKSimMet Windows 153 and in the topic Editing Equipment Data 195 .
Step 1 Ensure the flowsheet is locked ( ), then open the Configurable

Equipment Manager window by clicking on the Configurable
Equipment Manager button ( ) or by selecting Configurable
Equipment Manager from the Flowsheet menu. When first opened, this
window will look similar to the illustration below.

Step 2 Click the New Unit Overview button ( ). This brings up the Add
Unit Overview dialog box.
In this case we will enter Ball Mill Overview for the name and select
'Ball Mill (Perfect Mixing)' from the Select Model pull-down list. Since
the flowsheet we have been dealing with for demonstration purposes
has only the one item of each type of equipment, using the
Configurable Equipment Manager in preference to dealing with the
model by clicking on the item of equipment itself does not confer a lot
of advantages. The major benefits of using this option are to be had
when you are dealing with multiple equipment items in your
flowsheet that all use the same model.
Step 3 Click OK and something similar to the screen below will appear.

The Default
New
Overview
Window
When first opened, the new overview window contains a single row
labelled 'Ball Mill' because in this case it is the only equipment item in
our flowsheet that uses the Ball Mill (Perfect Mixing) model. If we were
dealing with a flowsheet that had multiple items using this model,
then each of these items would have been listed on a separate row.
The new overview window also contains just the one column to begin
with, which is headed 'No Selection'. This is where we need to carry
out some configuration to display the data that we wish to manipulate
and/or view in relation to the equipment items using this model. To
select the data that you wish to show in any column of an overview,
click on the first line of the column. This brings up a dialog box where
the tabs, options and parameters may be set as is appropriate to
display the required data items.
Step 4 Click the No Selection to bring up the Tab/Option/Parameter dialog
box. Let's say that in this case we are interested in the effect of having
a slightly larger mill. We would select 'Scaling' from the Tab drop-
down and then 'Internal Length' from the Parameter drop-down.

When you then close this dialog, the Configurable Equipment Manager
should look like the image below.
Next we would like to look at the effects on the output parameters

associated with this equipment unit such as the power draw of the
mill. We will set up a second column to enable this to be observed.
Step 5 To add an extra column, click on the Insert Column button ( ). Now
click in the first row of the new column to open the dialog box where
the contents of the new column is defined.
Positioning Note that you can control the positioning of a new column at the time
Columns of placement. A new column will always be placed to the right of the
currently selected cell. You can also move a column after it has been
placed. To do this you need to first unlock the display ( ), then click
on the column to select it and then click on it again, this time holding
down the mouse button to drag and drop the column to its new
location. Potential new locations will be indicated while you are
dragging it, by a vertical red line between the existing columns. Don't
forget you will need to click on the lock button again before continuing
with other operations.
Deleting Note also that is easy to eliminate columns that are no longer needed.
Columns Just click anywhere in the column in question - anywhere that is
except the top header cell, because this would just open the Tab/
Option/Parameter dialog box. Having one of the cells in the column
selected is enough to identify this column as the one to be removed.
Then click on the Delete Column button ( ) to remove it.
Step 6 In the Tab/Option/Parameter dialog box that will have opened after
Step 5, select Power from the Tab menu and Total Power (Overflow
kW) from the Parameter menu. When you click on the Close button,
the Configurable Equipment Manager should look like the one shown
below.

Step 7 Now take note of the mill power reading and change the mill length
from 7.3 to 9.5 m. You will need to re-run the simulation to observe the
effect of this. Back on the main window, click on the large Simulate
button that is located just above the left (flowsheet listing) panel and
press the Start button once this window opens to run the simulation.
Now navigate to the Configurable Equipment Manager. You will then
be able to see any resultant changes to the output parameters
associated with the equipment items of interest. In this case it is just
the power consumption parameter that we have set up for
observation. You should see that this will have increased from around
4395 kW to 5705 kW.
Step 8 The overview may be printed directly from the dialog box, but it is also
possible to copy the overview to the clipboard for pasting into Word,
or export the overview into Excel using the Export function ( ).
Using these buttons a single overview may be exported, or if there are
multiple overviews, several can be exported at once using the Export
All function ( ).
4.3.6 Defining Stream Data Info Blocks
Information Blocks may be added to a flowsheet to display certain information

about streams or equipment on the flowsheet itself.
Adding Stream Step 1 Ensure the flowsheet is locked ( ), then click on the Setup Info
Information
Blocks button ( ) on the toolbar. The Streams tab at the top of the
Blocks
Define Information Blocks window is the default active tab.
Step 2 Set the Select No. Parameters value to 6. After you make this
selection, the Information Block definition table will be generated in
the area beneath the drop-downs. This table will have a cell for each
of the required parameters - 6 in this case. Initially it will just
display 'No Selection' in all of its cells.
Note that the second drop-down is for selecting the recovery basis
stream. This is only relevant where you are dealing with assay data
i.e. in a mass balancing exercise. As the current exercise does not
involve the mass balancing of assays, it is not necessary to make a
selection from this drop-down.

Selecting the Step 3 Click in the top left cell to bring up the Selection Options dialog box
Type of Data to for choosing the data that you wish to have displayed in this cell. In
Display this particular cell we want to display the simulated value for the
solids flow in the streams. Select the appropriate values from the
drop down cells as shown below. Note that for the Streams Info
Blocks, the name for the selected parameter/data type is auto
generated and you do not have the option of modifying this name.
Hence the Selection Name area at the top does not have editable
fields.
Step 4 Carry out the same procedure to display the simulated value for the
volume flow figure in the top right cell of the table.
Step 5 Now repeat for the procedure for the next row down in the table,
this time selecting '% Solids (Sim)' for the left cell and 'Pulp SG
(Sim)' for the right cell. The Information Block set up should now
look like the one shown below.

Step 6 For the final row, we will display the Cum % Passing 0.15 mm in
the left cell and Cumulative % Retained on 1.18 mm the right cell,
again with both being simulated values. Click on the bottom left cell
to bring up the Selection Options dialog box once more. This time
select 'Size' from the Option 1 drop down. When you do this,
another dialog will open on which you select the size that you
require data for.
After you have selected the size required, it will appear in non-
editable form in the field to the right of the Option 1 drop down.
Step 7 From the Option 2 drop down you should now select the item 'View
As'. When you do this, another dialog box will appear on which
you can select the way in which the sizing data are expressed.
Select 'Cum % Passing' from the options presented on this dialog.
The screen grab below shows the set up during this selection
process.

Your selection here will then appear in the right hand cell next to
Option 2.
Step 8 For Option 3, select 'Simulated'. The set up just before you press the
OK button should look like the one below.
Step 9 Set up the lower right cell in a similar fashion, but this time select
1.18 mm from the Size drop-down at Option 1, Cum. % Passing
from the View As drop-down at Option 2 and once more 'Simulated'
at Option 3.
Step 10 You are now ready to specify which of the streams on your
flowsheet are to have these info blocks associated with them. You
can select streams from the available streams list on the left of the
Define Information Blocks window. To do this you can use the Ctrl
or Shift key with a left mouse click to select either individual
streams or a continuous group of streams, respectively. In the
illustration below we have just selected the feed and the two
cyclone products to have info blocks on this flowsheet. Once you
have made the selection, click on the Add Info Blocks button to place

them on the flowsheet.
Note that there is also an Update Info Blocks button. If you make
changes to the info blocks definition, pressing this button will
apply the changes to any info blocks already on your flowsheet. If
you make changes to the definition table and then just press the Add
Info Blocks button, the program will place the new info block but
will also update existing info blocks as well as the contents of the
key in the top left corner.
Step 11 You can now close the Define Information Blocks window. This
will return you to the main window where you may find that you
will need to move and/or resize the key so that the text is readable.
To do this you will need to unlock the flowsheet first. Remember to
lock it again before continuing. Note that you can re-size and move
the Stream Info Blocks themselves, without first unlocking the
flowsheet.
The flowsheet should now look similar to the one below, shown in
the process of expanding the size of the key.

4.3.7 Defining Equipment Info Blocks
As well as Stream Info Blocks you can also define Equipment Info Blocks to
display information about equipment items on your flowsheet. In this exercise
we will add info blocks to the ball mill and the cyclone in the Learner Project.
Step 1 Again ensure that the flowsheet is locked ( ) before clicking on

the Setup Info Blocks toolbar button ( ). The Streams tab at the
top of the Define Information Blocks window will be active by
default. Now click on the Equipment tab to enter the environment for
defining this type of info block. Select 'Ball Mill' from the Select
Equipment list on the left and then select 2 from the Select No.
Parameters drop down on the right.
Step 2 After you have selected the 2 from this list, default parameter names
will appear under Ball Mill - Parameter 0 and Parameter 1. You now

need to define these parameters. So first click on Parameter 0 and a

dialog box will appear where you can select from the various
options available. From the Tab drop down, select 'Scaling' and
from the Parameter drop down select 'Fraction Critical Speed'. On
this dialog you need to write in your own name for the parameter
you have selected. This is entered into the Parameter Name field.
This can be exactly as it appears in the list or your own abbreviation
of this.
Step 3 When you press close on this dialog, a further selection dialog will
appear where you have a choice in this case of displaying either the
simulated or original data. One would normally select simulated
data to be displayed. Click on this check box.
Step 4 When you close this dialog by clicking the apply button, you will
see that 'Parameter 0' will have been replaced by the text you entered
for the fraction of critical speed parameter. Now carry out the same

procedure for the 'Parameter 1', this time selecting 'Load Fraction' as
the parameter. You should end up with the Define Information
Blocks window looking like the screen grab below.
Step 5 Click on the Add Info Block button and this info block will be placed
on your flowsheet, somewhere in the proximity of the ball mill. We
will now add another Equipment Info Block, this time for the
cyclone. The procedure will be much the same. First select Cyclone
from the list of equipment on the left. In this case we will only select
the one parameter to display. You will again see that by default this
will be called Parameter 0 in the definition table.
Step 6 Again click on the Parameter 0 place holder to assign an actual
parameter for this display location. In this case we will select
'Performance Data' from the Tab drop down and then Operating
Pressure, KPa (mm) from the Parameter drop down. Once more you
may need to type in your own abbreviation of the parameter name.

After you close this another will open where you select the type of
data that you wish to display for this parameter. In this case we will
assume that only the calculated data type is to be shown. Note that
you can only make a single selection here. Therefore if you wanted
to show say the SD for this parameter as well, you would have to
select 2 parameters for display from the initial drop down, then go
through the same selections until the final data type selection.
Step 7 Tick the Calculated check box and then click on the Apply button.
When you close this dialog, the dialog for selecting the parameter
will also close and you will see the parameter you have defined now
shown in the information block table.
Step 8 Now click on the Add Info Block button and this will place an
Equipment Info Block in close proximity to the cyclone. This info
block will be displaying the calculated D50 value for this cyclone.
You can now close the Define Information Blocks window and the
flowsheet should look something like the one below.

Note that you can change the size and location of the Equipment
Info Blocks as well as the Stream Data Info Blocks without having
to unlock the flowsheet first.
4.4 Summary
By working through the topics under Learning JKSimMet, you should now
have learnt how to:
Create a completely new project and complete all the steps to simulate
a flowsheet.
Display the results of simulations and export them to Excel.
Make changes to an existing flowsheet and re-simulate after the
changes have been made.
Thus if you have worked carefully through the manual to this point, you
should now have the ability to perform all the basic techniques necessary to
use JKSimMet and obtain useful results. The section that follows (Using
JKSimMet) provides a mechanism for referring to and revising any of the skills
learned up to this point.

Part
V
Using JKSimMet 131
5 Using JKSimMet
Contents of This This section covers all the basic operational features of JKSimMet. While the
Section previous section (Learning JKSimMet) was structured as a tutorial, this
section is structured more as a reference guide to facilitate revision and
consolidation of the knowledge gained so far .
The first chapter in this section is entitled JKSimMet Description 131 and
contains an overview of JKSimMet. Following this there is a topic containing
some Definitions of Key Terms 135 . In the sections that follow there are
descriptions of how the program interfaces with the user; the Menus and
Toolbars 137 and the various Types of Windows 153 used to display
information.
After this there are chapters that cover Building and Manipulating a Circuit
Flowsheet 177 and then on Editing the Flowsheet Data 191 . Finally there are
chapters on Using Simulation 199 , Viewing Summaries of Stream Data 213
and on Using the Reporting Feature 226 .
5.1 JKSimMet Description
About the JKSimMet is a software package for simulating mineral processing operations,
Package particularly comminution and classification. It is based on more than 25 years
of modelling and simulation research and development at the Julius
Kruttschnitt Mineral Research Centre. The package has specifically been
designed for engineers who are familiar with plant operation, but are not
necessarily skilled in modelling and computing.
JKSimMet helps the user perform the following tasks:
specify the flowsheet and equipment types
select the necessary process models
specify circuit data such as stream size distributions, equipment
dimensions and so on
tune the models (using plant data) to emulate a particular operation
use the models to simulate a circuit and predict the circuit
performance
present the results as annotated flowsheets, tables and graphs -- on
the screen or as printed reports
mass balance and adjust plant data .
What JKSimMet JKSimMet allows metallurgists to:
Can Do perform analysis and optimisation of the performance of existing
operations using actual circuit data
pursue flowsheet design studies for new circuits
mass balance and adjust data for circuit audit and metallurgical
accounting
run a simulation of the plant.
assess the impact on metallurgical performance of various circuit

changes.
present the data and results on the screen, copy the data to the
clipboard or export results to MS Excel for printing and further
analysis.
Version 6 of JKSimMet is a user-friendly system that uses the Windows
interface, with features such as switching between applications, export of
data via copy and paste functions and drop-down menus for quick editing
and data manipulation.
5.1.1 JKSimMet Model Types
Process JKSimMet performs steady state simulation of a range of flotation circuit

Models operations. There are eight distinct types of equipment models available in
JKSimMet:
The Models
Type of Model Example Icon
Feed Feed
Water Feeder
Crusher Jaw Crusher
Gyratory Crusher
Cone Crusher
Roll Crusher
VSI
HPGR
Degradation
Mills Autogenous Mill
Rod Mill
Ball Mill
Screens Trommel
Single Deck Screen
DSM Screen
Double Deck Screen

(one under)
JKSimMet Description Version 6.0.1 - March 2014

Using JKSimMet 133
Classifiers Air Classifier
Hydrocyclone
Spiral Classifier
Rake Classifier
O-Sepa Classifier
Splitters 2 Product Splitter
3 Product Splitter
Storage / Transport Bin
Pump
Pump Sump
Sump
Stockpile
Thickener
Final Product
Separators Flotation Cell
Flotation Column
Spiral Separator
2 Product Separator
3 Product Separator
There is also the facility to add new equipment models via offline compilation
(contact JKTech for more information).
Model The equipment may be combined in both simple and complex flowsheet circuits
Descriptions to enable the user to simulate the operations of plants or subsections of plants.
Simulation outcomes will be dependent on the selection of appropriate process
models (mathematical models) for the equipment items in your flowsheet.
Further control is exercised through the specification of scale for the various
equipment items, the selection of model parameter values and through the
operating data inputs such as the feed stream properties.
The algorithms for each model are outlined in under the Model Descriptions 294
Version 6.0.1 - March 2014 JKSimMet Description

section.
5.1.2 JKSimMet Capabilities
Simulation In addition to the simulation capabilities discussed above, JKSimMet

Capabilities encompasses all the functions necessary for the user to use and maintain a
number of flowsheets within a single project.
JKSimMet provides process engineers and metallurgists with a powerful tool
for conceptual design, tuning and monitoring of process plants and their
elemental circuits and equipment. It enables an almost infinite number and
variety of circuit designs to be simulated so that the optimal design for the
task and for the expected range of variation of input and flow conditions may
be estimated before expensive experiments with the real plant are undertaken.
JKSimMet for JKSimMet allows metallurgists to assess the impact on metallurgical
Metallurgists performance of:
Plant throughput
Equipment operating conditions
Equipment volume
Circuit layout
Stream destination
New equipment addition
Change in plant feed sizing, floatability or mineralogy
JKSimMet for JKSimMet also has the capability of assisting Plant Operators to understand
Plant Operators the effects of day to day changes in circuit operation (e.g. equipment operating
conditions, plant throughput, feed properties) on metallurgical performance.
However, JKSimMet does not and cannot replace the process engineer. It
facilitates the simulation of circuit and plant designs; it does not design. Like
any tool, the quality of the results that it produces is directly related to the skill
of the artisan who uses it.
Size Distribution There is a maximum of 40 size fractions in the size distribution for any one
stream.
Number of There is no defined limit to the number of flowsheets which may be included
Flowsheets in a project. However, the database will become very large and may cause a
decrease in machine performance.
Model Fitting In SimMet a user is only able to simulate one flowsheet at a time. There are no
Constraints restrictions on the number of parameters that can be fitted.
Number and The user cannot add new models without assistance. However, JKTech
Type of Models welcomes suggested new models which will be considered for subsequent
releases of JKSimMet. JKTech can also develop custom models for an
individual client.
Mass Balancing The updated SimMet mass balance algorithm allows the user to balance any
realistic circuit, provided that they follow the correct mass balance process.

Using JKSimMet 135
5.1.3 JKSimMet Constraints
System While JKSimMet is a powerful and flexible system there are, necessarily, some
Constraints constraints. These are:
Number of Flowsheets There is no defined limit to the number of

flowsheets that may be included in a project.
However, the database will become very large
and may cause a decrease in machine
performance.
Number of Equipment The maximum number of equipment units
Units per Flowsheet that can be put into a single flowsheet is
limited only by the available space on the
flowsheet screen. If large numbers of
equipment units are added, then the drawn
circuit requirements may initially exceed the
flowsheet window area available. However, a
Zoom to Fit button ( ) is provided and will
re-size your flowsheet so that it fits neatly into
the current size of the flowsheet window.
Number of Streams Although the flowsheet allows an infinite
Connected to Equipment number of feed streams to be connected to an
equipment unit, the simulation engine only
recognises the first 50 streams entering an
equipment unit.
Property: Size There is no limit to the number of size classes
that can be defined.
Number and Type of For a list of the available models refer to
Models Section JKSimMet Model Types 132 . JKTech
welcomes suggestions for new models. Such
suggestions would be considered for
subsequent releases of JKSimMet. JKTech can
also develop custom models for an individual
client.
5.1.4 JKSimMet Expandability
Package JKSimMet is a self-contained package providing within itself all the features
Expandability required to build, execute and maintain a library of projects.
JKSimMet is supplied with process models for the equipment listed under the
heading JKSimMet Model Types 132 . While these models cover many of the
typical processes encountered in comminution plants, JKSimMet has been
designed to facilitate the incorporation of new models. While the user cannot
add new models to the system, recommendations to JKTech will be considered
for inclusion in later releases. Custom designed versions of JKSimMet may
also be considered; contact JKTech for more information.
5.1.5 Definition of Terms Used in JKSimMet
A number of the terms and names used within the JKSimMet system have a
specific meaning, which it is important to understand. These terms are

defined here to avoid ambiguity.

Project JKSimMet is organized and based upon the concept of a project. A project can
be considered as a portfolio in which the user stores one or more flowsheets
and their related data.
Process Circuit A process circuit is a diagram containing a set of Equipment items
interconnected by Streams, which has been drawn in a JKSimMet Flowsheet
window to represent a particular sequence of processing steps. To be
complete, a circuit must always have at least one Feed unit and at least one
Final Product unit.
Flowsheet A flowsheet consists of one or many process circuits and their related data.
The flowsheet may contain one item of equipment or many. It can contain one
complex multi-stage circuit or many circuits in parallel. While multiple
circuits are acceptable within one flowsheet, there is no facility for linking
circuits from separate flowsheets within a project.
A user may create a project to model several flowsheets, such as a crusher
circuit and a grinding circuit. Simulation would be executed for the crushing
circuit first to a defined convergence, using the equipment data and
configuration supplied. The data resulting from the execution of this
simulation could then be manually passed as input to the grinding circuit
and simulation executed through this circuit to convergence. For both circuits
to be simulated at the same time however, the circuits must be contained
within one flowsheet, which is probably the more sensible approach in this
situation.
When you are comparing two alternative flowsheets, you can first prepare one
of them fully, including the input of the feed data. Then you can create a clone
of this flowsheet, with the clone becoming your starting point for creating the
alternative flowsheet. More detail on this approach is covered under the topic
Creating a New Flowsheet 180 .
Equipment Process equipment items are components of the circuit. Each equipment item
consists of:
an icon on the flowsheet diagram
a data window that details the process model and associated model
parameters.
Streams Streams provide the mechanism for the flow of material between equipment
items. The streams can be named by the user and each stream contains the
simulated stream data after simulation. The stream data for the feed stream is
entered into the Feeder equipment rather than directly into the feed stream.
As well as the components outlined above, it is important to understand some
concepts relating to properties and the way these are defined in JKSimMet.
These concepts are described below.
System There are two default system properties available for selection in JKSimMet:
Properties Miscellaneous
Elements
There is also the capacity for the user to define their own properties.

Using JKSimMet 137
Classes of Each of the system properties has one or more classes. The user can define as
System many classes of the elements property as desired but is unable to define extra
Properties miscellaneous value properties.
When adding or altering an element the user can change the characteristic
label and units value selected for the element; choosing either a percentage
representation or grams per ton representation. While the user cannot add to
or change the label of the miscellaneous values, they are able to change the
values assigned to them.
These settings are global characteristics that are not changed during
simulation.
Sieve Series A sieve series represents the series of gauges used to filter material in the
process circuit. JKSimMet allows the user to add as many sieve series as they
require to each flowsheet in a project. Each series may contain up to 40 size
fractions and once defined, the user is able to assign a particular sieve to
individual streams.
Ports Each equipment unit has one input port and up to three output ports,
depending on the type of equipment. Only one connector can be attached to
each output port. For the models in JKSimMet the stream characteristics of
interest are density, size distribution and solids and liquid flow rates.
5.2 The JKSimMet Menus and Toolbars

JKSimMet V6 has been developed to run under the MS Windows 7/Vista/
XP(SP3) operating systems and makes use of the Windows interface to provide
easy and flexible access to the large amount of data stored in the JKSimMet
software. A typical JKSimMet screen is shown below with various components
of the screen labeled.
A Typical JKSimMet6 Window - Showing the Main Features
The various components of the JKSimMet menus and toolbars are described in
detail in the remainder of this section.

5.2.1 The Main JKSimMet Menu
The main menu of the JKSimMet interface follows a standard Windows menu
layout, with a selection of drop-down menus that allow the user to access a
range of commands. Each drop-down menu is accessed by clicking on the
appropriate word on the Menu bar.
Menu bar
The flowsheet symbol ( ) at the left-hand end of the Main menu provides a
drop-down menu for options relating to the flowsheet window; these options
are discussed below.
The other Main menu items are dealt with in the topics that follow. You can
safely move to the next topic 139 if you wish to skip the remainder of this
discussion on the flowsheet symbol menu items.
When you click on the flowsheet symbol, you get the drop-down menu pictured
below.
Restore Clicking on the Restore item changes the Flowsheet window from its default
maximized state into a re-sizeable window within the flowsheet area. When
you do this, the flowsheet symbol ( ) will disappear from the left-hand end of
the Main menu and will now be located at the left-hand end of the new re-
sizeable Flowsheet window. Note that with a mouse you can always carry out
the restore function using the Restore button, which is the middle of the three
buttons at the right-hand end of the Main menu - see below.
Move and Size The items Move and Size are de-activated in the drop-down menu that appears
when you click on the flowsheet symbol on the Main menu. This is because
when the Flowsheet window is maximized it cannot be moved or sized until
after you have pressed Restore to make it a re-sizable window. These two items
are therefore only activated when you click the same symbol on the re-sizeable
Flowsheet window. The resizing or moving of a window is generally best
achieved by using your mouse. However, these commands are there as an
alternative by which you can achieve the same result without the mouse. If you
click on Move, you can then move the window using the keyboard arrow keys. If
The JKSimMet Menus and Toolbars Version 6.0.1 - March 2014

Using JKSimMet 139
you click on Size, you can use the arrow keys to change the size of the window.
In this case if you initially press the right arrow key, the change in size will be
achieved by movements of the right edge. Conversely initially pressing the left
arrow key will adjust the left edge. The same principle applies to the up and
down arrows and associated changes to the vertical dimension of the window.
Minimize and Minimize and Maximize items are also present on this menu, their activation
Maximize status depending on the current status of the window. Minimize reduces the
Flowsheet window to a bar at the bottom of the flowsheet area while Maximize
will resize the Flowsheet window to fill the available space. Both of these
functions are available to mouse users from the buttons at the end of the header
bar of the re-sizeable window.
Close The second last item on the menu is Close. While this can be used to close the
active Flowsheet, opening a different Flowsheet (the most likely reason to close
an active Flowsheet) will automatically close the active Flowsheet.
Next The item on this menu labeled Next is currently non-functional in this version
of JKSimMet.
5.2.2 The File Menu and Main Toolbar
The File Menu Clicking on the File menu item brings up a list of options relating to the
opening, saving and creating of JKSimMet files. It also includes a list of the
most recently opened files to provide you with quicker access to projects that
you may be working on through a number of sessions. The File menu plus a
brief explanation of the items, is shown below.
New Project ( ) - opens the New Project window so that the user
can create and name a new project.
Open Project ( ) - opens the Open Project window so that the user
Version 6.0.1 - March 2014 The JKSimMet Menus and Toolbars

can select an existing project to load from a list.

Some further information on the above two items is available under the
Session Window 172 topic.
Save Project ( ) - saves the project, including all the data

associated with the equipment and streams of each flowsheet, as a
JKSimMet data file (.jksf6 extension).
Save Project As - allows the user to save the current project under a
new name.
Print ( ) - prints only the flowsheet section of the session window.

Selecting this option opens the Print window to enable the printer
properties to be selected and the flowsheet to be printed.
Exit - closes JKSimMet. The user is prompted to save the current
project if the project has not been saved after the most recent changes
were made.
Main Toolbar
Many of the functions that are available in the File menu can be accessed via
the icon buttons on the Main Toolbar.
Note that, if required, this toolbar can be moved to a more convenient place on
the screen by clicking and dragging it. When in this state the shape of the
toolbar can be adjusted to personal preference by dragging the edge.
The first three buttons on the Main toolbar provide shortcuts to the standard
New Project, Open Project and Save Project options. The next two buttons are
the copy and paste buttons.
The final button is the Help button. Click on this button to access the
comprehensive JKSimMet help system.
5.2.3 The Edit Menu
Clicking on the Edit menu item brings up a list of options relating to flowsheet
editing functions and the setting of default and/or global characteristics for
various flowsheet items. A screen capture of the Edit menu is shown below,
followed by a brief explanation of each of the menu items.

Using JKSimMet 141
Undo - reverses the last editing change. You can continue clicking on
this to reverse a whole sequence of editing changes if required.
Redo - this reverses the action taken when the Undo button was last
pressed. Note that it is only available immediately after the Undo
button was pressed. If you carry out another editing action after
pressing Undo, then the Redo will no longer be available. Note also
that it can store a whole sequence of Undo events for potential
reversal, but only as far back as such events have been uninterrupted
by normal flowsheet editing.
Cut ( )- removes the selected item from its original location and
places it on the clipboard, ready for pasting elsewhere.
Copy ( ) - leaves the selected item in its original location and puts a
copy on the clipboard, which is then available for pasting elsewhere.
Paste ( ) - this has the normal paste functionality - places the

clipboard contents into the current cursor location.
Delete - this completely removes the selected item.
Select All - this selects all of the items on the current flowsheet.
Default Equipment Properties - this controls the default auto label
settings for any new equipment.
Default Stream Properties - this controls various features of any new
streams added to the flowsheet, including the line width and colour,
the type and size of arrowheads and the auto label positions. You can
also elect to have new streams either always orthogonal or else free
with respect to drawing direction. In addition you can change the

colour coding if you wish, for the major, minor and missing stream
categories (relevant only for mass balancing).
Default Text Properties - you can set the characteristics of any new
text that is placed on your flowsheet, including all stream and
equipment labels.
Default Drawing Object Properties - here you can change the default
appearance of any further drawing objects added to the flowsheet -
including line colour, fill colour,
Equipment Auto Label Properties - the dialog box that opens when
you click on this item allows you to control the colour and thickness of
the equipment label outlines, the fill pattern and colour as well as the
font characteristics of the text within the labels. Note that any changes
made here affect all of the existing equipment labels, not just ones that
are added after the setting has been changed.
Stream Auto Label Properties - this provides the same controls over
the appearance of the Stream Auto Labels as was described above for
the Equipment Auto Labels.
Port Properties - here you can (if you wish), change the colour of the
ports. There are two tabs, the first is for the product ports and the
second is for the feed ports. Pattern selection is also possible, but not
really practical in this case since the ports are too small for a pattern to
be visible.
Flowsheet Settings - this menu item allows you to change the
background colour of the flowsheet and the page dimensions and
orientation. It also provides the option to toggle the display of the
icons in the software between JKSimMet5 icons and JKSimMet icons
as well as allowing the user to choose the number of significant
figures displayed in the information blocks. Note that zooming out
will better allow you to appreciate how your flowsheet is structured
relative to the size and shape of the paper you have chosen for
printing. You can also get to this item from the menu that appears
when you right-click on your flowsheet.
Properties ( ) - This menu item allows the user to view and alter
the properties of a selected stream or equipment item on the flowsheet.
Here the user can alter the name, label position, line style and fill style
of the selected item.

Using JKSimMet 143
5.2.4 The View Menu
View Menu
The View command on the Main JKSimMet Menu controls which of the
available flowsheet features are visible in the session window. Some of the
items on this menu are also available via toolbars, but others are only
available from this menu. The items on this menu are listed and explained
below, in the order that they appear on the menu.
Toolbar - when checked, the main JKSimMet toolbar is visible.
Status Bar - is visible at the bottom of the JKSimMet session window
when checked.
Workspace - this refers to the list of flowsheets contained in your
project, which normally appears as the left-most panel of the session
window. This panel will disappear if the Workspace item is
unchecked. This may be useful if you have a large flowsheet and need
more space to accommodate it.
Grid - this toggles the visible grid on or off. Note that snapping to the
grid is still possible, even when you have switched the grid to "off" so
that it is no longer visible.
Snap to Grid - this determines whether the items on your flowsheet
will snap to the grid when they are moved. This setting provides a
convenient tool for aligning the items on your flowsheet.

Angle Snap - this applies to rotation of equipment items; when

switched off, any angular position is possible whereas when
switched on, the only angular positions possible are those in which
the corners of the equipment item line up with the grid.
Grid Properties - this allows adjustment of the grid spacing and other
properties via the Grid Properties windows, shown below.
Vertical Rulers - this is a toggle for turning on or off, the vertical ruler
along the side of your flowsheet. Note that it only applies to the
flowsheet that is currently active.
Horizontal Ruler - similarly, this toggles on and off the horizontal
ruler at the top of your flowsheet. Again, it only effects the appearance
of the currently active flowsheet.
Ruler Properties - this brings up a dialog box in which you can select
the colour and width of the rulers plus the colour of the ruler tracking
line that appears within the rulers to indicate the current cursor
position.
Equipment Auto Labels ( ) - this toggles on and off, the equipment

auto labels.
Stream Auto Labels ( ) - likewise, this toggles on and off, the

Using JKSimMet 145
stream auto labels.

Note that both the Equipment and Stream Auto Labels can be also
switched on or off via buttons on the Flowsheet toolbar.
Port ( )- via this item you can control whether or not the ports are
to be visible on your equipment items. It is very useful to have these
switched on at least while you are constructing the flowsheet. After
this, it is a matter of preference as to whether you have the ports
highlighted or not. This toggle is also available via a button on the
Flowsheet toolbar.
Redraw ( ) - this is sometimes needed if you have a large flowsheet
to which you have just made changes and immediately after making
them you find that the computer is not rendering them properly.
Clicking on Redraw will normally remedy this type of problem.
Zoom Normal - this zooms back to the normal level after you have
used the other zoom functions to move away from this zoom level.
Zoom Percent - this allows the user to select the zoom percent from the
options 50%, 75%, 100% (normal) and 200%.
Zoom Custom - with the Custom Zoom you can either select one of the
above from the drop-down or you can type in any percent value from
50 to 500.
Zoom to Fit ( ) - this is a convenient way to get the whole of your

flowsheet to fit neatly into the available window size. Note that there
is a button on the Flowsheet toolbar that also achieves this result.
Zoom to Selection ( ) - if you have selected part of your flowsheet

for closer inspection, this command will zoom to the point where the
selected part of the flowsheet just fits into the available window size.
Again note that on the Flowsheet toolbar there is a button for this
function also.
5.2.5 The Flowsheet Menu and Toolbar
The Flowsheet The drop-down menu that is triggered when you click on the Flowsheet item of
Menu the main JKSimMet Menu bar, is shown below.

This menu allows an alternative route into most of the functionality provided
via the Flowsheet toolbar (see below). There are some differences however.
The Run Model Fitting item on this menu is not on the Flowsheet toolbar, but is
located on the separate Model Fit toolbar.
The Flowsheet If required, the Flowsheet toolbar can be moved to a more convenient place on
Toolbar the screen by simply clicking and dragging it. Once moved to a floating toolbar
position, the shape of the toolbar can be adjusted to your personal preference by
dragging the edges. This applies to all the other toolbars as well.
Below is a screen-grab of the Flowsheet toolbar, followed by a listing of all the
buttons it contains with explanations of their functions:
Lock The Lock button controls access to the various other functions on the Flowsheet
toolbar.
When unlocked, access is available for making changes to the flowsheet's design
and layout, including the addition or subtraction of equipment and streams,
changes to the locations of equipment items and to the routes taken by
connecting streams. In addition all properties associated with the appearance of

Using JKSimMet 147
all flowsheet components can be accessed when this button is in the unlocked
position.
When this button is in the locked position, none of the above functionality is
available. Instead, the System Properties, Sieve Series, Survey Data, Configurable
Equipment Manager, Run Simulation, Configurable Stream Overview,
Simulation Manager, Run Balance, Equipment, Stream, Reporting, Config Graph
and Setup Info Blocks buttons now become accessible. In fact the flowsheet must
be locked before any changes can be made to the data. Requiring that the
flowsheet be locked for data entry ensures that items are not accidentally moved
when you are trying to access the data.
Select The Select button is normally activated by default when you first open a project.
It will be de-activated however when you press the Zoom button ( ) and you
will then need to re-activate it before you can select any items on your flowsheet.
When the Select button is active, the cursor will turn back to the normal selection
cursor ( ). This may look different to the illustration here, as it will depend on
the cursor option settings on your computer. With the Select button activated
you can click on any individual equipment item, stream or label on your
flowsheet to select it. This is the case regardless of whether the flowsheet is
locked or unlocked. The locking status just affects what you can do with the
items once they have been selected. Note that you can select multiple items by
holding down the left mouse button and dragging the mouse until the dotted
line encloses all the items you wish to select. Letting go of the left-button will
then select these items. You can also select any number of individual items by
holding down the Control key and clicking the mouse as the cursor moves over
each of them.
Zoom When you click on the Zoom button, the Select button will be switched off and
the cursor will change to a zoom cursor ( ) to indicate that the zoom function
is now active.
When this cursor appears on your flowsheet, you can hold down the left-button
and drag your mouse to outline the area you wish to zoom into. When you let go
of the mouse button, the area you have outlined will be expanded to occupy the
whole of the current flowsheet window.
Also when you have the Zoom button activated, clicking on the left mouse
button will increase the degree of zoom by a set increment and clicking on the
right button will decrease it by the same amount.
To turn off the zoom facility, click again on the Select button ( ).
Zoom to Clicking on the Zoom to Fit button will zoom in or out sufficiently to just
accommodate the whole of your flowsheet. This is usually the best way to zoom
Fit back out again after you have zoomed in to a particular region of the flowsheet.
Zoom to For the Zoom to Selection button to be available, you first need to have selected
some items on your flowsheet. When you click on this button, the program will
Selection zoom in or out as needed, so as to just include all of your selected items within
the boundary of the visible flowsheet.

The Equipment Auto Labels and Stream Auto Labels buttons are used to add
labels to the equipment and streams on the flowsheet; the labels become a part of
Auto Labels
the equipment and streams and move when the equipment or stream is moved.
for To change the default label, double-click on the equipment and type in the new
Equipment name, see chapter on Annotating the Flowsheet 187 .
and Streams Clicking on the Equipment Auto Labels button or the Stream Auto Labels button
toggles between having the labels for this flowsheet either displayed or not
displayed. Note that these buttons can be operated irrespective of the flowsheet
locking status.
As noted above, in the menu system these two functions are available via the
View menu rather than the Flowsheet menu.
Ports This button acts as a toggle for switching on and off the display of the ports for
each of the equipment item. Feed ports are represented by blue dots and product
ports by red dots. This facility is normally turned on by default. Note that the
position of this switch does not affect functionality. You can still connect
streams to ports, even when they are not displayed. However for icons with
vertical axis symmetry, such as the one used for flotation cells, you can't easily
tell which side is the feed port until you turn on the ports display. Thus it is
usually better to have ports switched on, especially while the flowsheet is being
constructed.
Redraw The Redraw button is used to refresh the screen. This is particularly useful after
equipment has been repositioned.
If you have made changes that are not yet appearing on your flowsheet, click on
the re-draw button and the whole flowsheet will be redrawn. It should then
include all of your modifications.
System The System Properties button opens the System Properties Window 176 , where
the user can add Elements to the system and alter the miscellaneous properties.
Properties
Sieve The Sieve Series button opens the Sieve Series Window 175 . It is in this window
that the user can add and remove sieve series, as well as assign them to
Series
individual streams.
Survey The Survey Data button opens the Survey Data window 175 . This allows the user
to input and transfer survey data into the streams, overwriting any existing
Data
experimental data.
The Configurable Equipment Manager button brings the Configurable Equipment
Manager Window 116 into view. This window allows the user to create an
Configurabl
overview to view and if necessary alter the settings for the different models used
e Equipment in the current flowsheet.
Manager
Run Clicking on the Run Simulation button opens the Run Simulation 164 window,
which allows the user to select the equipment and streams to simulated, set the
Simulation
simulation settings and run simulations.
The Configurable Stream Overview 213 window is accessed by clicking on this
button. This feature allows the user to create one or more summary tables of
Configurabl
selected stream data after simulation of the flowsheet. The data in the table can
e Stream
then be printed, copied to the clipboard or exported to MS Excel.
Overview

Using JKSimMet 149
The Simulation Manager 201 allows multiple simulations to be performed in a

batch operation. The user can set a range of key operating parameters in the
Simulation
simulations and record the key performance indicators for each simulation
Manager
performed.
Run The Run Balance button brings the Input/View Mass Balance 259 window into
view. This window allows the user to select the streams, equipment, elements
Balance
and sizes to include in the balance and control the scope of the fitting.
The Equipment button brings the Equipment Window 193 into view. A drop-
down list in the Equipment window displays all of the equipment on the current
Equipment
flowsheet. The Equipment window allows the user to select the model to be used
for the equipment via a drop-down list, and to input the parameters for the
chosen model. The Equipment window also shows the feed and product streams
from the equipment; the Stream window for each of these streams can also be
accessed from the Equipment window.
Stream Clicking on the Stream button opens the Stream Window 165 from which the
user can view the stream data after simulation.
The Reporting button opens the Reporting to Excel 162 dialog. This allows the
user to configure one or more reports by listing which stream and equipment
Reporting
data are to be exported to an Excel workbook for further analysis and printing.
The Config Graph button opens the Configurable Graphing Window 154 . Here
the user can create one or more graphs to view the data held in the streams and
Configurabl
equipment on the current flowsheet.
e Graphing
Setup The Setup Info Blocks button is used to set up both Equipment and Stream Data
Info Blocks 120 . These are configurable information blocks that can be attached to
Info Blocks
selected equipment items and streams. They are used to provide a convenient
flowsheet based readout of the results and the settings of your simulations.
5.2.6 The Balance, Fitting and Simulate Toolbar
Toolbar for The Balance, Fitting and Simulate toolbar is located in the left side panel, just
Main above flowsheet list.
JKSimMet
Functions
Run Balance The Run Balance button brings the Input/View Mass Balance 259 window
into view. This window allows the user to select the streams, equipment,
elements and sizes to include in the balance and control the scope of the
balancing process.
Run Model The Run Model Fitting button opens the window for model fitting 272 , where
Fitting the user can tailor the process models associated with the various equipment
items in their flowsheet, to their individual treatment characteristics based on
the data that has been gathered for this circuit.

Run Clicking on the Run Simulation button opens the Run Simulation 164 window,
Simulation which allows the user to select the equipment and streams to simulated, set
the simulation settings and run simulations.
5.2.7 Drawing Toolbar
The Drawing toolbar contains buttons for all the commands associated with the
preparation of your flowsheet. A screen grab of this toolbar is shown below.
Note that these buttons are all de-activated once the flowsheet has been locked.
The functions of the various buttons on this toolbar, going from left to right, are
described below.
Properties The Properties button gives you access to the properties dialog box for the
currently selected flowsheet item or items. Properties in this context refers to the
properties of the icon itself, not the properties of the physical equipment that it is
representing. The later properties are associated with modelling of the
equipment and are only available once the flowsheet has been locked.
Line This button simply allows you to draw a line on your flowsheet. When click on
the button and move the cursor down to the flowsheet, you will see that the
cursor now takes the form of a cross ( ). Click the left mouse button and drag in
any direction to create the line. Let go when it is at the desired length. If you hold
down the Shift key while you are dragging, the line will then snap to the grid
and will be either horizontal or vertical, depending on which direction you are
moving your mouse.
Rectangle When you click on this button, you will again note that the cursor takes the form
of a cross once the mouse is positioned over the flowsheet. Click the left button
and drag in the direction of the diagonal of the proposed new rectangle. The
proposed rectangle will be outlined by a dashed line while you continue to hold
down the mouse button. Once you let go of the button, the new rectangle will be
placed on the flowsheet and its perimeter will change to a solid line.
Text Clicking on this button followed by clicking on the active flowsheet will add a
resizable, editable text box to the flowsheet.
Image When you click on this button you will be presented with a file open type dialog
box, where you will be able to select the directory where your images are stored.
Click on the image file you require and then on the Open button.
If the image you have imported initially occupies the whole of the flowsheet
panel, use the zoom buttons to zoom out. This will allow you to see the handles
around the perimeter of your image and by using these you can re-size the image
to whatever is required.
Rotate After clicking on the Rotate button, you will see that the cursor changes once
you are hovering over the selected item, to a circular arrow symbol, similar to the
image on the button itself. If you then click and drag, the item of equipment will

Using JKSimMet 151
rotate. Let go when it has reached the orientation you require.

Rotate Left & The Rotate Left button rotates the selected item anti-clockwise by 90 degrees. The
Right Rotate Right button also rotates by 90 degrees, this time in the clockwise
direction. For the Rotate Left and Right commands, the rotation is occurring
about a line that is perpendicular to the plane of the computer screen.
Flip Vertical & The Flip Vertical and Flip Horizontal buttons effectively rotate the object
Horizontal concerned through 180 degrees, through a plane that is at right angles to the
screen. The rotation occurs about a line that passes through the centre of the
object and lies flat on the computer screen.
Align Top & These buttons can be used to align either the tops or the bottoms of a group of
Bottom objects that you have selected. First select the set of objects required, either by
using the Control key and clicking on the separate objects or else by dragging
the mouse to encompass the objects with the left button held down. Then click
on whichever of the buttons is appropriate for your purposes. Note that the
alignment will be to the top (or bottom) of the last selected item. You can see
which item was last selected as it will have grey rather than open selection
indicator squares around its perimeter.
Align Middle To align either the horizontal or vertical centre lines of a number of objects, you
& Centre again need to first select the set of objects for alignment (see above). Then just
click on the appropriate button for middle or centre alignment, as required (see
left). Again, the alignment will be to the centre line of the last selected item.
Align Left & Left and right alignment of objects is achieved by again selecting the set of
Right objects before clicking on whichever is required of the two buttons shown at
left.Again, the last selected object will be the one that determines the alignment
position.
Space Across These buttons allow you to evenly space objects that you have placed on your
& Down flowsheet. Pressing the Space Across button distributes the selected objects so
that the entire spacing between the far left object and the far right object is
divided evenly between entire row of selected objects. Note that the objects do
not necessarily have to be first lined up in the vertical direction for this
horizontal spacing function to work.
Similarly, pressing the Space Down button divides the entire vertical spacing
between your highest and lowest object so that all the selected objects will then
have equal vertical spacing between them.
Same Width, Using these buttons the user can make a set of objects on a flowsheet all have the
Height or Size same width, height or both. Note that the last selected object (indicated by the
grey selection handles), will be the one to which the other selected objects are
matched. Use the Same Size button when you wish to make sure that the
dimensions stay in the same ratio as they exist in your last selected object.
Nudge Up, There are four Nudge buttons that allow you to make small adjustments (up,
Down, Left down, right and left) to the positioning of objects on your flowsheet. First select
and Right the object to be moved and then click on the appropriate Nudge button. These
functions are mainly useful for adjusting the positioning of equipment units
when the attached streams have gone slightly out of horizontal or vertical. You
can use it to make the small adjustments needed to return the streams to an
orthogonal arrangement.
Front and Back The Front and Back buttons can be used if you have overlapping items on your
flowsheet. Pressing one of these buttons will determine which of the

overlapping items appears to be at the front and is therefore fully visible and
which appears to be at the back and therefore partially obscured. When a Front
or Back button is pressed, the item currently selected responds by moving to the
front or back as appropriate. Note that if you have several overlapping items
selected and you press Front, then the item last selected will move to the front
and the overlap order for the other items will also mirror the selection order.
This means that for instance, the second last item selected will be just under the
last item selected, but will be over all of the other items.
5.2.8 The Tools Menu
The Tools menu on the Main JKSimMet Menu allows the user to customise
which tools and menus are displayed in the session window. Click on
Customize then there are two tabs, Toolbars and Command.
In the Toolbars tab the user can choose which toolbars appear at the top of the
JKSimMet screen. The 'look' of the toolbars can also be adjusted using the
Show Tooltips and Cool Look options. Users can also add and name new
toolbars by clicking on the New button. Once created, the new toolbar can be
populated with buttons by either moving existing buttons from other toolbars
or by moving copies of the existing buttons from the Command tab of the
dialog box into the new toolbar..
The Command tab shows all of the buttons that make up each of the existing
toolbars and the menu. Selecting one of the buttons will provide a description
of the functionality it offers in the description box at the bottom of the
window, as shown below.

Using JKSimMet 153
To customize an existing toolbar users can drag any button of their choice
from this tab onto the toolbar. While this dialog box is open users can also
remove or reposition buttons on existing toolbars, allowing a large degree of
customization.
5.2.9 The Help Menu
Help Menu
The Help menu on the Main JKSimMet Menu allows the user to access the
help files, and provides software version information:
Help ( ) - (or pressing F1) takes the user to the contents page of the Help
File.
About - gives details of the JKSimMet version number, the version numbers of
the databases and copyright information.
5.3 JKSimMet Windows

Version 6.4 of JKSimMet makes full use of the Windows interface to allow
users to view whichever data they choose on the screen at any one time by
simply opening the required windows. This section describes briefly each of
the main window types in JKSimMet.
5.3.1 Configurable Equipment Manager
The Configurable Equipment Manager window displays a summary table of

selected data for a currently selected model in the flowsheet. The user can
configure one or many tables for display in this window.
The Configurable Equipment Manager window can be opened by two methods:
1. Selecting Configurable Equipment Manager from the Flowsheet menu.
2. Clicking on the Configurable Stream Overview button.
Opening the
Configurable
Equipment
Manager
The Configurable Equipment Manager feature can only be accessed when the
flowsheet is locked.
The Configurable Equipment Manager provides a data summary for a selected
model in the flowsheet after simulation has occurred. The information
displayed in the Configurable Equipment Manager window is exactly the same
as the information displayed in the individual Model Data windows. The
advantage of the Configurable Equipment Manager is that all of the data for the
equipment items that use this model can be viewed together, rather than having
to view each equipment item in a separate window.
The summary table can be printed directly from this window, copied to the
clipboard for pasting into other programs such as Word or exported to Excel for
further analysis or graphing.
5.3.2 Config Graph Window
The Configurable Graphing window lets the user set up and view data from
streams and equipment in a graphical format.
Users can open the Configurable Graphing window via the flowsheet menu or
from the icon on the flowsheet toolbar.
Note that the Graphing feature can only be accessed when the flowsheet is
JKSimMet Windows Version 6.0.1 - March 2014

Using JKSimMet 155
locked.
Create a New To create a new graph click on the 'New' button, in the dialog that opens, the
Graph user is required to give a name to the graph (or accept the default) and to
choose whether the graph will display stream or equipment data.
The user must then choose a format for the sizing data:
They then must choose which type of data the report is going to display:
They are then required to select the streams or equipment that they wish to
view:
Version 6.0.1 - March 2014 JKSimMet Windows

Viewing the The Graph tab displays the data that you have selected in the stream tab. To
Graph alter the settings of the graph, select the Format button (highlighted).
Formatting the The format window allows you to set the name for each axis, the range that
Graph each axis covers and how the data is plotted and shown to the user.

Using JKSimMet 157
5.3.3 Configurable Stream Overview Window
The Configurable Stream Overview window displays a summary table of

selected data for selected streams in the flowsheet. The user can configure one or
many tables for display in this window.
The Configurable Stream Overview window can be opened by two methods:
1. Selecting Configurable Stream Overview from the Flowsheet menu.
2. Clicking on the Configurable Stream Overview button.
The Configurable Stream Overview feature can only be accessed when the
Configurable Stream Overview provides a data summary for selected streams in
the flowsheet after simulation has occurred. The information displayed in the
Configurable Stream Overview window is exactly the same as the information
displayed in the individual Stream Data windows.
The summary table can be printed directly from this window, copied to the
clipboard for pasting into other programs such as Word or exported to Excel for
further analysis or graphing. The Configurable Stream Overview window is
discussed in more detail under the heading Using the Configurable Stream
Overview 213 .

5.3.4 Information Blocks
Information Information blocks allow the user to display information about the performance
Blocks and characteristics of both streams and equipment on the flowsheet.
The Information Blocks window can be opened by two methods:
1. Selecting Info Blocks from the Flowsheet menu.
2. Clicking on the Setup Info Blocks button.
Note that the Info Blocks feature can only be accessed when the flowsheet is
locked.
Experimental or simulated data may be displayed, and the Info Blocks feature
allows the information to be displayed for as many streams or equipment units
as the user wishes. Information Blocks 158 are discussed in more detail within
the section Building and Manipulating a Flowsheet 189 .

Using JKSimMet 159
Information Once added to the flowsheet, the information blocks can be moved around and
Blocks Display re-sized as the user requires.
5.3.5 Model Windows
The Model window collects data required for the selected model calculation
and displays the equipment parameters calculated during simulation. The
Model window is accessed by clicking on the double arrow button next to the
selected model in the Equipment window. While the contents of the model
window vary depending on the models chosen, the general layout of the
model windows is common to all models; see below.

Whilst all model options for particular equipment are accessible from the
Equipment Model drop-down list, JKSimMet can only use a model in
simulation if its prerequisite stream properties have been added via the
System Properties 176 table. An error message will be displayed during
simulation if a model has been selected for which the required stream
properties have not been chosen.
The data associated with a particular model are displayed on a series of tabs.
Most tabs have an associated drop-down list for the model option selection.
The model window consists of:
1. A title bar in which the chosen model option is displayed.
2. A series of tabs used to display or allow data entry for the chosen
model.
The data layouts for all of the model types, including details of prerequisite
stream property requirements, are detailed in the Model Descriptions 294
section. The Model windows 193 are also discussed in more detail within the
chapter on Editing the Flowsheet Data.
5.3.6 Property Windows
The properties of the flowsheets, equipment, streams and labels can be

accessed in the Flowsheet, Equipment, Stream Properties and Label Properties
windows, respectively.
Flowsheet Right click on the flowsheet name and select Properties to open the Flowsheet
Properties Properties window. This window allows the user to change the flowsheet
Window name, add any comments about the flowsheet and view the last modified date.
Note that there is a 50 character limit for the flowsheet name and comments
sections.

Using JKSimMet 161
Equipment To open the Equipment Properties window unlock the flowsheet and double-
Properties click on the equipment item to be examined. Alternatively, you can right-click
Window on the equipment item and select properties from the right-click menu. The
Equipment Properties window allows the user to change the equipment name
and orientation as well as various aspects of the equipment item's physical
appearance on the flowsheet.
Stream To access the Stream Properties window for a stream, unlock the flowsheet
Properties and double-click on the stream you wish to examine or again use the right-
Window click menu. This will open the Stream Properties window in which the user
can change the name of the stream as well as various other characteristics
affecting the streams physical appearance. Note that it is recommended
streams be given meaningful names, such as Rougher Feed, Rougher Conc,
Rougher Tail, as this will enable them to be more easily recognized later,
when the simulation results are reviewed.

5.3.7 Reporting to Excel Window
The Reporting to Excel window allows the user to select any stream or
equipment data for export to an Excel workbook. Reporting is the main
method for exporting data from JKSimMet, with the formatted data in the
Excel workbook being available for printing and graphing as required. The
user can configure multiple reporting formats.
The Reporting window can be opened by two methods:
1. Selecting Reporting from the Flowsheet menu.
2. Clicking on the Reporting button.
Note that the Reporting to Excel feature can only be accessed when the

Using JKSimMet 163
The stream data and equipment data are exported together. Multiple report
formats can be created. The Reporting feature is discussed in more detail
under the heading Using the Reporting Feature 226 .
5.3.8 Simulation Manager Window
The Simulation Manager window is where the user can set up multiple
simulations, which can then be run in sequence as a batch operation. The user
can configure multiple scenarios for simulation and can edit key operating data
used in the simulations, which are displayed in the tables (e.g. Feed tonnage, %
solids).
The Simulation Manager window can be opened by two methods:
1. Selecting Simulation Manager from the Flowsheet menu.
2. Clicking on the Simulation Manager button.
Note that the Simulation Manager can only be accessed when the flowsheet is
locked.
Selected results of the simulations are displayed on the stream and equipment
data tabs (labelled Results - Streams and Results - Equip), once the batch of
simulations has completed. This allows the user to readily compare simulated
results under the different operating conditions.
The simulation operating data summary and the results of the simulations
displayed on stream and equipment tabs in the window can be printed directly
from the Simulation Manager window or copied to the clipboard for pasting into
other programs such as Word or Excel. The Simulation Manager window is
discussed in more detail under the heading Simulating Using the Simulation
Manager 201 .

5.3.9 Simulation Window
Simulation The Simulation window is where a simulation of the current flowsheet settings
Window can be run, and the controls set for this simulation.
The Simulation window can be opened by two methods:
1. Selecting Run Simulation from the Flowsheet menu.
2. Clicking on the Run Simulation button ( ).
Note that the flowsheet must be locked before the user can select the Run
Simulation button.
The Simulation window provides the selection and configuration options for
running a simulation. Here the user may choose which simulation to run or to
create a new simulation using a different selection of equipment and streams.
The user can also configure the required convergence, the number of iterations,
the interpolation used and the starting condition of the simulation.

Using JKSimMet 165
Simulation is discussed in more detail in under the heading Using Simulation

199 .
5.3.10 Stream Windows
Accessing The Streams window provides access to the Stream Data window to view the data
the Stream for each stream.
Data
Stream The Streams window for each stream can be opened by three methods:
Button 1. Double-clicking on a stream.
2. Selecting Stream from the Flowsheet sub menu.
3. Clicking on the Stream button.
All of the streams in the current flowsheet may be accessed from the Streams
window via the Stream Name drop-down list. The Streams window can only be
accessed when the flowsheet is locked.
The Stream Data window is accessed by clicking on the double arrow button next
to the selected stream. Once the Stream Data window is open the user can view the
stream data in a variety of ways, as required since there is considerable scope for
customising the way these data are viewed. Note that in the column displaying
simulated data, the fields will not contain values until simulation has been
completed.

Totals Tab The data associated with a particular stream are displayed on a series of tabs. The
tabs visible in the Stream Data window are always present. The Totals tab lists the
overall properties of the stream.
The default window shows various data types - simulated, experimental, SD, mass
balanced, error and fitted. The data types that are shown in these windows can be
controlled by the user. If you click on the Data Type View button, a dialog box will
appear where you can exercise a choice about the data types you wish to see.
Click on any of the data type headings and you will be presented with a drop-
down list containing the six available data types plus the option of selecting
"none". If you chose "none", the column concerned will be eliminated from the
Stream Data window display. If you try to select any given data type twice, you
will get an error message. If you are carrying out simulations only for instance, you
would probably want to see the Sim, Exp and Error data types and eliminate the
other three.
SD To the right of the Data View Type button is a button labeled "SD Calculation".
Calculation This button brings up the Automatic SD Calculation window. Note that this is only
relevant when you are carrying out mass balancing or model fitting. It is not
required for simulations.

Using JKSimMet 167
The Automatic SD Calculation window allows you to set up an SD calculation

method differently for each property within each stream. From the left panel
containing the list of streams, you can select either a single stream or a group of
streams. To make this selection you can use the Control key with a left mouse click
to pick out individual streams for the group. Alternatively, you can use the Shift
key and the left mouse button to add all the streams between the one initially
selected and the one currently under the cursor. Once the stream or streams have
been selected, you then select the property to which the SD method is to apply. This
is done via the Property drop-down at the top right of this window. You can select
All if you want this SD calculation method to apply to all properties of the selected
streams.
Having selected the streams and the properties, you then go to the SD Calculation
Option drop-down where you can now select the method of determining the SD's
for this group of streams/properties.

If you select Poor, Average, Good or Excellent, the program will use a fixed
percentage of the stream. Note that you can change the percentage however, that
applies to each of these selections, if required. The other possible selections include
"Fixed" where you can again change the value to whatever you deem to be
appropriate. But in this case keep in mind that you are selecting the actual value of
the SD rather than a percentage of the stream value. There are several other
methods that can be applied for SD calculation.
Whiten SD If you select All Sizes from the Property drop-down, then there will be an extra SD
calculation option available at the top of the list. The extra option is "Whiten" -
which is an SD calculation method that only applies to sizing data. This option is
not visible in the screen grab above because the image was generated after
selecting TPH or All from the Property drop-down. Note that Whiten is the most
commonly used SD calculation method for sizing data. To apply this to your sizing
data but still apply some other chosen method to all of your other data, you could
first select All and apply the appropriate "other method". After this you can select
All Sizes and apply Whiten, which would then leave the other method still in force
for all of the non-sizing data.
Sizing Data The other available tab contains the stream sizing data. These data will be
displayed in the format that has been selected via the buttons on the main toolbar.
The sizing data can be expressed as either % Retained ( ), Cum % Retained (
) or Cum % Passing ( ) . Note that this selection can be changed at any time,
even when this stream data window is open.

Using JKSimMet 169
Selecting In the case of the error column you can change the form of the error that is
the Type of displayed and the currently selected form will be shown in the column header.
Error This is done by clicking on the Error Sum button, which is the button second from
Calculation the right on the Stream data toolbar.
These new calculations are for display purposes only. The weighted error is used
in all Mass Balance and Model Fit calculations.
After pressing this button, the Error dialog box will appear where you can specify
both the types of data that are to be compared for determining error values and the
method by which these errors are calculated. For instance in the settings shown in
the screen grab below, the errors will be obtained by comparing the experimental
and balanced data and the method of calculation will just be a straight percentage
error calculation.

Also in this screen grab, you will notice there is a frame labelled Error Sum below
the drop-down selection boxes. Here there are radio buttons where you can select
the errors that are to contribute to the calculation of the error sum figure that is
displayed in a field (shown circled below), at the top of the Stream data window.
Note that it is only when you select Exp v Bal data for comparison that all three
options are available for the error sum calculation. Because JKSimMet does not
contain models that predict element distributions, the last two options cannot be
selected where either Fit or Sim data are one of the data types to be compared.
These options will be greyed-out in all but the Exp v Bal data case.
Error The types of error calculation available for selection are Weighted, Percent and
Calculation Absolute. Weighted errors take account of the reliability assigned to the various
Methods data points by dividing the difference by the SD value. Larger SD values mean that
and the differences will contribute less to the total error calculation. The other two
Summing of methods take no account of the assigned SD values.
Errors The calculation methods are:
Weighted errors are calculated as [(Exp - Bal)/SD]2

Percent errors are calculated as Abs[(Exp - Bal)/Exp] * 100
Absolute errors are calculated as just (Exp - Bal)
In the case of the first two error calculation methods, the individual errors are
always going to be positive values. Thus to obtain the error sum in these two cases,
the individual values are simply totalled.
For the Absolute error values though, there will be negative values displayed for
some data points and positive ones for others. To make these values all contribute
to the total error and do not tend to cancel each other out, in this case it has to be
the modulus of each value that gets incorporated into the Error Sum calculation.

Using JKSimMet 171
Accessing The Configurable Graphing window is also available via a button on this toolbar as
the shown below.
Configurabl
e Graphing
Window
Changing You can change the column layout of the Stream data window if required. This is
the Column achieved by clicking on the Data Type View (Dv) button - circled in the following
Layout screen grab.
The Change Data Type View window will then open. The image below shows this
window with the user selecting None from the data type options for the last
column. This action will remove the last column once the user has returned to the
Data Type window. Note that selecting None does not delete any existing data; it
merely tidies up the display.
The Streams window also lists the equipment from which the stream originates
and the equipment to which the stream flows. Clicking on the double arrow button
next to the From Equipment and To Equipment display panels opens the Equipment
window relating to that equipment. The Equipment window 171 is discussed
above. The Stream Data windows 210 are discussed in more detail within the Using
Simulation chapter.
Copy Grid The copy grid button allows the user to copy the data from the active grid to the
clipboard, from where it can be pasted into other applications as required.
5.3.11 The Equipment Window
The data for the equipment can be viewed in the Equipment window.
The Equipment window can be opened by three methods:
1. Double-clicking on the equipment item itself.
2. Selecting Equipment from the Flowsheet menu.
3. Clicking on the Equipment button on the Flowsheet toolbar.
All of the equipment units in the current flowsheet may be accessed from the
Equipment window via the Equipment Name drop-down list. The Equipment
window can only be accessed when the flowsheet is locked.

The equipment models available for the selected equipment unit are accessed via
the Equipment Model drop-down list. The Model window is accessed by clicking
on the double arrow button next to the selected model. The Model window is
discussed in more detail in the next topic.
The Equipment window also lists the feed and product streams of the selected
equipment. Clicking on the double arrow button next to the names of the streams
that are feeds or products from the selected equipment opens the Streams
window. The Streams window is discussed below. The Equipment and Model
193 windows are discussed in more detail in the chapter on Editing the
Flowsheet Data.
5.3.12 The Session Window
The session window is the driving seat of JKSimMet. In this window the user
creates the flowsheets for analysis.
After starting the JKSimMet program a blank session window appears as shown
below.

Using JKSimMet 173
The user can create a new project or load an existing (i.e. previously saved)
project.
Create a New To create a new project click on the New Project icon on the toolbar. In the dialog
Project that opens, the user is prompted to name the new project and specify its path.
This loads a blank project containing a single flowsheet, automatically given the
default name of "FlowSheet1".
Now that a flowsheet exists, the equipment list is displayed between the
flowsheet list and the flowsheet display pane on the right. The procedure for

creating a flowsheet will be discussed in more detail below.

Load an Alternatively, the user can select a previously saved project from the list of
Existing existing projects by clicking on the Open Project icon. This displays an Open
Project dialog which allows the user to select the project to be opened.
The title bar in the session window displays the open project and flowsheet in
the form JKSimMet - [Project Name Flowsheet Name]. Note that the equipment
list is not available until a project has been opened or created and therefore at
least one flowsheet is present.
Resizing the Note that the session window can be resized by moving the cursor to any edge of
Session the window. When it is positioned over the border line, the cursor will change
Window and from the normal arrowhead to a thin line with an arrowhead at each end. While
the Internal the cursor is in this state, left click and drag with the mouse to change the
Panels window size to whatever you require and release the mouse button when
finished. Note that you can drag the top, bottom, sides and the corners using this
method. When you drag a corner, both the height and width of the window can
be changed simultaneously.
The three main panels within the session window can also be resized in a
similar manner. You will see the mouse cursor turn into the double headed
arrow form as you move it over one of the vertical panel dividing lines. By
shifting the panel dividers, you can control how the overall window width is
partitioned between the three panels.

Using JKSimMet 175
5.3.13 The Sieve Series Window
The Sieve Series window displays a summary table of selected data for selected
streams in the flowsheet. The user can configure one or many tables for display
in this window.
The Sieve Series window can be opened by two methods:
1. Selecting Sieve Series from the Flowsheet menu.
2. Clicking on the Sieve Series button.
The Sieve Series feature can only be accessed when the flowsheet is locked.
The Sieve Series window provides a visual display of the different sieve series
available in the current flowsheet and the sieve series that each stream in the
flowsheet uses.
The Sieve Series window is discussed in more detail under the heading
5.3.14 The Survey Data Window
The Survey Data screen shows the survey size data for the sieve series in the
current flowsheet.

The Survey Data window can be opened by two methods:

1. Selecting Survey Data from the Flowsheet menu.
2. By clicking on the Survey Data button in the toolbar area.
The Survey Data window can only be accessed when the flowsheet is locked.
The Edit Sieve Series button is used to bring up the Sieve Series 175 window.
The Transfer button is used to transfer the survey data into all of the streams,
replacing the experimental data. If the user has selected a sieve series that is not
the master series, the data will be transferred using the selected interpolation
method.
5.3.15 The System Properties Window
The global characteristics for the system property classes are defined in the
System Properties window.
The System Properties window can be opened by two methods:
1. Selecting System Properties from the Flowsheet menu.
2. Clicking on the System Properties button ( ) on the Flowsheet toolbar
The System Properties window can only be accessed when the flowsheet is
locked.

Using JKSimMet 177
A drop-down list in the System Properties window shows the list of properties
that can be defined for use by JKSimMet. The System Properties 192 function is
discussed in more detail within the chapter on Editing the Flowsheet Data.
5.4 Building and Manipulating a Flowsheet

In this section we will go through the process of building up a new flowsheet
from scratch and then examine how one can make modifications to an
existing flowsheet.
5.4.1 Loading an Existing Project
Loading an In JKSimMet V6, each flowsheet is stored as a sub-unit of a project. Therefore,

Existing Project to work with an existing flowsheet the user must first load the appropriate
project into the session window by clicking on Open Project in the File menu
or by clicking on the Open Project icon on the main toolbar (see topic File
Menu and Main Toolbar 139 for more detail). This brings a standard Windows
Open dialog into view.

Open Project Dialog
5.4.2 Creating a New Project
Creating a To create a new project select New Project from the File menu or click on the New
New Project Project icon on the main toolbar. A dialog box will request a name for the new
project. This name will be used as the file name and as the project name.
New Project Window
To change the name of an open project, use the Save Project As from the File menu
of the main JKSimMet menu. This will create an extra project with whatever new
Building and Manipulating a Flowsheet Version 6.0.1 - March 2014

Using JKSimMet 179
name you give it. You can delete the original project if required - but remember that
you will need to delete both the .jksf6 file and the .jksysdb file. To clean up
completely, you will also have to delete the associated AutoSave files, which will
have been created while you have worked on this file under its original name.
There should be two of these; one for the .jksf6 file and one for the .jksysdb file.
When a new project is created, it will initially be blank and will be loaded with a
single blank flowsheet, which will be given the default name of FlowSheet1. More
flowsheets can be added to the project as required, see the Creating a New
Flowsheet 180 section for further details.
Session Window Default Flowsheet
5.4.3 Loading an Existing Flowsheet
Loading an The list of existing flowsheets for the open project will be displayed in the left
Existing hand section of the session window. Double click to open the desired flowsheet.
Flowsheet The flowsheet can also be opened by right clicking on the flowsheet name and
selecting Open. The name of the current flowsheet open in the project appears in
the title bar at the top of the JKSimMet session window, in the format JKSimMet
[Project Name Flowsheet Name].
Version 6.0.1 - March 2014 Building and Manipulating a Flowsheet

Session Window with Blank Default Flowsheet Loaded
5.4.4 Creating a New Flowsheet
Create a New To create a new flowsheet right click in the left hand section of the session
Flowsheet window and select Add New from the menu that appears. Any number of
flowsheets can be added in this manner. Double click on the name of a
flowsheet to make it the active flowsheet.
Creating a New Flowsheet
Add New creates a new flowsheet in the current project.

Open opens the selected flowsheet in the right hand side of the session window.
The flowsheet can also be opened by double-clicking on the flowsheet name (see
topic Loading an Existing Flowsheet 179 ).
Clone a New Clone copies the flowsheet exactly. This option is particularly useful to run a
Flowsheet series of simulations while keeping the same flowsheet as a basis instead of re-
drawing and entering the data many times over. To clone a flowsheet, right-
click on the flowsheet and select "Clone" from the drop-down menu.

Using JKSimMet 181
Deleting a If you need to delete a flowsheet that you have added by cloning or otherwise,
Flowsheet you can do this by once again right-clicking on this flowsheet in the left hand
panel listing and selecting "Delete" from the drop-down menu. Note that you
will not be able to delete the flowsheet if it is open in the right hand pane. If you
get a message that the flowsheet can't be deleted for this reason, just double-
click on another of your flowsheets before right-clicking again on the one you
are trying to remove. The delete function from the drop-down menu should now
work.
5.4.5 Defining the Flowsheet Name
As a project can contain more than one flowsheet it is advisable to give each
flowsheet a unique name. The list of flowsheets for a project appears in the left
hand side of the session window. New flowsheets created in JKSimMet are
given default names FlowSheet1 for the first and then FlowSheet2,
FlowSheet3 etc. To edit the flowsheet name, right click on the flowsheet name
and select Properties from the menu to open the Flowsheet Properties
window.
To change the name of the flowsheet the user must highlight the text in the
Flowsheet Name box, type in the new name (maximum 50 characters) and
press OK to register the name. The new flowsheet name will appear in the left
hand side of the session window.
The user can also edit the Comments text for the flowsheet, however note that
there is a 50 character limit for this text.
5.4.6 Deleting a Flowsheet
Right clicking on the flowsheet name in the left hand side of the session
window opens a pop-up menu.

The Pop-Up Menu
Delete deletes the flowsheet. An open flowsheet cannot be deleted. A flowsheet

can be closed by clicking on the Close icon in the top right hand corner of the
flowsheet window (not the Close icon in the top right hand corner of the session
window), or by opening another flowsheet. The closed flowsheet can then be
deleted.
5.4.7 Building the Flowsheet - Equipment
When FlowSheet1 has been loaded, the user is presented with a blank
flowsheet. The first step in entering the data for the project is to build the
flowsheet.
JKSimMet uses an equipment unit to represent each process on a flowsheet.
The list of equipment that is available in JKSimMet is shown below in the
same form as it appears in the Session window.

Using JKSimMet 183
The default equipment has typical values for the equipment dimensions,
model parameters etc. as its default data. The user can edit these data at any
time.
Circuit Feed JKSimMet uses the Feed equipment unit to introduce the feed flow to the
circuit. This means that the parameters of the feed stream are actually defined
in the Feed equipment rather than in a Feed stream. A flowsheet therefore
must contain at least one Feed equipment unit.
Adding To place the appropriate equipment icons on the flowsheet:
Equipment to the 1. Unlock the flowsheet by clicking on the Lock/Unlock icon, by
Flowsheet selecting Lock from the Flowsheet menu or by selecting Lock/Unlock
from the right click menu on the session window.
2. Click on the icon of the desired equipment.
3. Move the cursor to where the unit is to be drawn on the flowsheet and
click to place the unit. To place multiple units of the same equipment
type, hold down the control key while selecting the equipment type
from the equipment list, then repeatedly click in the flowsheet to place

as many units as required.

Alternatively, additional units may be placed by placing a first unit in the
usual way, pressing the Copy button and then using the Paste function to
place as many units as are required.
Editing To edit equipment once it has been placed on the flowsheet, double click on
Equipment on the item of equipment in the flowsheet. The flowsheet must remain in
the Flowsheet unlocked mode to access the editing features. The equipment can then be
moved and have its name and orientation changed, as described below.
Moving To move equipment to a different position on the flowsheet place the cursor
Equipment over the equipment and hold the left mouse button down while dragging the
equipment to its new position. When the equipment is in the required position
release the mouse button to place the equipment. Any streams that are
attached to the equipment will remain attached after movement of the unit.
Naming The equipment is given a default name when it is initially added to the
Equipment flowsheet. To change the name of the equipment double-click on the
equipment and type in the new name next to the Name in the Component
Properties window and click OK.
Displaying The Equipment Auto Labels icon can be used to display the equipment name
Equipment on the flowsheet. When the Equipment Auto Labels icon is selected an
Name equipment label will automatically appear when equipment is added to the
flowsheet. The equipment label takes the Equipment Name from the
Component Properties window, as described above. The Equipment Auto
Labels function is discussed in more detail in the chapter on Annotating the
Flowsheet 187 .
Orientation The orientation of the equipment can be changed so that the feed end of the
equipment changes from left to right or vice-versa. The default orientation is
the feed on the left and the products on the right. Select one of the Flip or
Rotate buttons on the toolbar to change the equipment orientation.
Deleting To delete equipment ensure the flowsheet is unlocked and click on the
Equipment equipment to be deleted. Once selected press the Delete key or select Delete
from the Edit pull-down menu.
5.4.8 Building the Flowsheet - Streams
JKSimMet uses streams to represent the flow of material (solids and water)
between the equipment on the flowsheet. Material enters equipment through
its feed inlet and leaves equipment through its product outlet(s). The flow of
material between the equipment is created on the flowsheet by connecting the
feed and product outlets of the appropriate equipment items.
Although the drawing engine does not impose a limit on the number of feed
streams that can be connected to an individual equipment unit, the simulation
engine does only recognise the first 50 feed streams per equipment item. Note
that there is also a limit on the total number of streams per flowsheet and this
limit has been set at 999.
The number of product outlets from an equipment item depends on the type of
equipment; for example a flotation cell has two product outlets, a pump sump

Using JKSimMet 185
has one product outlet.

Note that there are two specialised equipment items that do not have a feed
inlet. These are the Feed equipment item, which is the source of new feed to a
circuit, and the Water Feeder, which is the source of water addition to a
circuit.
Adding a Stream Streams can be added to the flowsheet in a similar manner to equipment. Once
to the Flowsheet tee equipment has all been added to your flowsheet, it is simply a matter of
using your mouse to join the appropriate output and input ports of the
various equipment items.
1. Unlock the flowsheet by clicking on the Lock/Unlock icon or by
selecting Lock from the Flowsheet menu. In unlock mode the
flowsheet may be altered.
2. To connect a product outlet to a feed inlet, place the cursor over the
product outlet or feed inlet of an equipment item. When the cursor
changes to a circle containing a cross, left click to start the connection
process. The cursor will then change to a cross and when you now
move the mouse, it will drag a line representing the stream to
wherever you select as the destination.
3. When you have positioned the cursor over the inlet or outlet (as
appropriate) of the destination equipment item, the cursor will again
turn into a circle containing a cross. Note that this will only happen
where a connection is possible. If you have started at an inlet port and
you move to another inlet port, the cursor will not change because in
this case the connection is not possible. When the cursor has changed
to indicate the potential for connection, left-clicking again will
complete the stream.
Streams can be connected in straight lines in this manner, or they can be made
to follow more complex paths. The above procedure will produce a connection
that is just a straight line stream from one item of equipment to another. While
a straight line stream may be acceptable in a very simple circuit, more often
than not you will require points of inflexion so that your streams take a less
direct route to their destination. You can achieve this during the connection
process if you left click at the various intermediate points where you require
the stream to change direction. Again, you just terminate the stream when the
cursor turns to a cross within a circle over the destination port.
To produce the stream connection below for instance, left-click over the outlet
from the feeder, move the cursor downwards to the desired position for the
right angled bend and click again. Finally, move the cursor to the right and
click on the flotation cell inlet to complete the stream.

Flowsheet with a Single Stream Connection
Note that if you wish to abort the drawing of a stream at any point during the
process, all you have to do is right click and the entire stream you have
entered to that point will disappear.
Editing a Stream To edit the formatting of a stream once it has been placed on the flowsheet
on the Flowsheet double click on the stream. The flowsheet must be in unlocked mode to access
the editing features. This will open the Common Properties window for the
chosen stream.
Naming Streams The streams are given default names when they are initially added to the
flowsheet. To change the name, open the Component Properties window by
double-clicking on a stream. Type in the new name into the Name text box and
click OK. It is recommended that the streams be given meaningful names such
as Cyclone O/F, Ball Mill Feed etc, so that they can be easily identified.
Displaying Labels can be added to the flowsheet to display the stream names using the
Stream Name Stream Auto Labels icon. Labels are discussed in more detail under the
heading Annotating the Flowsheet 187 .
Manually Re- JKSimMet provides a mechanism for re-routing existing streams in the event
route Streams that you are not satisfied with your initial placement. First ensure the
flowsheet is unlocked and then right-click on the stream you wish to re-route,
at the point where you require the point of inflexion (or stream node). The
right-click menu will look similar to the image below.

Using JKSimMet 187
Click on the Add/Remove Stream Node menu item. This will insert a new
stream node at the cursor location. You can then move the cursor over this
new node, then left-click and drag it to the location required for re-routing this
stream.
You can remove a stream node in a similar manner. For this you need to bring
up the right-click menu while the mouse is hovering over the stream node in
question. Selecting the same menu item will in this case delete the stream
node.
Deleting a Whole streams can be deleted in the same manner as equipment items. Ensure
Stream the flowsheet is unlocked, then click on the stream to be deleted. Then you can
either press the Delete key or select Delete from the Edit pull-down menu.
Before the stream is actually deleted you will get a warning and an
opportunity to cancel, so as to guard against accidental deletion.
Once all of the equipment and streams have been added to the flowsheet and
the editing of names is complete, lock the flowsheet by clicking on the blue
Lock icon, by selecting Lock from the Flowsheet menu or by selecting Lock
from the right click menu in the session window.
5.4.9 Annotating the Flowsheet
JKSimMet allows the user to annotate the flowsheet by adding general labels
to the flowsheet or by adding equipment or stream specific labels, as well as
information blocks.
There are three ways in which labels can be added to the flowsheet:
1. General Text Labels used to add general text (e.g. circuit name) to
the flowsheet; the labels can be moved independently around the
flowsheet.
2. Equipment Labels used to automatically add the equipment name
as a label near the equipment on the flowsheet; the label becomes part
of the equipment and moves when the equipment is moved.
3. Stream Labels used to add labels of the existing stream names to the
flowsheet; the labels are of the same form as the Equipment Labels.
Adding General To add General Text Labels to the flowsheet:
Text Labels to 1. Unlock the flowsheet by clicking on the Lock/unlock button or by
the Flowsheet selecting Lock from the Flowsheet submenu.
2. Select the Text icon from the toolbar. A text icon now appears next to
the cursor when it is placed over the flowsheet.

3. Move the cursor to the desired location and click to place the label.
4. Double click the label and type in the desired text. Press Enter when
finished.
Editing Labels on To edit a label once it has been placed on the flowsheet click on the label. The
the Flowsheet flowsheet must remain in unlocked mode to access the editing features. A
label can then be moved and be edited, as described below.
Moving Labels Text labels can be moved in the same manner as equipment. Simply place the
cursor over the label and hold the left mouse button down while dragging the
label to its new position. When the label is in the required position release the
mouse button to place the label.
Changing the To change the text of the label, double-click on the label and type in the new
Text of a Label text. Press Enter to complete.
Deleting Labels Labels can be deleted in the same manner as equipment and streams. Ensure
the flowsheet is unlocked then click on the label to be deleted. Either press the
Delete key or select Delete from the Edit pull-down menu.
Adding To automatically add the equipment name as a label above the equipment on
Equipment the flowsheet click on the Equipment Auto Labels button. To remove the
Labels to the equipment name labels click on the Equipment Auto Labels button again. The
Flowsheet Equipment Auto Labels function is available whether the flowsheet is locked
or unlocked.
Editing Unlike the general labels, the labels added to equipment on the flowsheet
Equipment using the Equipment Auto Labels function cannot be independently renamed.
Labels These equipment labels become a part of the equipment; they move when the
equipment is moved, are renamed when the equipment name is changed
(using Equipment Properties, see topic Property Windows 160 ) and are deleted
when the equipment is deleted. The position of the label in relation to the
equipment can be changed, however. To do this, double click on the label or
the equipment to bring up the Component Properties window. Select the Auto
Label tab and select an option for the positioning of the label relative to the
equipment. Note that clicking the On/Off option in this tab will mean that
the label for this particular item of equipment will not be displayed on the
flowsheet.
Stream Labels may also be edited using the same procedure as Equipment
Labels.
Adding Stream To automatically add labels of the existing stream names to the flowsheet:
Labels to the 1. Unlock the flowsheet by clicking on the Lock/unlock button, by
Flowsheet selecting Lock from the Flowsheet submenu or by selecting Lock from
the right click context menu in the session window.
2. Click on the Stream Auto Labels button.
IMPORTANT Note that if the stream names are changed subsequent to adding stream labels
NOTE to the flowsheet, the stream label text automatically changes, however the
stream label box does not automatically resize to match the size of the new
stream name. To fix this, click the Stream Auto Labels button to remove the
labels, then click on the Stream Auto Labels again to add the labels again.

Using JKSimMet 189
5.4.10 Information Blocks
On opening the Information Blocks window (via the toolbar button or the
Flowsheet menu) the user will be presented with a tabbed display, with one tab
for setting up Stream Information Blocks and one for Equipment Information
Blocks.
Stream The same data is displayed for all active Stream Information Blocks. You cannot
Information tailor the blocks for individual streams so that they are different from those of
Blocks other streams.
The procedure for adding Stream Information Blocks is as follows:
1. First ensure that the Stream tab is active.
2. From the first drop-down box, select the number of parameters to be
displayed in the Information Block.
3. Select the basis stream for recovery calculations. Note that his selection
is only needed if a recovery value is to be one of the display fields and
this will only be a possibility in cases where mass balancing is being
performed.
4. Next left click on each parameter cell in turn to select the data that you
wish to have displayed in that cell. Each time you do this, another
window labelled Selection Options will open. Here you specify the type
of data to be displayed in more detail. A screen grab of this window is
shown below.
5. In this window you work your way down (starting with the drop-down
at top left in Selection Options), to make a full specification of the data
type that is to be displayed in the selected cell. Note that lower drop-
downs will become available when needed, depending on your
selections in the drop-downs above. The name that will appear in the
stream information block key for this data cell is auto generated by
default. You will notice that there is a tick in the Auto Generate Name

box when the window opens. If the system generated name is too long
however, you can manually enter an abbreviated form, after clicking to
remove the tick from this check-box.
6. Select the stream or streams for the info block multiple selection can be
achieved using the Ctrl and Shift keys.
7. Click Add Info Block to add the blocks to the flowsheet.
The Info Blocks will be added to the flowsheet, roughly centred on each stream.
In addition there will be a key displayed at the top left of the flowsheet that will
show which parameters are displayed in which cells of the Info Block.
To modify the information displayed in the Stream Information Blocks, make the
changes required and click Update Selected Info Blocks.
Remember that the same data is displayed for all streams, so clicking Add Info
Block after changes have been made in the Stream Info box tab will result in all
of the Stream Info Boxes updating.
Equipment Equipment blocks are conceptually different to Stream blocks, but operate in a
Information similar way. As each Equipment unit may use a different model and therefore
Blocks different data, the information blocks are set up on a per unit basis.
The procedure to add an Equipment Information Block is:
1. Select the equipment unit or units for the info block multiple selection
is achieved with the Ctrl and Shift keys.
2. Select the number of parameters to be displayed.
3. Left click on each parameter cell to select which data is to be displayed
in that cell. The selection method is the same as the Configurable
Equipment Manager, except that the parameter name is also defined.
Click Close when finished.
4. Click Add Info Block to add the blocks to the flowsheet.
The info blocks will be added to the flowsheet, adjacent to each unit. The
parameter names will be displayed in the cell next to the values.

Using JKSimMet 191
To modify the information shown in one or more Equipment Information Blocks,

make the changes required in the Equipment Info box tab, select the Equipment
unit or units to modify and click Update Selected Info Blocks.
General When the flowsheet is unlocked, the Info Blocks may be moved, resized and
Information deleted using the Delete key.
The data that is not able to be edited will be greyed out. Other values can be
edited, and will update throughout the system.
5.5 Editing the Flowsheet Data
Overview Once the flowsheet has been built complete with equipment and connected by
streams to form a circuit, the next step is to input the data itself. The flowsheet
must first be locked by clicking on the Lock button, by selecting Lock from the
Flowsheet menu or by selecting lock from the right click menu in the session
window. Once locked the System Properties, Sieve Series, Survey Data,
Configurable Equipment Manager, Run Simulation, Configurable Stream
Overview, Simulation Manager, Run Balance, Equipment, Stream, Reporting,
Config Graph and Setup Info Blocks icons are all accessible. These tools will
be described in subsequent sections.
Data Entry There are three different background colours used to represent the different
Conventions types of data in the JKSimMet windows:
1. White the user is required/permitted to enter data (e.g. feed
tonnage).
2. Light grey this data does not change (e.g. some labels).
3. Medium grey user entry is not required but the data will change
depending on a user selection or calculation during simulation (eg a
calculated value such as pulp volume of each cell).
These conventions apply to all of the data windows.
Note that the exact appearance and colours of each window will also depend
on the setup of the MS Windows desktop.
5.5.1 Stream Structure
After input of the feed stream data and equipment and model data, JKSimMet
predicts the sizing and mass flow data in the streams throughout the circuit
using an iterative technique.
Comminution models are used within each of the specified comminution
equipment units to determine the resulting size data for the relevant output
streams. A detailed explanation of the terms used to define the stream
structure has been provided under the heading Definition of Terms Used in
JKSimMet 135 .
Remember that the feed stream data are defined in the Feed equipment item
rather than in the stream from this unit.

5.5.2 System Properties
System Click on the System Properties icon or select System Properties from the
Properties Flowsheet sub menu to open the System Properties window.
There are two system property classes available to the user; Elements and
Miscellaneous items. The user has the option of defining as many or as few
elements as required, but cannot define additional miscellaneous items.
The two classes of system properties are accessed via a drop-down list at the
top of the System Properties window, under the heading Select property.
System properties must be defined for each flowsheet; they cannot be copied
between flowsheets or between projects.
Miscellaneous The first item on the drop down list is Miscellaneous and this will be chosen
initially by default. There are just two miscellaneous items in the system for
which you need to set values; Solids SG and Liquid SG. The default values are
2.7 and 1.0 (t/m3 ) respectively. You can simply edit these values in the white
cells to adjust them if required.
Elements The other item on the Select property drop down is Elements. In JKSimMet
elements are only needed for the mass balancing function of the program. If
you are not going to be doing any mass balancing, then it is not necessary to
enter any elements into the system for the flowsheet in question.
If you do need to specify elements, firstly select Elements from the drop-down.
Once you do this you will see the appearance of the window change to
resemble the screen capture below, which in this case also shows the
expanded drop-down.
Adding Elements The main difference you will notice after Elements has been selected, is that a
Delete selected row(s) button will be present at bottom left. This is to provide
the option of removing elements already in your list if you have changed your
mind or made an error.
The table is configured such that it will always contain a blank row at the
bottom where you can add further elements. When you enter an element you
can either leave the units in the adjacent Units cell with the default setting of
"%" or else select "g/t" (if appropriate) from the drop-down in this cell. To
remove an element that is not required, click anywhere in the row you wish to
remove and use the Delete selected row(s) button.
There is no limit to the number of elements that can be added.
Editing the Flowsheet Data Version 6.0.1 - March 2014

Using JKSimMet 193
The width of the columns can be changed by placing the cursor on the right
border of the column in the heading row, then holding down the left mouse
button and dragging the cursor.
IMPORTANT Note that there is no internal check of consistency of these data in JKSimMet. It
is up to the user to ensure that the SG values are correctly defined.
NOTE
When all changes to the System Properties window have been made, click on
the Close button to close the window.
5.5.3 Accessing the Equipment and Model Data
The Equipment and Model windows contain all of the information about the
equipment that JKSimMet requires to perform simulation tasks.
Accessing the The data for the equipment can be viewed in the Equipment window. The
Equipment Data Equipment window can be opened by:
1. Double-clicking on the equipment in the flowsheet.
2. Selecting Equipment on the Flowsheet menu or clicking on the
Equipment icon.
Equipment There is one Equipment window in JKSimMet; all of the equipment can be
Window Layout accessed via the Equipment Name drop-down list in the Equipment window.
The Equipment window can only be accessed when the flowsheet is locked. A
typical Equipment window is shown below.
A Typical Equipment Window
The Equipment window also shows the feed and product streams from the
selected equipment. Clicking on the double arrow buttons next to the streams
that are feeds or products from the selected equipment; opens the Streams
window, which enables display of stream data.
Version 6.0.1 - March 2014 Editing the Flowsheet Data

5.5.4 Editing the Model Data
The Model window collects the data required for the selected model
calculation and displays the equipment parameters calculated during
simulation.
Selecting a The Equipment Model drop-down list in the Equipment window shows the
Model models available for the selected equipment. All models for a particular type
of equipment are available for selection.
Accessing the Select a model and click on the double arrow button next to the selected
Model Window equipment model to open the Model window.
Model Window The Model window for all the models has the same general layout, see below.
Layout Click on the tabs at the top of the Model window to input and view the model
data. The data layouts for all of the model types are detailed in the Model
Descriptions 294 section. Note that some of the calculated model data will
update on input and some will update only after simulation.
Copy Grid The Copy Grid button allows the user to copy the currently displayed grid to
the clipboard, from where it can be pasted into other applications.
Units in Parallel The units in parallel text box is used to show how many of the selected unit in
question exist at this location in the circuit.
A Typical Model Window
Parameter If a value is entered for a parameter that is outside the normal range for the
Values parameter, JKSimMet will display a warning message. Users are given the
choice of either having the value entered clipped to the nearest edge of the
normal parameter range (eg, for a range of 1 to 15, an entered value of 20
would be clipped to 15) or continuing with the entered value.

Using JKSimMet 195
If the user needs to know the maximum and minimum values for a parameter
value, double clicking on the cell for that item will launch the Parameter
Detail window. This displays the minimum and maximum values, as well as
the default value and other available information about the selected
parameter.
5.5.5 Editing Equipment Data
There are two options for viewing and editing the equipment and model data.
The first option is to access the Equipment and Model windows for the
individual equipment units as previously described 193 . The alternative is to
use the Configurable Equipment Manager, which allows the user to view and
edit data for all units of the same type in a summary table format. This can be a
more efficient means of accessing equipment data during simulation work. As
its name implies, the Configurable Equipment Manager can be configured as
required by the user.
The Configurable Equipment Manager window displays a summary of selected
equipment unit parameters. The user can configure multiple summary tables
for display and can edit the values displayed in these tables. This window
provides a simpler and more efficient means of reviewing and adjusting
equipment information than using the individual equipment data screens.
The Configurable Equipment Manager window can be opened by two methods:
1. Selecting Configurable Equipment Manager from the Flowsheet menu.

2. Clicking on the Configurable Equipment Manager button.
The Configurable Equipment Manager can only be accessed when the flowsheet
is locked.
Configurable Equipment Manager provides a summary of the equipment unit
data for selected units in the flowsheet. The information displayed in the
Equipment Overview screens is exactly the same as the information displayed
in the model screens for the individual equipment units.
The summary table can be printed directly from the dialog, copied to the
clipboard for pasting into other programs such as Word or exported to Excel
for further analysis.
A Typical Configurable Equipment Manager Window
Configurable The Configurable Equipment Manager window has four main components:
Equipment 1. Current Overview drop-down list
Manager
Window 2. Configurable Equipment Manager toolbar
3. Model drop-down list
4. Data table
Current The user can create one or more Configurable Equipment Manager tables. Each
Overview List table created is listed by name in the Current Overview List drop-down,
allowing the user to change from one table to another by selecting the required
configuration from the list.
Configurable The toolbar allows the user to create new configurations, delete unwanted
Equipment configurations, add or delete data columns, print, copy or export the data to
Manager Excel.
Toolbar
New Unit To create a new configuration the user clicks on the New Unit Overview
Overview button. This opens the Add Unit Overview dialog which prompts the user to
enter a name for the new overview and to select from the Select Model drop-

Using JKSimMet 197
down list, a model that is to be associated with this newly configured

overview.
Delete Clicking on the Delete Overview button deletes the current overview. A
Overview warning dialog asks the user to confirm that the current configuration is to be
deleted as this operation cannot be undone.
Rename The Rename Overview button allows the user to rename the selected overview.
Overview
Insert Column Inserts a blank data column to the right of the column where the cursor is
currently located.
Delete columns Deletes the column where the cursor is currently located. Note that the column
is deleted immediately without the user being asked to confirm their action.
Print Overview Prints the current overview table.
Copy Grid Copies the entire data grid for the current overview to the clipboard, allowing
the data to be pasted into other programs such as Word.
Lock Cols When this button is unlocked (appearing as shown in image at left) the user is
able to change the position of the columns of data.
Export Exports the data for the current Equipment Manager overview to Excel.
Overview Clicking on the Export Overview button opens the Export Report to Excel
dialog where the user can enter a name for the Excel file and choose where to
save the file. Note that if the file name chosen is the same as an existing Excel
workbook, the user is prompted to choose whether to overwrite the existing
workbook or to append the current data as a new worksheet in the existing
workbook. The name of the Overview which has been exported is shown in the
tab of the Excel worksheet.
Export All As for Export Overview, except that in this case all of the overviews listed in
the Current Overview drop-down list are exported to Excel, each on a separate,
named worksheet in the workbook.
Below is an example of a new overview that has been created for cyclones in a
flowsheet that are using the Asomah Advance Inclined Cyclone model. In this
case there is only the one cyclone using this model. The overview has been
configured to show the cyclone diameter (Dc) under the Operating Conditions
category of parameters and also the various data types associated with the
Water Split to Overflow parameter under the Performance Data category of

parameters.
An Example of the Default Configurable Equipment Manager Layout
Configuring a When a new column is added to the Overview table by clicking on the Insert
New Data Column button, the added column is headed No Selection and contains no
Column in the data. The user must select the data to be displayed in the column by first
Overview ensuring that the Lock Cols button is locked and then clicking on the header
cell for the column. This opens the Tab/Options/Parameter dialog.
The user can select the required options from the drop-down lists in the dialog.

Using JKSimMet 199
The selected parameters are then displayed in the overview table.

Adding or The user is able to add or remove equipment units from a configuration. Data
Deleting for other unit types or similar unit types that are using a different model, must
Equipment be viewed and edited by setting up another configuration for that model type.
Units
Changing the To change the order in which the data columns are displayed the user must
Data Column unlock the Lock Cols button, select the column in the data table by clicking in
Order the header cell and then drag the column to its new location on the table as
indicated by a red line. Two or more adjacent columns can also be moved by
selecting all of the columns together (click and drag or Shift-click) and
dragging the group to their new location in the table.
5.6 Using Simulation

During simulation JKSimMet calculates the mass flow of the particle classes
in each stream of the flowsheet. The mass in each particle class in the product
streams of each equipment unit is calculated using the mass in each particle
class in the feed stream(s) to the equipment and the model algorithm for the
equipment. These calculations are performed iteratively until the difference in
the stream flows from two consecutive iterations are below a specified
convergence limit. The particle class information is then combined to enable
calculation of the data displayed in the Stream data and Stream Overview
windows. Various unit parameters are also calculated during simulation and
can be viewed in their associated equipment data windows.
What Simulation Prior to simulation, the user must:
Requires 1. Create the flowsheet (see Section 4.5). Note that each feed stream to a
comminution circuit (unless it consists entirely of water; see Water
Feeder models in Appendix B3) must be preceded by a Feed
equipment unit before it can be simulated. In addition, all equipment
units must have feed streams for the flowsheet to be valid.
2. Define the characteristics of the property classes in System Properties
(see Section 4.6.2).
3. Input the feed stream data in the Feed equipment unit (see Appendix
B2).
4. Select the models for each equipment and input the required model
data (see Sections 4.6.4 to 4.6.6).

Performing Simulation within JKSimMet can be performed in two ways. If the user simply
Simulations wants to simulate the circuit with the current equipment and feed stream data
values only, the Simulation window is used. Alternatively, the Simulation
Manager allows one or more simulations to be performed on the flowsheet
with the user being able to set selected data values (e.g. solids flow rate, %
solids) for each simulation in the batch. The use of each simulation control is
described below.
5.6.1 Simulating Using the Simulation Window
Accessing the To perform a simulation with the current data in the flowsheet the Simulation
Simulation window is used. The Simulation window can be opened by two methods:
Window Selecting Run Simulation from the Flowsheet menu, or
Clicking on the Run Simulation icon.
Simulation The system provides a default simulation for the whole circuit; the user is then
Select free to create new simulations and delete or rename the simulations that they
add. The whole circuit simulation cannot be renamed or deleted.
Add a new Choosing to add a new circuit brings up this dialog, where the user can choose
circuit to accept the default name or enter a name of their choice.
On returning to the main simulation dialog, the user can then choose which
equipment and streams they require for the new simulation
Equipment / In all simulations except the default whole circuit simulation, the user can
Streams choose which equipment items and streams are to be used by the simulation.
Using Simulation Version 6.0.1 - March 2014

Using JKSimMet 201
Settings The options in the settings area allow the user to set the convergence limit, set
the iteration count, choose the interpolation method and set the starting
condition for the simulation.
Interpolation options
Starting Conditions
Run When the user has selected the simulation that they wish to run, checked the
Simulation choice of the selected equipment and streams and reviewed the settings for the
simulation, they click the start button to run the simulation. The simulation will
run until either the specified iteration count is reached or the fitted convergence
value reaches accuracy level specified in the settings. As the simulation runs it
provide the user with feedback by updating the Convergence and Iteration
count text boxes.
5.6.2 Simulating Using the Simulation Manager
The Simulation Manager is a powerful feature that allows multiple

simulations to be performed in a batch operation. The user can set a range of
key operating parameters in the simulations and record the key performance
indicators for each simulation performed. The results of all of the simulations
within a scenario can then be viewed on the same screen, allowing direct
comparison of simulated flowsheet data under different operating conditions.
The user is able to view any parameter relating to stream or equipment unit
data. The equipment viewing platform is similar to the Configurable
Equipment Manager viewing platform
Accessing the Click on the Simulation Manager icon or select Simulation Manager from the
Simulation Flowsheet menu to open the Simulation Manager window. The Simulation
Manager Manager window consists of the Simulation Manager toolbar and three data
tabs, one for setting the simulation conditions (Simulation Scenario) and two
for viewing the simulation results (Results - Streams and Results - Equip).
When the Simulation Manager window is opened, the Simulation Scenario tab
is active.
Version 6.0.1 - March 2014 Using Simulation

Simulation The Simulation Manager allows the user to perform multiple flowsheet
Scenarios simulations varying key operating parameters in a batch operation called a
Simulation Scenario. Any number of Simulation Scenarios may be created,
however only one Simulation Scenario may be active at any one time. The
active Simulation Scenario can be changed to another previously created
scenario by selecting the required item from the Scenario Name drop-down
list.
Within each Simulation Scenario, the user can create a large number of
simulations to investigate the effects on the circuit performance of a single
parameter, or the effects of different values of a multiple of equipment
parameters. The results of these simulations can then be viewed in the
different results tabs of the Simulation Manager.
The different areas of the Simulation Manager window are as follows:
1. Toolbar contains the functions to configure and use the Simulation
Manager. The toolbar is always visible at the top of the window.
2. Tabbed data viewing region each tab contains a data display header
and a data display area, and only one tab can be viewed at any one
time. The three tabs display the simulation conditions and simulation
results:
a) Simulation Scenario used to define the equipment parameters
which are to be varied in the simulations and to set the value of
each parameter for each simulation;
b) Results - Streams for viewing results associated with streams on
the simulated flowsheet;
c) Results - Equip for viewing results associated with equipment
units on the simulated flowsheet.
Data Display The parameter description is displayed in the data display header in each of
Header the tabs. See further down in this topic under the heading Selecting the

Using JKSimMet 203
Parameters 204 for the method used to select the parameters.

Note that all of the drop-down lists in the data display header list items in
alphabetical order.
Data Display The data display header for the Simulation Scenario tab is similar to the data
Header: display header in the Configurable Equipment Manager, containing data
Simulation headers to describe the selected parameter. These data headers are:
Scenario Tab Row 1 Equipment name
Row 2 Model Tab
Row 3 Model Tab Option
Row 4 Parameter name
Rows 5 to 7 Description of property specific parameters
Row 8 Type of Change: choose either replacing the value of the
parameter with a user defined value (select Value), or increasing or
decreasing the value of the parameter by a defined percentage (select
% Change).
Row 9 Original Data: the base case value of the parameter is
automatically displayed when the parameter is added. This provides
a reference point for comparison with the other simulations results.
Data Display The data display header for the Results - Streams tab is similar to the data
Header: Results- display header in the Configurable Stream Overview, containing five data
Streams Tab headers to describe the selected stream data.
Row 1 Stream name
Row 2 Property
Row 3 Calculation Type: select
Row 4 Assay Basis
a reference comparison point for the other simulations.
Data Display The data display header for the Results - Equip tab is similar to the data
Header: Results- display header in the Configurable Equipment Overview, containing several
Equip Tab data headers to describe the selected parameter. These are:
Row 1 Equipment name
Row 2 Model Tab
Row 3 Model Tab Option
Row 4 Parameter name
Rows 5 to 7 Description of property specific parameters
a reference comparison point for the other simulations.
Using the Using the Simulation Manager requires the user to:
Simulation 1. Create a Scenario in the Simulation Scenario tab.
Manager

2. Select the parameters to be varied for the simulations.

3. Define different simulation conditions.
4. Select the parameters to be displayed in the Results - Streams tab and
the Results-Equip tab.
5. Perform the batch simulation.
Delete Scenario The current Scenario can be deleted by clicking on the Delete Scenario button
from the toolbar at the top of the Simulation Manager window. Click Yes to the
prompt to delete the current scenario.
Rename The current scenario can be renamed by highlighting the existing name in the
Scenario Scenario Name box and typing the new name to replace the old one.
Create a Scenario Click on the Simulation Scenario tab, then click on the New Sim Scenario
button on the toolbar at the top of the window, type in the name for the new
scenario and click OK.
The Simulation Scenario tab then displays one column in the data display
area with No Selection in the top row of this column.
Note that when selected subsequently, a particular Simulation Scenario
window appears as it was last left by the user.
Selecting the The Simulation Scenario windows can be configured by the user to allow
Parameters many parameters to be varied in the simulation. The parameter displayed in a
column can be changed by editing at any time. New columns can be added,
and existing columns deleted as required using the Insert Column and Delete
Column buttons on the toolbar.
Adding a New To add a new parameter to the Simulation Scenario tab display, first click in
Parameter the data display area of the window then click on the Insert Column button on
the toolbar. A new column will be added to the right of the cursor position.
When a new column is added to the scenario, the words No selection are
displayed in the top row of the column. This parameter description can be
changed as outlined below.
Changing To display a different parameter (or to select a parameter for the first time),
Existing lock the columns, then click in the top row in the data display header of that
Parameters column (initially this row will display No selection). A new window
appears to select the parameter.
In this window the user selects the required parameter from the drop-down

Using JKSimMet 205
lists by selecting first the Equipment unit for the parameter, and then the Tab,
Option and finally the Parameter to be displayed. Note that the Equipment/
Group drop-down list contains all of the equipment units in that flowsheet, in
alphabetical order. The Tab, Option and Parameter are selected in an identical
manner to the Configurable Equipment Overview.
When parameter selection is complete click on the Close button. The
parameter description will then be displayed in the data display header of
the Simulation Scenario tab. The Type of Change and Original Data are also
displayed at the bottom of the data display header.
If a parameter is selected that requires further property-specific parameter
selection, then a Select Properties window opens on top of the Simulation
Manager window, as is the case in the Configurable Equipment Manager. This
window opens after the user has made the Tab, Option and Parameter
selections and then clicked on Close in the Equipment/Tab/Option/Parameter
window.
An Example of a Select Properties Dialog
The Select All and Deselect All buttons can assist in the selection of the
specific properties. When this window is closed by clicking on the Close
button, the property combinations that were checked are then displayed as
one parameter per column under the overall parameter label in the Simulation
Scenario tab, as shown below.

An Example of the Simulation Scenario Tab After Parameter

Selection
Delete a To completely delete a parameter from a tab in the Simulation Manager, place
Parameter the cursor on the column/s to be deleted then click on the Delete Columns
button from the toolbar. The whole column will then be deleted from the
window. Note that the deletion occurs immediately.
Setting Up The Simulation Scenario tab is used to define the conditions for the different
Simulations simulations that are to be performed in the current scenario. Place the cursor
in the data display area and click on the Insert Simulation button on the
toolbar. A new row for a new simulation will be inserted in the row below
where the cursor was placed. Each simulation is automatically given a name,
Simulation 1, Simulation 2, etc. It is also possible for users to change the
names of the simulations. When a simulation has been inserted, ensure that
the Lock Cols button is pressed and then double click in the cell which reads
Simulation 1 (or Simulation 2 etc depending on the number of simulations
inserted). Type in the new name for the simulation and press Enter when
complete.
A simulation can be deleted from the Simulation Scenario tab by selecting the
row to be removed and then clicking on the Delete Simulations button on the
toolbar.
Entering Data Once a simulation has been created as a row in the Simulation Scenario tab,
new parameter values for that simulation can be entered into the appropriate
columns. To do this, click on the parameter cells for a given simulation and
type in the Value or % Change value to be used for each parameter in the
simulation. The Original Data value for each parameter can be seen in the
bottom row of the data display header for comparison purposes.
Note that other than the parameters selected for display in the Simulation
Scenario tab, all other data used in the simulation calculations are the current
data for the flowsheet. In other words, only the parameter values displayed in
the Simulation Scenario tab can be varied in the simulations all other

Using JKSimMet 207
parameters remain fixed at the values that have previously been entered for
each equipment unit, and the feed stream, in the respective Equipment and
Stream windows.
If there are no data entered on the Simulation Scenario tab for a parameter for a
particular simulation (i.e. the cell is left blank), the Original Data value for
that parameter will be used for simulation calculations. Note that the range
limits for parameters are applied when the simulation is run.
Different Simulation Scenarios as well as different simulations within a
scenario may be used to determine the effects of changing parameters on the
circuit performance. For example, it may be useful to determine the effect on
circuit performance of only one parameter at a time, in which case the
Simulation Scenario would only have one parameter selected. A new
Simulation Scenario would then be created to determine the effect on circuit
performance of a different parameter.
The Simulation Manager allows columns to be moved inside the window. To
do this, ensure that the Lock Cols button is turned off, then click anywhere in
the grey area at the top of the column to be moved in order to highlight the
entire column. Once this is done click and drag the column to its desired
location.
Setting up the The results of the simulations are recorded on the two Results tabs and the
Results Tabs data to be displayed on these tabs should be set up before simulations are
performed. If a simulation is run and the Results tabs have not been set up, no
results are recorded. In this case you would need to run the simulation again
to see values in any new results cells you have added.
The two Results tabs display the list of simulations that have been defined in
the Simulation Scenario tab in the left hand column, and initially display only
one other column with No Selection in the top row. As with the Simulation
Scenario tab, when these tabs are subsequently opened they will appear as
last left by the user.
All of the cells in the results tabs are dark grey to indicate that they are
calculated values, and cannot be edited by the user.
Results-Streams Parameters are added to the Results-Streams tab, and existing parameters are
Tab changed in the same manner as for the Simulation Scenario tab. The dialog
that appears and which allows the user to select the stream parameter, is
shown below.
In this window the user first selects from drop-down lists the Stream, and
then the Property, Calc Type and the Assay Basis to be displayed. Note that

the Stream drop-down list contains all of the streams in that flowsheet in
alphabetical order. Click on Close to select the parameter. The rows in the data
display header and the Original Data row are automatically filled with values
once a parameter has been selected. The zero values present in some cells are
replaced with simulation results after a simulation run has been performed.
The basis stream for the recovery calculations is selected from a drop-down
list of all of the streams in the toolbar of the Results-Streams tab. Note that if a
different stream is chosen as the basis for the recovery calculation, the new
recovery values calculated using this basis stream will only be displayed after
simulation is performed again.
Results-Equip Parameters are added to the Results-Equip tab and existing parameters are
Tab changed in the same manner as for the Simulation Scenario tab. The dialog
which appears and which allows the user to select the equipment parameter
is the same as in the Simulation Scenario tab.
Click on Close to select the parameter. The rows in the data display header
and the Original Data row are automatically filled with values once a
parameter has been selected. The zero values present in some data cells are
replaced with simulation results after a simulation run has been performed.

Using JKSimMet 209
Batch Simulation There are two ways to perform the batch simulations:
1. Simulate Select used to run only the simulation selected in the
Simulation Scenario tab. This feature enables the user to investigate
the simulated data associated with a particular simulation in more
detail. After running Simulate Select, the user can exit the Simulation
Manager and the streams and equipment in the flowsheet will display
the data associated with the simulation selection. To return the
program to the original data, the user must return to the Simulation
Manager, highlight the Original Data row, then click on the Simulate
Selection button again.
2. Simulate All - as the name implies, this option runs all of the
simulations in the current scenario in the sequence listed by the user.
The program always runs the Original Data simulation after
performing all the simulations defined by the user. This returns the
flowsheet to its baseline conditions so that all streams and equipment
within the flowsheet will have the data pertaining to its original
condition, rather than that of the last simulation. The simulation
scenario data are displayed in the Simulation Manager tables.
Close Window Click on the Close button in the top right hand corner of the window to close
the Simulation Manager window.
Edit Groups The Edit Groups button allows the user to combine equipment units of the
same type and same model together into a named group. When a group has
been defined, it appears in the drop-down list of equipment in the Simulation
Manager, and this allows the user to select the group to change the value of a
parameter for all of the equipment units in the group in one step. For example
in a plant where there are a number of mills, the user could increase the ball
loading by 10% in each of the mills by assigning them to a group and then
setting the % Change for the Load Fraction parameter for this group to 10%.
To create a group the user clicks on the Edit Groups button to display the
Select Equipment for Groups dialog.
Click on the Add Group button to open the Add New Group dialog which
allows the user to create a new group and also to define the equipment and
model types to be included in the group.

Then insert a new column in the Simulation Scenario, choose the newly
created group in the Equipment/Group drop-down list and choose the
parameters in the usual way.
Print Scenario Click on the Print Scenario Grid button on the toolbar to print the data
Grid displayed on the active tab. Each tab must be printed separately.
Copy Grid The data displayed in the current tab can be copied to the clipboard by
clicking the Copy Grid button. These data can then be pasted into another
program such as Excel or Word.
Lock Cols Click on the Lock Cols button to lock the current position of the rows and
columns in place. When the Lock Cols button has been clicked, the position of
the rows and columns cannot be accidentally changed.
5.6.3 Accessing the Stream Data
After Simulation, the data associated with a stream can be viewed in the
Streams and Stream data windows. The feed stream data are defined in the
Feed equipment (see Appendix B2) rather than in the feed stream. This
means that all of the information in the Stream data windows is for viewing
only; no data are entered here.
Accessing the The Stream window provides access to the Stream data window to view the
Stream Data data for each stream. The Streams window for each stream can be opened by
three methods:
1. Double-clicking on a stream in the flowsheet.
2. Selecting Stream on the Flowsheet sub menu or
3. Clicking on the Stream icon.
window via the Stream Name drop-down list. The Streams window can only
be accessed when the flowsheet is locked. A typical Streams window is
shown below.
The Streams window also shows the equipment from which the stream
originates and the equipment to which the stream flows. Clicking on the
double arrow buttons next to the From Equipment and To Equipment dialog
boxes opens the Equipment window relating to that equipment. Accessing the
Equipment data is discussed under the heading Accessing the Equipment and
Model Data 193 .

Using JKSimMet 211
A Typical Streams Window
The Stream data window is accessed by clicking on the double arrow button
next to the selected stream. The stream name of the stream being viewed is
displayed in the header of the Stream data window. Once this window is
opened, the layout and the actual data on display can be changed to suit your
requirements (see below).
Stream Data The layout of the Stream data window is the same for every stream. A tabbed
Window Layout interface is used to display the different types of stream data. The Totals,
Sizing data, Elemental assay data and Size by elemental assay data tabs are
always displayed.
The types of data available to view in each tab include simulated,
experimental, balanced, SD, error and fitted, and can be selected by clicking
on the Data Type View button. Unwanted data types can be turned off by
selecting the selecting None in the appropriate column.
A typical Stream data window is shown below. In this case, all data types
other than Sim have been switched off.
A Typical Stream Data Window
Totals Tab The Totals tab is always displayed, and lists the overall properties of the

stream. The values in the Totals tab for each stream are calculated during
simulation. Note that the values in the Totals tab for the feed stream are
defined in the Feed equipment.
The other tabs and the data displayed are:
Name of Tab Data Displayed
Sizing data Size fractions and the proportion of the

stream in each size fraction
Elemental assay data Elements and the proportion of each

element in the stream
Size by elemental assay data Proportion of each size class that is

made up of each element
Note that in JKSimMet, the last two tabs are not relevant for simulation. One or
both of these tabs will only become relevant and of interest when you are
looking at the results of a mass balancing operation.
5.6.4 Water in Simulation
There is a selection of models available for water feeders. To associate an

appropriate model with a water feeder you need to double click on the water
feeder icon, just as you would do for any other equipment type. This will bring
up the water feeder Equipment window. From here you select the required
model using the Equipment Model drop-down.
In this case we will select the Required % Solids model for both of the water
feeders. Once the model has been selected, you can click on the double arrow
button to the right of the drop-down to set the parameters associated with this
model.

Using JKSimMet 213
In the case of the Learner Project, the required % solids should be set to 75% for
the BM Water feeder and 35% solids for the other water feeder (the one adding
water to the cyclone feed sump).
A detailed description of the Water Feeder models 295 can be found
under Model Descriptions.
Remember:
Select the two water feeders from within the Select Equipment / Streams frame
and then select "Adjust" for TPH water within the Control frame of the Mass
Balance sheet.
5.7 Viewing the Data - Summaries & Reports

To view the summary table of the stream data the user the user will need to
access and configure the Configurable Stream Overview.
5.7.1 Using the Configurable Stream Overview
An alternative to entering data individually into the stream windows is using

the Configurable Stream Overview. This is recommended when the data is
initially configured, or can be configured, into a similar style table in Excel
and simply copied and pasted into JKSimMet.
Configurable The Configurable Stream Overview can be selected from the flowsheet menu,
Stream or launched by the icon on the flowsheet toolbar.
Overview

Configurable The Configurable Stream Overview window has several main components:
Stream 1. Select List drop-down list
Overview
Window 2. Configurable Stream Overview toolbar
3. Data view choice drop down
4. Button to launch the SD calculation window
5. Data table
Select List The user can create one or more Configurable Stream Overview tables. Each
table created is listed by name in the Select List drop-down, allowing the user
to change from one table to another by selecting the required configuration
from the list.
Configurable The toolbar allows the user to create new configurations, rename or delete
Stream existing configurations, add or delete rows and/or columns, print, copy, clone
Overview or export the data to Excel.
Toolbar
New Stream To create a new configuration the user clicks on the New Stream Overview
Overview button. This opens the Add New Stream Overview dialog which prompts the
user to enter a name for the new configuration.
Delete Overview Clicking on the Delete Overview button deletes the current overview. A
warning dialog asks the user to confirm that the current configuration is to be
deleted, as this operation cannot be undone.
Insert Column This button will insert a blank data column to the right of the column where
the cursor is currently located. To select a column, click inside the column
itself, not on the column header. Clicking the column header will open the
Selection Options 217 window where you determine the contents of the
column in question.
Copy Column Pressing this button will insert an extra column that will be a copy of the
currently selected column. You can use this if the new column is to be similar
to the previous one. For instance you could copy a column containing
experimental data and just switch the data type in the copy to simulated data.
Remove Column Removes the column where the cursor is currently located. Note that the
column is deleted immediately without the user being asked to confirm their
action.
Insert Row Inserts a stream data row in the overview table, in the row below the current
position of the cursor. When the button is clicked the Add Stream dialog
opens, requiring the user to select the stream to be added to the table from the
list of streams that are not already displayed in the table.
Viewing the Data - Summaries & Reports Version 6.0.1 - March 2014
Using JKSimMet 215
If no streams are listed in the dialog, it means your table already contains all
the streams from this flowsheet and therefore no further rows can be inserted
in this table.
Remove Row Pressing this button removes the currently selected row from the table.
If necessary, the deleted stream can be added back into the table using the Add
Row button.
Print Overview Prints the current overview table.
Copy Grid Copies the entire data grid for the current overview to the clipboard, allowing
the data to be pasted into other programs such as MS Word.
Lock Move When this button is unlocked (appearing as shown in image at left) the user is
Rows/Cols able to change the position of rows and columns of data.
Export Overview This button exports the data for the current overview to Excel. Clicking on the
Export Overview button opens the Export Report to Excel dialog where the
user can enter a name for the Excel file and choose where to save the file. Note
that if the file name chosen is the same as an existing Excel workbook, the user
is prompted to choose whether to overwrite the existing workbook or to
append the current data as a new worksheet in the existing workbook. The
name of the Overview that you have just exported will be adopted as the name
of this new worksheet.
Export All Selecting Export All will export all of the overviews listed in the Select List
drop-down to Excel, with each one occupying a separate named sheet in the
Excel workbook.
Clone Overview Clone Overview creates a new overview, which will be an exact copy of the
current overview. This option is useful when viewing or inputting data for
the streams on a sized basis and more than one similar overview screen is
required.
Creating a new When the user clicks on the New Stream Overview button the default data
Configurable table is displayed. As shown below, this lists all of the streams in the
Stream flowsheet, and displays the TPH Solids (Sim) and TPH Water (Sim) values for
Overview each of the streams.
Version 6.0.1 - March 2014 Viewing the Data - Summaries & Reports
The Default Configurable Stream Overview Layout
Adding Streams To add a stream to the overview table click on the Add Row button and select
to the Table the required stream from the list shown in the dialog.
Changing the The order that the stream names appear in the table is the order in which the
Stream Order streams were added to the flowsheet when it was first drawn. To change this
order unlock the Lock Move Row/Cols button and then select a stream in the
data table by clicking in the stream name cell and then drag the row to its new
location on the list as indicated by a red line. Two or more adjacent stream
rows can also be moved by selecting all of the rows together (click and drag or
Shift-click) and dragging the group to their new location in the table.
Removing To remove a stream from the overview table click in the row which is to be
Streams from the removed and click the Delete Rows button.
Table
Setting Up to It is possible to enter your experimental data via the Configurable Stream
Enter Overview window. To do this you need to select 'Experimental' as the type of
Experimental data from within the Selection Options dialog box.
Data via the Clicking on the header cell in each column of the Configurable Stream
Overview Overview window will bring up the Selection Options window, an example
of which is shown below. In this window you need to select the parameter, the
calculation type and the data type that are to be displayed in the column you
are configuring. Normally these are selected from the Options 1, 2 & 3 drop-
down lists respectively.
The various data types available (Option 3 listing) are as follows:
Experimental Displays experimental values.
Standard Deviation Displays standard deviations.
Simulated Displays simulated data.
Fitted Displays the fitted values (following the run of a simulation).
Balanced Displays mass balanced data following the running of a mass
balance.
Error Displays error data.
Note that the above is the full list of data types. This will sometimes be
Using JKSimMet 217
reduced, depending on the selections that have been made from the Option 1
and Option 2 drop-down lists above.
For preparing a column that is to be used for the entry of your raw data, you
need to select 'Experimental' from the data type (Option 3) drop-down. The
example below shows a situation where the user has chosen to display
elemental assay data for copper and has selected experimental as the data
type.
On returning to the Configurable Stream Overview, you will find that data can
now be entered into this column for the various streams that you have set up
in this particular overview and that this will also be the case for any further
streams that you may later add to this overview.
Configuring the The configuration of a new columns is covered in greater detail in the next
Columns topic.
5.7.2 Configuring Columns in the Stream Overview
Configuring a When a new column is added to the Configurable Stream Overview table by
New Data clicking on the Insert Column button the added column is headed 'No
Column in the Selection' and contains no data. The user must select the data to be displayed
Overview in the column by first ensuring that the Lock Move Rows/Cols button is locked
and then single clicking on the header cell for the column. This opens the
Selection Options dialog.
The user can select the required property, calculation type and data type from
the drop-down lists in this dialog. You will see as you start making selections
from the Options drop-downs, that the items available in each will always
depend on what has been selected from the preceding drop-downs. As you
will soon realise, there are a lot of permutations possible, so in this topic we
will just look at a couple of examples. In the examples selected, the user is
presented with quite a few choices before arriving at the complete
specification of the data to be displayed in the column being configured.
Option 1 In the first drop-down list (labelled Option 1), the items available for selection
Selections are as shown below:
Difference If you select % Passing you will be presented with a data entry dialog where
between % you can type in the size (in mm). The data will then relate to the proportion of
Passes and % the particles that are smaller than your chosen size. In the illustration below,
Passing Data the user wishes to see data relating to the % of the ore particles that are finer
than 0.25 mm.
Using JKSimMet 219
If you select % Passes, then you are requesting data in the form of the screen
size that a given percentage of the particles will pass. In this case you are
again presented with a data entry dialog, but this time what you are entering
is a percentage value rather than a size.
In the illustration above, we are setting up the overview table to display data
relating to the 50% passing size for each of the streams in our flowsheet. Note
that one of the other options in the Option 1 drop-down is P80. Selecting this
item will generate the same type of data, but in this case the 50% value entered
above is replaced by the standard 80% value. Obviously in this case there is
no need for the % Passes data entry dialog, so this will not appear.
Elemental Data If you select Elemental from the Option 1 drop-down, you will then generate a
for the Option 1 further selection dialog box where you have to choose the particular element
Selection and that you wish to retrieve the data for. Of course this is only relevant for mass
Subsequent balancing in JKSimMet since none of the JKSimMet models deal with the
Choices distribution of elements around the flowsheet.
Once you have selected the element required, the Option 2 selection drop-
down will require you to select between the options TPH, Assay and
Recovery. If you select either TPH or Recovery, the Option 3 alternatives will
be Experimental, Balanced and Size.
If you select Assay from the Option 2 drop-down, the situation becomes a
little more complex, with more options available as shown below.
In this case if you now select Size, you will get a dialog for selecting the size
that you wish to obtain data for.
Using JKSimMet 221
Once this selection of the required size has been made, the Option 4 drop-
down will become available where you can then select which type of size
related elemental data is to be displayed. In the case below we are selecting
Error data for copper assays in the +0.6 mm size fraction.
Be Sure to Select Selecting Error from the above list then requires you to make another choice
Exp vs Bal Error regarding the type of data to be compared for the error determinations. Note
Data if that although at this point you can select from the 5 options available in the
Elemental Data dialog box shown below, only the first option of Exp vs Bal will yield any data
Selected when you return to the Configurable Stream Overview table. This is again due
to the fact that we are dealing at this point with elemental data so there will be
no simulated or fitted data for use in the error calculations.
Once you make this selection, another dialog will appear for selecting the
error calculation method.
Here you can select whichever type of error 94 you wish see displayed in the
Configurable Stream Overview table. Assuming in this case you wanted to
display the weighted errors, then after pressing OK, the Selection Options
dialog would look like the one shown below.
Using JKSimMet 223
Error Sum for If you select Error Sum for Option 1 (last item on the list), you will be presented
the Option 1 with a dialog box for selecting the type of errors that are to be summed. A screen
Selection and grab of this dialog box is below. In this instance, all 5 options are meaningful
Subsequent since we have not at this stage narrowed the selection to elemental data as we had
Choices in the case described above.
After you have selected the types of data are to be compared to give the individual
data point errors, you will next be presented with a dialog for selecting the type of
error calculation used to arrive at error values for each of these data points. The
choices here are weighted error, percent error and absolute error. The way these
errors are calculated is explained in the topic Viewing Individual Stream Data 94
.
If you have selected Exp vs Bal from the list of data type comparisons (see the
second last screen grab), then you will be presented with a further choice
regarding the circuit parameter errors that are to incorporated into the error sum.
Note however, that you will only be presented with the above selection drop-box
in JKSimMet if your selection of data types for comparison is Exp vs Bal. The last
two possibilities for inclusion in the error sum are not relevant if you selection
includes simulated or fitted data as the distribution of elements throughout the
flowsheet is not modelled in JKSimMet.
Your selections from these three dialog boxes will be concatenated into an
automatically assigned name for the overall Option 1 selection. This name
appears in the display box to the right of the Option 1 drop-down. As can be seen
from the screen grab below, this name can be rather long and in fact doesn't fit
into the display area in this case.
Using JKSimMet 225
When you press OK on the above dialog box to close it, the column you have been
setting up in the Configurable Stream Overview will now have this name as its
header. The automatically generated name for the error sum makes the column a
lot wider than it needs to be to accommodate the data (see below).
Modifying To overcome this problem, there is the facility to make your own abbreviation or
the Column acronym for the type of error sum that has been selected. To do this you simply
Names uncheck the Auto Generate Name check-box and replace the auto generated name
with an acronym or abbreviated name that will make sense to you. This can be
done before or after you have gone through the Options selection sequence.
In this case one might abbreviate the above error sum descriptive name to ErrS
(EvB W T&S) to make the column width closer to that needed for display of the
numbers themselves. To illustrate this, a second column with the same data but
with the abbreviated error sum header, has been included in the screen grab
above.
Note that this ability to insert your own name for the column headers is available
for all of the other data type options as well. It has been illustrated for the error
sum data type as this is where the auto generated name ends up being the longest.
5.7.3 Using the Reporting Feature
The Reporting feature is the main means for exporting data from JKSimMet. By
using this feature the user can export the data to Excel for printing or further
analysis
Overview The reporting functionality is accessed either from the flowsheet menu or from
the reporting icon on the flowsheet toolbar.
Reporting to The Reporting feature allows the equipment and stream data to be exported to
Excel Window Excel. The user can select which equipment units and which streams have
their data exported. Each report configuration is named by the user when it is
created and this allows the user to create multiple report configurations.
Reporting to The toolbar allows the user to create new configurations, delete unwanted
Excel Toolbar configurations, select or de-select data in the selection list and export the data
to Excel.
Using JKSimMet 227
New Report To create a new Report configuration the user clicks on the New Report
button. This opens the Add New Report dialog , allowing the user to name the
new report configuration.
To generate a report the user can either choose to use an existing report, or
create a new report. To create a new report the user will need to:
1. Add a report to the system
2. Select the format of the report
3. Choose whether to summarise the report data
4. Select which equipment units and streams are to be used in the report
5. Choose which data types to export
6. Choose whether to use a circuit select list
7. Choose to export port data
8. Export the data
Report Name Each report configuration created is listed by name in the Report Name drop-
List down list, allowing the user to maintain as many report configurations as
they require.
Delete Report Clicking on the Delete Report button deletes the current configuration. A
warning dialog asks the user to confirm that the current configuration is to be
deleted, as this operation cannot be undone.
Export Report Exports the selected items on the reporting dialog to an Excel workbook.
Format of the The Excel workbook created by the Reporting to Excel feature displays the
Excel Workbook selected data in a standard layout. The user is then free to format the data in
the report as they choose.
Part
VI
6 Mass Balancing
Mass Balancing This section provides information about the mass balancing capabilities of
JKSimMet V6.
6.1 Introduction to Mass Balancing
Purpose This chapter describes how to use the JKSimMet mass balancing component
of the software.
Overview Even the most carefully collected plant survey data are subject to many
sources of variation. Some of these errors are generated within:
the natural variation in process flows, assays, etc.
sampling procedures or design
assaying procedures
sizing procedures
fluctuations in plant flow rates, operating variables, feed parameters, etc.
As with all data improvement processes, the usefulness of the mass balanced
data will be strongly dependent on the quality of the input data. The mass
balancing module can assist the user to assess data and to refine their
experimental technique when problems are detected. Mass balancing will
improve the quality of good data. It will not fix poor quality data or do
anything more than highlight inadequate experimental techniques.
The module is used to mass balance sizing data, head assay data, assay data
in size classes and flow rate data collected at steady state. The balancing
process produces best fit estimates of flow rates, size and assay data which
are consistent within the mass balancing constraints.
The overall process is:
Collect data, using appropriate sampling methods (see Gy (1982), etc.)
Review data
Mass balance data,
Check accuracy of data fit and
Refine experimental technique and instrumentation until desired level of
accuracy is obtained.
6.2 Data Collection

Good data collection procedures are essential to the success of a mass
balance. While this section is not essential for learning how to use the mass
balancing program, it should be studied in detail as poor data collection will
have a significant impact on the quality of mass balance that can be achieved.
Flow Rates Numerous flow rate measurements are very useful. Hence, calibration of all
flow measurement devices (weightometers, flow meters, etc.) is important.
Whenever possible, try for an independent flow rate check. In small or pilot
plants, time and weigh a known volume of material. As a minimum

Mass Balancing 231
requirement, the feed tonnage to the circuit is required.

Percent Solids The percent solids of a slurry as measured with a Marcy scale are subject to
error, due to solids density variations in the circuit. Such variations are
common in cyclone underflow streams. Therefore, percent solids determined
from wet and dry sample weights are preferred.
Steady State JKSimMet is a steady state simulator. Hence, models can most usefully be
fitted to data which were taken at steady state. The most common approach is
to take a series of regular samples and combine them to make composite
samples which cover a period which is long (several hours) compared with
circuit fluctuations, which must be kept to a minimum.
If circuit variations are a serious problem, sample and fit one process unit at a
time. JKSimMet can be used to combine the units and predict circuit steady
state behaviour.
Sampling Good sampling practices are a topic in themselves. Some useful references are
those of Gy (1982) and Lyman (1986) 269 .
For a simple estimating technique for sampling requirements refer to the paper
by Lyman (1986).
There are well established rules for calculating the accuracy of a sampling
and assay process. These can be used to establish an error model which can
then be used to provide estimates of standard deviation for each point.
Alternatively, 5 to 10 replicate samples can be taken and processed. If these
input accuracies are established, then the estimates of accuracy used for flow
rates and assays will be real estimates and not relative estimates.
If replicate sampling is carried out for assays on a number of streams (i.e. a
range of assay values), a simple two term error model can be generated by
plotting relative standard deviation against average assay values from each
stream.
The intercept and slope of this plot will provide fixed (minimum) and relative
(%) error components which can be used in the generalised version of the
Whiten model.
A sensible maximum (absolute) error will also need to be specified.
Determining good estimates of the errors associated with each sampling point
will provide a more reliable mass balance.
6.3 Background
Mass Balancing is a type of model fitting. The models in this case are quite
fundamental. Hence, they do not impose the experience knowledge (which is
built into other mathematical process models) onto the data.
The mass balancing models are:
a stream combiner (for example, a pump sump),
a general stream splitter (for example, a hydrocyclone or a flotation
cell),
a unit that conserves some properties but not others
(for example, a grinding mill will preserve total assays and flow rates but not
Version 6.0.1 - March 2014 Data Collection

size fractions).
The basis of the mass balancing algorithms is the differences in composition
of various streams; that is, the differences generated by the process equipment.
Consider a process with these streams having assays a, b, c:
If the solids flow rate in a stream of assay "a" is 100 tph, then:
(1)
where x is the solids flow rate in stream of assay "b" and then:
(2)
This is the basis of the traditional two-product solution, where a, b and c may
be assays for a size fraction, element or any other conserved property.
It does not matter what kind of assays a, b and c are, as long as there is some
difference in their values. For example, if the process is a splitter and the
assays are all the same:
a=b=c
and therefore, using equation (2), then x= 0/0 which is undefined.
Expressed another way, the flow rates can be estimated only if a process
imposes a difference on its products; that is, some information is imparted by
the process. If no information is imposed, as is the case with a splitter, then
the information cannot be used to make estimates, as it is not there to begin
with. Note that the split ratio of a splitter can be used in the mass balance.
It follows that the most useful properties to use for mass balancing around a
process unit will be those which have the largest difference in the product
streams.
This means that size assays will work well around a size classifier such as a
screen or a hydrocyclone, and elemental assays will work well around a
flotation circuit. The reverse will generally not be true, with some notable
exceptions. For example, elemental assays such as gold or lead are often very
useful around a hydrocyclone classifier because its density-separating
characteristic will usually produce a large difference in these assays.
The power of this program lies in its ability to use a wide range of assays
across a large flowsheet. The program algorithm is driven by the assays with
large differences but still takes account of those with small differences.
The mass balancing module takes all selected streams and calculates the
Concept: Mass
smallest set of data adjustments which will make the data consistent.
Balancing
If some (or all) of these streams are measured (sampled and sized, etc), the
experimental measurements can be compared with the data. The root mean
square of the normalised differences between measured data and adjusted
Background Version 6.0.1 - March 2014

Mass Balancing 233
data is taken as a measure of goodness of fit of the model.
i.e.
Hence, the mass balancing program adjusts user selected flow rates to find a
best set of flow rates which make the balance output match the experimental
measurements as closely as possible.
If the precision of each data point is measured (or can be estimated from
Concept:
experience), then each difference between experimental data and mass
Weighted Sum
balanced prediction is normalised by dividing by its precision. That is, a
of Squares
small difference (or adjustment) between an accurate data point and its mass
balanced prediction will make the same contribution to the weighted sum of
squares as a large difference from an inaccurate data point.
The usual measure of precision is the standard deviation. If repeated
Concept:
measurements are made of any data point, experimental variations will cause
Standard
variations in the measured value xi.
Deviation
Then with many repeats, the mean of the values will provide an estimate of
the true value of x.
Subject to a number of assumptions, the expected variations from true x can be
characterized by one number - the standard deviation defined as:
Standard
Deviation
If the measurements are normally distributed then, out of 100 measurements,

67 could be expected to lie within plus or minus one standard deviation of
the true value (as estimated by the mean), 95 within plus or minus two
standard deviations and 97 within plus or minus three standard deviations.
Experimentally, 5 to 10 complete observations, that is, independent sampling
Concept:
plus analysis, will provide an estimate of the standard deviation. The mean
Estimating
of such a set of measurements should provide a good test of sampling
Standard
precision - if the test circuit was at steady state.
Deviation
As its name suggests, the RMS (root mean square) error is the square root of
Concept: RMS
the residual mean square error, which is the error associated with the
(Root Mean
calculated mass balanced data and the experimental data.
Square) Errors
A root mean square error of value 1 means that all data points were estimated
with errors similar to the measured standard deviations of the experimental
data points. Obviously, the more the RMS error varies from one, the more error
is associated with fitting the data.
6.4 How the Mass Balancing Program Works

The mass balancing program used by JKSimMet is a program called
JK2DMBal written and developed by Dr Stephen Gay. Other JKMRC staff,
including Michael Andrusiewicz, Jake Stoll, Ricardo Pascual and Robert
Lasker, provided assistance with the integration of JK2DMBal into the
Version 6.0.1 - March 2014 Background

JKSimMet program.
The mass balancing problem is essentially a minimisation of sum of squares
with multi-linear constraints. This corresponds to a common set of
mathematical problems generally described as the quadratic problem.
The algorithm is based on a Quasi-Newton approach which means that the
errors in the constraints are used to determine the changes required in
calculated variables, with the amount of movement of the calculated variables
controlled by the standard deviations of the experimental values.
Hence standard deviation values of 0 mean that a calculated value will equal
the experimental value and will not change. If all the standard deviations are
near 0, the program will not have enough freedom to find a solution, and
therefore will not converge. The JKSimMet standard deviation interface
provides formulae to allow appropriate standard deviation values to be set.
When a plant is surveyed, size and assay information are often obtained, as
well as percent solids. However, the solids flow is only known for a small
number of streams (and in some cases, the feed stream only). Very high
standard deviation values imply that the corresponding experimental value is
unreliable. Hence, large standard deviation values are often used for the
solids flow values.
The main algorithm (Quasi-Newton algorithm) needs reasonable starting
values of solid and water flow in order to converge satisfactorily. In order to
estimate these flows (principally where experimental values are not given), a
second algorithm is used.
This second algorithm uses information such as assays and size distribution
data to estimate solids flows. This algorithm is very similar to the method
described as the Morrison solution in JKSimMet. The main difference is that it
also uses the standard deviations of the assay and size information, and it
provides an estimate of the standard deviation of the estimated solids flow.
If there are many missing streams, or missing data, the algorithm will still
have some difficulty in obtaining a solution as the standard deviation values
are too high. A third algorithm is used to reduce the standard deviation
values as the algorithm proceeds to ensure that convergence is obtained.
The three algorithms (Quasi-Newton, missing flow estimation and variable
standard deviation reduction) are all integrated together within the one
algorithm interfaced to JKSimMet. Even though the algorithms work together
it still remains that in some circumstances data reduction may be required to
improve performance. For example, if there are many missing solids flow
values it is best to mass balance solids flow first with information such as
sizes and head assays prior to mass balancing assays within size classes.
JKSimFloat has a hierarchy of data associated with the mass balancing
algorithm. This hierarchy has the solids mass flow at the top, with head
assays, size fractions and % solids all subordinate to the solids mass flow.
The assays of size fractions are subordinate to size fractions, and the mass
flow of water is always a bottom level measurement.
This can be represented schematically by the following diagram.
How the Mass Balancing Program Works Version 6.0.1 - March 2014
Mass Balancing 235
6.5 Learning Mass Balancing

The mass balancing module of JKSimMet is useful in two areas. Firstly, it
provides a check on data accuracy that is not model dependent. The mass
balancing models are correct (that is, they contain no built in experience).
Hence, if the data balance well but the model fitting does not fit well, it
indicates that the model is not appropriate.
Where coarsely sized samples are used, as in crushing and screening circuits,
the mass balanced data may be more useful as the starting point for model
fitting than the raw data.
Secondly, mass balancing is useful for determining flow rates and recoveries
around complex circuits. The example we will use in this section, Learning
Mass Balancing, is concerned with flow rates in the comminution circuit of a
copper concentrator.
Normal It should be noted that JKSimMet V6 provides the ability to balance assays
Sequence for within size classes as well as total assays and sizes. Unlike V5, the user does
Mass Balancing not balance everything at once. Under the assumption that in a comminution
in a circuit your sizing data will be the most reliable survey data, the suggested
Comminution process to balance a whole circuit is as follows:
Circuit 1. Make selections for all required equipment, streams, sizes and
elements.
2. Set TPH Solids and Sizes to Adjust and all other components to
Unused, then run the balance.
3. Then set the TPH Solids and Sizes to Fixed, the TPH Water to Adjust
and % Solids to Influence and run the balance again.
4. Set the TPH Water and % Solids back to unused and the Elements to
Adjust and run the balance again.
The individual steps will be covered in more detail over the remainder of this
chapter.
Version 6.0.1 - March 2014 How the Mass Balancing Program Works
Mass Balancing In cases where your assay data is considered more reliable that the sizing
Sequence where data, you would modify the above sequence as follows:
Assay Data is the 1. Make selections for all required equipment, streams, sizes and
Most Reliable elements.
Data
2. Set TPH Solids and Elements to Adjust and all other components to
Unused, then run the balance.
3. Then set the TPH Solids and Elements to Fixed, the TPH Water to
Adjust and % Solids to Influence and run the balance again.
4. Set the TPH Water and % Solids back to Unused and the Sizes to
Adjust and run the balance again.
5. Set the Sizes to Fixed and Size x Element to Adjust and run the
Mass Balancing In cases where your % solids data is considered the most reliable data, you
Sequence where would be better using the balance sequence below:
% Solids Data is 1. Make selections for all required equipment, streams, sizes and
the Most elements.
Reliable Data
2. Set TPH Solids and TPH Water to Adjust and % Solids to Influence
and all other components to Unused, then run the balance.
3. Now set the TPH Solids to Fixed, TPH Water and % Solids to
Unused and the Sizes to Adjust and run the balance again.
4. Set the Sizes to Fixed and the Elements to Adjust and run the
balance again.
6.5.1 Model Types for Mass Balancing
In V6.0.1 of JKSimMet the flowsheet drawing for mass balancing is the same
one used for simulation and model-fitting, with the full range of equipment
icons available to draw the circuit diagram. However, no matter what
equipment icon is visible, there are only two model types in mass balancing.
These are:
classifier or mixer unit
This unit either selects particles to go to different product ports of
the unit (classifier) or adds particles from different feeds (mixer).
That is, particles are sorted or mixed in this type of unit, not
broken down or altered.
transform unit
In this unit assays are preserved but size structures are destroyed.
In mass balancing all comminution devices are transform units.
The mass balance algorithm decides which type of mass balance unit is
required according to the flowsheet icon selected by the user.
Learning Mass Balancing Version 6.0.1 - March 2014

Mass Balancing 237
6.5.2 Entering the Data
Data Entry The first step in a mass balancing exercise is to enter the experimental data.
Alternatives This can be performed in two ways:
Individual Stream data windows, or
Configurable Stream Overview
Both methods have their advantages and disadvantages; it is mainly
dependent on what form the experimental data is in.
Accessing the The Streams window provides access to the Stream data windows to view the
Individual data for each stream. The Stream data window for each stream can be opened
Stream Data by three methods:
1. Double-clicking on a stream in the flowsheet.
2. Selecting Stream on the Flowsheet sub menu or
3. Clicking on the Stream icon.
window via the Stream Name drop-down list. The Streams window can only be
accessed when the flowsheet is locked. A typical Streams window is shown
below.
The Streams window also shows the equipment from which the stream
originates and the equipment to which the stream flows. Clicking on the double
arrow buttons next to the From Equipment and To Equipment dialog boxes
opens the Equipment window relating to that equipment.
The Stream data window is accessed by clicking on the double arrow button
next to the selected stream. Once the Stream data window has opened, the user
can view the various categories of data by selecting the appropriate tab. The
name of the stream being viewed is displayed in the header of the Stream data
window. The Streams window remains open and accessible after the required
Stream data window has opened. If you then select another stream from the
drop-down and click again on the double arrow, you will open a second Stream
data window for the new stream. You can open as many Stream data windows
as you require in this way.
A typical Stream data window is shown below.
Version 6.0.1 - March 2014 Learning Mass Balancing

The status of the stream can be set to Major, Minor, or Missing from the
drop-down box at top right. See later 248 in this help file for an explanation of
these terms.
Totals Tab The Totals tab lists the overall properties of the stream. The other tabs and the
data displayed are:
Name of Tab Data Displayed
Sizing data Size fractions and the proportion of the stream in

each size fraction
Elemental assay Elements and the proportion of each element in

data the stream
Size by elemental Proportion of each size class that is made up of

assay data each element
Data can be inserted into the individual stream windows using the copy and
paste functions from Excel.
Sizing Data If you click on the Sizing Data tab you will here be able to enter the sizing data
for the size fractions that have been defined for this project and the associated
SD values. The Stream data window will then look similar to the one shown
below:

Mass Balancing 239
The above window will also show balanced values from the most recent
balance, provided the balancing engine has been run at this point.
Elemental The next tab is for the elemental assay data and the appearance of this window
Assay Data will be similar to the one shown below when this tab has been selected.
The last tab is for size by elemental assay data and a screen grab of the
appearance with this tab selected is shown below:

In this case the numbers are all zeros since no sizing data have been entered at
this point.
Configurable An alternative to entering data individually into the stream windows is to use
Stream the Configurable Stream Overview. This is recommended when the data has
Overview been initially configured into a similar style table in Excel. Such a table can
then simply be copied and pasted into JKSimMet.
Click on the Configurable Stream Overview icon or select this item from the
Flowsheet menu to open the Configurable Stream Overview window. You
may need to create a new overview that will have the data in the same order
as it is structured within the Excel source file. Alternatively you could
manipulate the setting out of the Excel file to match a structure you have
previously created within the Configurable Stream Overview. For more
information on how to make changes or create new Stream Overviews, you
should revise the topic Using the Configurable Stream Overview 263 .
6.5.3 The SD Calculation Window
SD From the Stream Data window, the Automatic SD Calculation window can be
Calculation opened by pressing the SD Calculation (SD) button which is the button second
Window from the left on the Stream data window toolbar.
From here you can specify numerous different methods of automatically

calculating SD values for the various experimental data fields.

Mass Balancing 241
More detail on how to set the options for SD calculation are covered in the Stream
Windows 165 topic, in the Using JKSimMet section.
The data types associated with the other default columns are simulated (Sim),
fitted (Fit), balanced (Mbal) and the error (Err).
Selecting In the case of the error column you can change the form of the error that is
the Type of displayed and the currently selected form will be shown in the column header.
Error This is done by clicking on the Error Sum button, which is the button second from
Calculation the right on the Stream data toolbar.
After pressing this button, the Error dialog box will appear where you can specify
both the types of data that are to be compared for determining error values and the
method by which these errors are calculated. For instance in the settings shown in
the screen grab below, the errors will be obtained by comparing the experimental
and balanced data and the method of calculation will just be a straight percentage
error calculation.

Also in this screen grab, you will notice there is a frame labelled Error Sum below
the drop-down selection boxes. Here there are radio buttons where you can select
the errors that are to contribute to the calculation of the error sum figure that is
displayed in a field (shown circled below), at the top of the Stream data window.
Note that it is only when you select Exp v Bal data for comparison that all three
options are available for the error sum calculation. Because JKSimMet does not
contain models that predict element distributions, the last two options cannot be
selected where either Fit or Sim data are one of the data types to be compared.
These options will be greyed-out in all but the Exp v Bal data case.
Error The types of error calculation available for selection are Weighted, Percent and
Calculation Absolute. Weighted errors take account of the reliability assigned to the various
Methods data points by dividing the difference by the SD value. Larger SD values mean that
and the differences will contribute less to the total error calculation. The other two
Summing of methods take no account of the assigned SD values.
Errors The calculation methods are:

Mass Balancing 243
Weighted errors are calculated as [(Exp - Bal)/SD]2

Percent errors are calculated as Abs[(Exp - Bal)/Exp] * 100
Absolute errors are calculated as just (Exp - Bal)
In the case of the first two error calculation methods, the individual errors are
always going to be positive values. Thus to obtain the error sum in these two cases,
the individual values are simply totalled.
For the Absolute error values though, there will be negative values displayed for
some data points and positive ones for others. To make these values all contribute
to the total error and do not tend to cancel each other out, in this case it has to be
the modulus of each value that gets incorporated into the Error Sum calculation.
6.5.4 Standard Deviation Calculations
All Data Points Every data point must have a standard deviation entered, even if it is
Require Missing. During the mass balancing routine, if any data point has 0 as its
Standard standard deviation, an error message will be displayed with an option for the
Deviations user to enter the correct SD.
Standard deviations can be entered individually in the stream data windows,
or through the Configurable Stream Overview 263 window. They can also be
copied and pasted from Excel.
Entering a standard deviation in the individual stream data windows is
particularly useful if, for instance, no experimental data for a particular
stream exists. The procedure for this is outlined below.
Entering Ensure the flowsheet is locked and double click on a stream to bring up the
Individual stream window for that stream.
Stream Standard If the sample or flow data for a particular stream is not available, you can
Deviations leave the experimental value set to zero and then set the standard deviation
value to Missing.
Setting the SD to If missing is entered for the standard deviation, the mass balancer will
Missing recognise that no experimental data was recorded for this stream. However,
the stream will be included in the mass balance and a balanced value will be

generated using the rest of the data set.

For an initial pass, the actual stream can be omitted from the balance routine,
rather than setting the SD values to missing. This will not make much
difference in a simple flowsheet, but may speed up the balance in a more
complex one.
Alternatively, if experimental data exists for that stream and the standard
deviation is known, it is possible to enter that standard deviation directly in
this window. Simply click in the appropriate cell of the SD column and type
in the standard deviation. Press Enter when complete.
It is also possible to copy and paste standard deviation values from Excel into
the individual stream data windows and the Configurable Stream Overview
window.
The Automatic SD Calculation window allows the user to set SD values for
multiple streams and data points simultaneously. This is accessed by the SD
Calculation button in both the individual stream window and the
Configurable Stream Overview windows.
Entering The Automatic SD Calculation window appears as follows.
Standard
Deviations for all
Streams
The left-hand panel lists all the streams in the current flowsheet. Individual
streams can be selected by clicking on the stream name. Multiple streams can
be selected in a similar manner to the way this is achieved when using
Windows Explorer. A contiguous group of streams can be selected by holding
<Shift> when clicking on a stream further down the list. A selection of non
contiguous streams can be made by holding down <Ctrl> and clicking on the
streams required.
The Property drop-down permits the user to select the parameter that is to
have the standard deviation formula applied to it. To select a property, click
the drop-down arrow and double click on the desired property.
The SD Calculation Option drop-down allows the user to choose from a list
of mathematical formulae and other options for setting the standard
deviations. This list contains the following formula options: Bounded
percentage, Parabolic, SD Multiplication Factor, Exp Val Multiplication

Mass Balancing 245
Factor, Replacement Value and Missing Value.

If you tick the check-box labelled Include SD values currently set to
missing? the program will take the experimental value for the stream and
will apply the selected SD calculation to this value. If you do have some of the
SD's set to missing, then it is likely that the experimental values for these
would have been zero. Where this is the case, the value that goes into the SD
field will depend on the SD calculation method selected. If you have selected a
method that involves just a fraction multiplied by the experimental value, then
obviously you will get an SD value of zero. This will mean that when you run
a balance involving these parameters, you will get an error message and be
requested to give the offending SD's some values other than zero. If you
choose another SD calculation method (such as Whiten), where a non zero SD
value will be the result, there is still a problem with balancing because the
balance engine will be trying to accommodate a zero value whereas the actual
experimental value (if a sample had been taken) would no doubt be well
removed from zero. So if you are going to place a tick in this check box, make
sure you have some guessed values in the experimental value fields and that
you are setting a large SD on these values.
There are also some default values that have been pre-set to enable rapid SD
calculation:
Fixed : SD = 0.001
Poor : SD = 20% of the experimental value
Average : SD = 10% of the experimental value
Good : SD = 5% of the experimental value
Excellent : SD = 2% of the experimental value
These values can also be changed if necessary in the Automatic SD
Calculation window.
Note that although this facility allows you to use relative SD's as a quick way
of setting up the balance, their use is not generally recommended because a
balance using relative SD's takes most notice of the smallest assay values and
these are often the least well defined.
Bounded When the Bounded Percentage option is selected, the user inputs the Upper
Percentage (U), Lower(L) SD limits and the percentage error in between (P) to calculate the
standard deviations for an experimental data value (x).
Parabolic When the Parabolic option is selected, the user inputs the proportionality
constant (a) which will be used to calculate the magnitude of the standard
deviations associated with each experimental data value (x).
SD When the SD Multiplication Factor option is selected, the user inputs the
Multiplication multiplication factor to be multiplied by the existing standard deviations in
Factor the system.

Exp Value When the Exp Value Multiplication Factor option is selected, the user inputs
Multiplication the multiplication factor to be multiplied by the existing experimental values
Factor in the system.
Replacement When the Replacement Value option is selected, the user is asked to input the
Value value to replace selected SD values in the system.
Missing Value When the Missing Value option is selected the user does not enter any value.
On calculation, the selected stream and property values are assigned as
missing values.
Note that the selections associated with a particular property class persist so
that when the user changes the property class selection, the calculation option
and its associated parameters last entered by the user for that property are
displayed.
When the user clicks on the Calculate button the program will calculate the
SDs only for the Stream and Property Class that are currently selected and in
view.
Note that even after SDs have been automatically calculated, the user is still
able to go to an individual experimental data point in the Stream Data
window and change the SD for that data point. However any changes to SD
values in the Stream Data window will not be reflected in the Automatic SD
Calculation window.
It is up to the user to decide which standard deviation calculation method
best suits the data.
Click Close to exit the Automatic SD Calculation window.
IMPORTANT All data points MUST have a standard deviation value associated with them
NOTE or else be set to Missing. This includes the TPH water and % solids, as well
as the TPH solids, overall assays and size-by-assay data.
The water balance is performed on TPH water, using the experimental %
solids and TPH solids to calculate the experimental values. The balanced
water flow rates are determined from the % solids values.
6.5.5 Preparation for Mass Balancing
Selecting The Mass Balance feature of JKSimMet allows the user to select the streams and
Streams and equipment items to include in the balance, as well as selecting which
Equipment parameters can be adjusted during the mass balancing process.
Open the the Mass Balance window by either pressing the Run Balance button
on the toolbar or by selecting Run Mass Balance from the Flowsheet drop-down
menu. Once this window is open, the user enters mass balance mode where no
alterations to the flowsheet, streams or equipment can be made.
For this tutorial, mass balancing will be performed on the Learner Project, which
has already been established and has been used for examples throughout this
help file. The Learner Project file will have been supplied with your copy of the
software.
You can either follow along using this project, or alternatively if you have your
own project with data, you can use the instructions as a general guide for mass
balancing your own flowsheet. See the section Create a New Project 61 if you

Mass Balancing 247
are unfamiliar with the steps necessary to establish a project and you wish to
create and then load data into your own project. .
Step 1 Load the Learner Project and select the Learner Flowsheet from the
drop-down list. If necessary, resize the flowsheet window to view
the entire flowsheet. Ensure that the flowsheet is locked.
Opening the Step 2 Click on the Mass Balance button on the main functions toolbar
Mass Balance located in the left panel just above the flowsheets list, to bring the
Window Mass Balance window into view.
The left-hand panel of the Mass Balance window is where you set up the
conditions for the mass balance that is to be carried out on your circuit. Here
you select which streams and equipment items are to be included in the balance
and you specify the components including the size fractions and elements
(mineral or chemical assays) that will be available for the balancing procedure.
At the bottom of this panel you have the Control fields where you select what is
to be included in the current balance and you specify values for the parameters
that control the balance.
The right-hand panel contains all of the results for your balance. When the mass
balance is under way, you can observe its progress in the top two fields which
show the number of iterations that have so far taken place plus the current
convergence value. The balance will be complete when the convergence value
goes below the convergence target that has been set in the Controls section.
6.5.6 Selecting Data
Opening the As is also the case for the Simulation and Model-Fitting modules, you may
Mass Balance select a single unit or a cluster of units from your flowsheet on which to perform
Window a mass balance. This allows you to check small parts of a circuit for data
consistency.
Step 1 Open the Mass Balance window by clicking on the first of the three
large buttons located in the left panel, just above the flowsheet list.
Step 2 When you first open this window there will be a default Mass

Balance Case called MBal Case 1 in the selection drop-down at top

left. There is a Rename button that can be used to change the name of
this Test Case to something more appropriate, if required. The New
button can be used to create further Test Cases with different
balance settings, which can then be saved and returned to later.
There is also a Delete button provided so that you can eliminate any
test cases that you have previously created but no longer need.
The default selection for a new Mass Balance Case is for all of the units and
streams to be selected. Therefore the first stage in defining a Mass Balance Case
is to examine the list of equipment and streams and to decide which items are
to be included in your balance.
The next step is to remove any unwanted items by clicking on the adjacent
check-box to remove the tick. Select All and Select None buttons have also been
provided to speed up the process of balance configuration. In this case we will
be balancing with all equipment units selected and all streams - apart from the
water streams, which we will add later.
Note that if you de-select an item of equipment, the input streams for that
equipment will no longer be balanced with the output streams, even if all of
these streams remain selected on the Streams list.
If only equipment has been selected, it is not necessary to specify which streams
to include in the mass balance. The mass balancer will automatically determine
which streams should be included in the mass balance based on which
equipment has been selected.
Designation In the streams list there is a second column labelled "Designation". There are
three settings possible for the designation field, Major, Minor and Missing.
This distinction between the different categories of streams enables selected
streams to be balanced or fixed at various times throughout the mass
balancing process.
A Major stream refers to one that can be balanced initially, for
example the plant feed, final concentrate and final tail streams,

Mass Balancing 249
and then fixed with the intermediate streams subsequently

adjusted within the circuit.
A Minor stream is an intermediate stream that may have some
data missing, restricting its usefulness in the balance.
A Missing stream is defined as a stream that is missing all data.
These streams can be omitted from the balance until such a stage
that there is enough information in the other streams to allow a
mass balance to be successful.
Note that streams belonging to the different categories are not treated
differently in the balancing process. The categories are simply groups to
which you can assign each of your streams and then later you can elect to
keep their values fixed or adjust them during the next run of the balancing
process.
There is visual feedback provided regarding the groups to which each stream
has been assigned to. When you have the Mass Balance window open, you
will notice that all the selected streams of the flowsheet are displayed in bold
black, which is the default for stream designated as Major. If you change a
stream's designation, the colour will change to bold blue for Minor or bold red
for Missing. These are just the default colours, so they can be changed to the
users preference if required. This is done via the Default Stream Properties
item on the Edit menu. These visual cues can help users identify the
equipment and streams that have been selected, which can be especially
useful when dealing with complex flowsheets.
By default, all streams are initially assigned to the Major group. As another
example of where you might make use of this facility, you may have a complex
circuit and wish to adjust values for a sub-section of the circuit only. In this
case you could assign all of the streams that make up this sub-section, to one
of the other two groups. You would then find that during the next run of the

balance, all plant values would remain fixed at their previous balanced levels
and it would be only the stream values for the required sub-section of plant
that would be adjusted as a result of this balance.
Note that the group assignation for each stream can be changed in the above
frame. To do this you just click on the required stream and then click the
appropriate button at the bottom of the list. Note that this assignation can also
be changed using the drop-down list in the top right corner of the Stream Data
window.
Step 3 In the Equipment / Streams frame, select all of the equipment items
and all streams with the exception of the two water addition
streams. Leave all the streams with the default designation of
Major.
Note that on the flowsheet there is also visual feedback for the selection of
equipment items, with those that have been selected being highlighted in bold
blue.
It is possible also to select and deselect items (both streams and equipment) for
your balance list, by clicking on these items on the flowsheet. You will see that
the bold highlighting will disappear to indicate de-selection. Clicking on them
performs a toggle action - so clicking again will re-instate the selection.
Step 4 Now examine your Mass Balance Case and ensure that:
all equipment units are selected
all streams are selected except for the water addition
streams (BM Water & Cyc Water)
all streams are designated "Major"
Because each Mass Balance Case has a name, you may set up several different
ones to examine different sections of a circuit. You can select all streams and
equipment units on your flowsheet, a single unit (together with its input and
output streams) or else a selection of units and their associated streams. Note
that they need to be contiguous i.e. with streams connecting all of the selected
units, to ensure that your selected sub-circuit does get balanced as a single
circuit.

Mass Balancing 251
In earlier versions all stream data were stored in equipment ports. To balance
a subset of the data, you needed to choose both equipment and ports
(streams). In this version, the stream data are now stored within the streams
themselves, but the same rule still applies for the balancing of data sub-sets.
6.5.7 Selecting Components
The mass balancing module can perform mass balances based on two types of
data; namely elements and size distributions. These can be used individually
or together to achieve the balance. If you also have assays of the size fractions,
then you can add an extra dimension to your balance by allowing the size by
element data to be used in the balancing process as well.
Mass balancing therefore contrasts with the model-fitting and simulation
modes in JKSimMet since in the latter modes it is only ever the size
distribution data that are used.
In the next frame of the Mass Balance window, you can select the elements
and sizes that are to be used for the current mass balance case.
In the left hand section of this frame is the list of elements that have been
entered during the project configuration stage. At the end of this list you will
see there is an element called Remainder that has been added to allow for any
mass not accounted for by the sum of the defined elements. All of the elements
will initially be selected by default. If for some reason you wish to leave out
one of these elements from the balancing process, then you can simply
uncheck the relevant check-box.
To the right of the elements selection area is a similar list for sizes, which
shows all the sizes (in mm) that have been defined for this project. Again they
will be all selected by default to begin with. In this case we will de-select all of
the sizes since we will be balancing on the assays alone.
Again, with both of these lists, there is a check-box provided at the top to
allow you to select or deselect all of them. This can be useful for speeding up
the process of defining the suite of components that are to be balanced for the
balance case in question.
Step 1 Ensure that all of the elements have been selected, but that none of
the sizes are selected.
To the right of the elements & sizes selection frame is another frame with the
heading "Adjust Streams". Here there are check boxes for the 3 categories 248
of streams. All three of these boxes will be checked by default. In this case we

want the balance to make adjustments to all streams in the circuit and in any
case, all the streams in this circuit have been left in the Major category. This
means that as long as the Major check-box is ticked, all streams will get
adjusted. However, there is no problem with leaving ticks in the other two
categories as well.
Step 2 Leave ticks in all three category check-boxes in the "Adjust
Streams" frame.
6.5.8 Solution Controls
To perform a mass balance the next step is to set the controls for this balance.
In the Control frame there are various drop-down selection fields where you
have the ability to choose the parameters that are to be involved in this
balance. In addition, you can control the way the balance begins and
concludes.
Step 1 It is wise to initially keep a balance as simple as possible, so for
the first run through of the current balance we will set the TPH
Solids to "Adjust" and likewise for Elements, but we will leave all
the other parameter fields set to "Unused".
Click in the white cells in the Select? column to change the settings on each
parameter. There are a total of four settings that parameters may be set to,
although not each setting will be available for each parameter.
Adjust The experimental values associated with this measurement are
included in the mass balance sum of squares calculation and a mass balance
adjusted data value is calculated by the mass balance which is consistent
with all other data in the system.
Fixed The previously calculated balance values are held at their current
value and are used in the calculation of other parameters selected as Adjust.
This is used, for example, to keep flow rates fixed when adjusting size so as to
stabilise the convergence.
Influence The experimental values associated with this measurement
influence the outcome of the mass balance (i.e. are included in the sum of
squares calculation) but are not returned as an adjusted consistent set of
values after mass balancing. This means the mass balanced values for this
parameter are left as zeros after balancing. The exception to this is in the case
of % Solids, where values are returned during mass balancing. The objective
of the Influence option is to allow the experimental data for the parameter
concerned to contribute to a higher level balance, even though the data for this

Mass Balancing 253
parameter are too sparse to allow the generation of its own set of mass
balanced values.
Unused The experimental values associated with this measurement are not
included in the mass balance sum of squares calculation and its mass
balanced value is not changed.
If only certain elements or size fractions are to be sent to the balance, use the
tick boxes provided to select the required parameter. These will then be used
according to the options set in the main drop-down boxes. If an inconsistent
selection is made, an error message will be displayed when the mass balance
is run.
For balancing complex circuits, it is suggested to select all 'Major' streams in
the first instance and balance (adjust) them. Once the user is happy with this
balance, set the Major streams to 'Fixed' and adjust the minor streams, then
the missing streams.
In this way certain parts of the circuit can be balanced and fixed to continue
balancing other parts of the circuit.
The other two fields within the Control frame are "Constraint" and
"Convergence". The first of these relates to how missing values are to be
handled by the balancing engine. There are two options for this field;
"Experimental" and "Balanced".
If you select "Experimental" here, any stream values that are missing will be
ignored in carrying out this balance. If you select "Balanced", then wherever a
missing experimental value is encountered, the balancing engine will
temporarily substitute the balanced value obtained from the last time the
balance was run.
Step 2 For the first run of this balance we will set the Constraint to
"Experimental".
The "Convergence" field is where you determine how close the agreement
between stream values has to be before the balancing engine decides that a
balance has been achieved. When you click on the "Convergence" drop-down,
the alternatives you will be presented with are "Average", "Good" & "Tight".
The values for the convergence criterion that are associated with these
alternatives are 0.1, 0.01 and 0.001 respectively. Once you have made your
selection, it will be the appropriate number rather than the associated word,
that will appear in the Convergence field.

Step 3 For this balance we will set the convergence to "Good", so the
number appearing should be 0.01.
Typically you would use either % solids or TPH water as a component when
balancing a flowsheet that involves gravity separations. Note that if you use
% solids as a component, then you must specify appropriate water additions.
For a description of what happens when % solids is included as a component,
see the next topic on Water 254 .
It is usually a good idea to run mass balancing in stages however. In this case
we will just run the balance using the TPH solids and the elemental assays as
we have good measurements of these on all streams except the cyclone feed
stream. After we have completed this simplified balance, we will then add in
the water as an additional parameter to be balanced. After this, size
distributions can be added in as well.
Some Comments Note that it is not necessary to understand the detailed workings of the mass
on Mass balance engine in order to make use the mass balance module. The following
Balancing comments about its workings may be useful however.
The mass balancing algorithm runs in several stages.
The first is the simple solution, which is analogous to multiple linear
regression. Unless the data have serious problems the balance will converge
in one step; that is, the second solution will be the same as the first.
If small negative values occur, you can increase the number of steps to
eliminate such values. However, recheck your data carefully. Negative values
indicate measurement bias.
For higher numerical accuracy you may increase the iteration limits. However,
there will be no gain in the balance accuracy because data accuracy will be
the usual limit.
Hint: Read the section on problems relating to mass balancing 267 before
adjusting these settings.
The values shown above are the default values.
If the adjusted data show unacceptable inconsistencies, then you must either
reduce the limit or re-scale the assays. As an example, if you have Au assays
expressed as a fraction (giving a number such as 1.0 E-06) this would not
work too well with a convergence criterion of 1.0 E-05. In this case it would be
most sensible to re-scale the assay, which might involve expressing your gold
assays as Au ppm. You would of course then also need to specify that the
assay total is not constrained to 100%.
6.5.9 Water in Balancing
If you have selected TPH Water as a component from within the Control frame,
then you will be also mass balancing any water additions to the circuit
together with the water contained in all the slurry flows throughout the
circuit.
Note that you cannot use % Solids unless you first select TPH Water as a
parameter to be adjusted. Except for the water addition streams, experimental
values for water are entered by specifying the % solids values for the streams.
However, the program calculates TPH Water values from these values and it is

Mass Balancing 255
TPH Water that is used by the engine as a balancing component. The % solids
is not adjusted per se, but it can be used in determining the error after each
iteration and this is what is meant by "influence".
To allow the mass balancing engine to include water in the balance, you need
to ensure that you have selected any water feeder product streams using the
streams select list, in the Equipment / Streams frame. In the Learner Project,
there are two water feeders on the Learner Flowsheet.
Measured data and estimated SD's are entered in the data window associated
with the water streams emanating from these water feeders.
6.5.10 Running the Mass Balance
Starting the This is the simplest step. Once the components have been specified, the
Balance desired equipment and streams selected and the balance controls set, the mass
balancing can begin.
Click on the Start button which is located at the bottom right of the Mass
Balance window.

The mass balancing program will run and when the balance has completed,
the results will be summarised in the right hand panel of the Mass Balance
window.
In the Results frame at the top of this panel is the actual convergence value.
This is the value that is compared with the required Convergence value
selected by the user in the bottom drop-down of the left-hand panel. The
program considers the balance is complete once the actual value goes below
this user specified convergence setting.
The right-hand field of the Results frame is the number of iterations that the
balance has gone through before arriving at the indicated convergence value.
The frame below the Results frame is labelled "RMS Errors" - standing for root
mean square errors. In this frame you can gauge how well the data has
balanced compared to the previous balance. Smaller values of the RMS errors

Mass Balancing 257
will indicate that a better balance has been achieved.

The RMS errors listed here are divided into the various areas of balancing, in
line with the areas that can be selected from within the Controls frame:
The Totals refers to the solids mass flows alone - it does not include
water.
Flows refers to the volume flows in the various streams, consisting of
the volumes of both the water and solids in all streams, including
slurry streams and water feeder flows. Note that balancing on the
volume flows only occurs when TPH water has been selected as one
parameters to be adjusted.
Assays will have an RMS error displayed if you have selected
"Adjust" in the Elements drop-down from the Control frame.
Sizes will have an RMS error when Sizes has been selected for
adjustment from the Control frame.
Likewise Assay by Size will have an RMS error value if Size by
Element has been selected for adjustment.
Below the listing of the RMS error values is the Parity Graph which allows an
easy visual assessment of how good the balance has been. This graph is
plotting the experimental values against the balanced values, so for a perfect
balance, with no adjustments needed, all the points would be sitting on the 45
degree line. The distance that points are away from the 45 degree or parity line
is a measure of how much adjustment was needed for these parameters to
achieve the balance.
Generalised If you have assays on most or all streams, the normal sequence for mass
Strategy for Mass balancing would be to initially set TPH Solids and Elements to "Adjust" with
Balancing all other parameters set to "Unused". Once a balance has been achieved using
these parameters, you would next set both of them to "Fixed" and now set the
TPH Water to "Adjust" and the % Solids to "Influence". Then after this balance
has run, the next step would be (if you have sizing data), to set both water
parameters to "Fixed" and set Sizes to "Adjust". Finally, if you also have Size
by Element data you would set Sizes to "Fixed" and the Size by Element
parameter to "Adjust".
If you are working with Sizing data only and do not have any assays, you
would start the process with TPH Solids and Sizes set to "Adjust". After this
balance runs, you would set these two parameters to "Fixed" and set the TPH
Water to "Adjust" and the % Solids to "Influence".
The next step in the Learner Project is to make the TPH Solids and the
Elements fixed and to balance on water, making the TPH Water set to "Adjust"
and the % Solids set to "Influence. After you change these balancing settings,
you should click on the Clear button prior to re-running the balance. The
Mass Balance window will then look like the one below.

Pressing the Start button will then produce a balance similar to the one shown
below.
Since in this case we also have sizing data, the next step is to balance on these
data. To set this up you need to click in the check-box labelled "Select/
Deselect All" above the Sizes list in the Elements / Sizes frame. This will select
all of the sizes that are present in the size analysis for the samples in this
circuit. You then need to uncheck the 13.2 mm size, since this contains a value
of zero for the experimental retained mass for all three products and this will
cause problems for the balancing routine.
In order to run the balance on the sizing data, you need to also switch the
TPH Water and % Solids back to "Unused". When the balance runs, you
should see the window looking similar to the screen grab below.

Mass Balancing 259
In this case we do not have any size by assay data, so at this point the
balancing process is complete. If you did have size by assay data, the next
step would be to set the Sizes back to "Fixed" and then the Size by Element to
"Adjust".
The next step is to look critically at the balance results and there are various
ways of doing this. The next topic discusses the options here and what you
need to look for in examining the balance results.
6.5.11 The Mass Balance Engine
The Mass Balance Results section reports the value at which convergence
occurred as well as the number of iterations that were required to reach that
value.
In most cases of mass balancing, there will be numerous missing data. The
ideal scenario of the mass-balance algorithm is that the user may specify all
their data, press a button and have the calculated values returned in seconds.
Unfortunately the number of missing data points generally prevents the
algorithm from being quite that accommodating. Therefore, mass-balancing
needs to occur using a hierarchical approach; that is by first mass-balancing
flows, then sizes and total assays, then assays within size-classes. This
hierarchical approach was discussed previously 235 . The key interface is
therefore the Control frame in the Mass Balance window you specify which
levels are to be mass-balanced.
The mass balancing algorithm in JKSimMet allows high level variables to be
calculated using lower level results without actually estimating the low-level
values. For example, it is possible to use size information to estimate flows
without actually having to estimate the calculated values of size. Data-
checking is performed only for those variables that are being mass-balanced
(not the values of lower level values used to influence the mass-balance).
However one needs to bear in mind that unrealistic low-level standard
deviations will cause unreasonable weighting to the lower levels
Data Checking Data-checking is required to ensure that values are realistic. The data-

checking occurs for all levels of variables to be calculated, and assumes that
higher level values have reasonably small standard deviations of the
calculated values. In other words data-checking treats upper level values as if
they are fixed.
Data-checking is used to check the reliability of the data. In particular, if
standard deviation values are too small, the algorithm will have difficulty
converging.
The data-checking algorithm works by considering the difference between
flow (of any property) going into and out of a unit. The difference should be
consistent with the standard deviations. For example, for a unit having one
stream in and two streams out, the total flow values may be represented by f1,
f2 and f3 with corresponding variance values v1, v2 and v3. The flow
difference is:
The expected variance of this difference value is given by:
Thus the statistic:
provides an estimate of the reliability of these data. The expected value of r is

1. This r value is referred to as the RMS (root mean square) value.
An RMS value greater than 3 usually indicates that the data contains an
outlier or that the standard deviations are too small.
Using the RMS The Error Analysis section of the Control/Run window gives an indication of
Errors the quality of the mass balanced data through the use of RMS (root mean
square) errors.
As its name suggests, the root mean square error is the square root of the
residual mean square error, which is the error associated with fitting the mass
balanced data to the experimental data.
A root mean square error of unity means that all data points were estimated
with errors similar to the measured standard deviations of the experimental
data points.
Therefore, when performing a mass balance, an RMS Total value of
somewhere between 0.5 and 2.0 indicates that the experimental data is good
and that the correct standard deviations have been used.
Along with the RMS Total value it is possible to check the error values (i.e.
(observed predicted)/sd) on the other parameters used in the mass balance.
Click the Detail button next to each parameter to see information about that
parameter.

Mass Balancing 261
This window, for instance, would indicate that particular problems exist with
the Cyc U/F and BM Product streams.
Identifying particularly problematic streams allows the user to immediately
focus on which data values may be less accurate than indicated by their
standard deviation. It may be necessary to change standard deviation values
to improve the mass balance.
6.5.12 Checking the Balance
There are various ways in which the user can assess the results:
The Overview window is probably the most useful way to check data and
results. It also allows recovery of any component to be displayed for all streams.
See the Using the Configurable Stream Overview 36 topic for details of the
Overview facility.
In the RMS Errors frame of the Mass Balance window, the magnitude of the
accumulated error values under the various parameter categories, are all
indicators of how close the original experimental data were to being already
balanced. Smaller values of the RMS Errors indicate less adjustment was
required to produce the balance. Moreover, in the case of these fields,
comparisons between successive mass balances can be made. If these values are
smaller than they were in the previous run, then the balance is getting better. If
they are getting larger, then the adjustments you have made are taking this
balance in the wrong direction.
You can also judge the relative success of mass balancing by looking at the
individual stream data windows. Examine the values in the Error column.
Again, smaller error values indicate less adjustment has been required.
The parity graph on the Mass Balance window allows for a good visual
assessment of the balance. The further the data points are away from the 45
degree line, the greater was the adjustment needed to balance the parameters in
question. The TPH Solids data usually consist of numbers that are very large
compared to the assay data and when the two are plotted together on this
graph, the assay data will lie in a clump near the origin, which is not very
useful for assessment. To overcome this problem, you can temporarily switch

the TPH Solids to "Unused", while leaving Elements on "Adjust". You will also
have to de-select "Remainder" from the elements list, since this will be a
relatively large number also, possibly approaching 100. After you have done
this, you should get a much better picture of how well the elemental data have
balanced. It should be noted though that you cannot actually carry out a
balance with the TPH Solids set to "Unused". Note too that you can hover the
mouse over individual data points to identify them, as is illustrated in the
screen grab below. Don't be too impatient here though - you do need to have the
mouse positioned over the point you wish to identify for between 1 and 2
seconds before the data will appear.
The Configurable Graphing facility allows the user to plot experimental and
balanced size distribution data on the same screen. Further description of this
can be found in the section Plotting Size Data Graphs 265 .
If mass balancing a large and complex circuit is proving difficult, a useful
technique for tracing the source of the problem is to dissect the circuit into
smaller chunks for balancing. The Mass Balancing module allows balances to
be carried out on a single unit or on a small set of units, isolated from the main
circuit by means of the Select List facility. This allows you to put the test data
under a microscope.
If circuit conditions were changing as you did your test work, you may find that the
unstable sections of the plant will have yielded unusable results. As a general
principal, a good balance depends on having steady state conditions and varying
conditions will usually produce nonsense.
6.6 Presentation of Mass Balance Results

There are two main ways to present the results of mass balancing:
viewing on screen via the Configurable Stream Overview window
and
printing or exporting via the Reports function.
We shall deal with these in turn. For mass balanced data, graph plotting is
limited to GSIM format.

Mass Balancing 263
6.6.1 Configurable Stream Overview
Using The Configurable Stream Overview 36 window gives you a powerful means of
Configurable summarising your data and checking it for adjustment problems. There are some
Stream built-in overviews that will already be present when you first open the
Overview to Configurable Stream Overview. This includes one that contains Experimental,
View Balance Balanced and SD data. This one is all you would normally need for assessing
Results the results of a mass balancing procedure. However, as implied by the name,
this overview window can be configured by the user and you can create your
own overviews with additional data displayed or with just a subset of the
streams in your flowsheet displayed.
The best way to use the overview feature is to compare experimental and
balanced values for each assay (or size fraction) across the complete circuit. This
will give a very useful picture of the accuracy of the data and the mass balance.
Step 1 Left-click on the Configurable Stream Overview button ( ) on the

main JKSimMet toolbar. This brings the Configurable Stream
Overview window into view.
Step 2 Select From the Select List at top left, select the pre-configured
overview the existing Overview that is labelled "Stream Data (Exp,
Bal & SD)".
Note that from within this window, you can elect to change the way you view
the sizing data. The drop-down at top right contains the sizing data options of
% Retained, Cum % Retained and Cum % Passing. You can also gain access to
the SD Calculation window 243 from here via the button next to this drop-down.
This is provided here since after examining the most recent balance data, it will
often be the case that you may need to modify certain SD values before re-
running the balance.
6.6.2 Reports Function and Printing
Printing Mass Normally for reporting the results of a mass balancing procedure you would most
Balance likely want to show the experimental, balanced and SD values for each type of
Results data involved and for each of the streams included in the balance.
Printing One way to do this is via the individual stream data windows. To open a stream
Individual data window, just double-click on the required stream in your flowsheet. These
Port Data windows all have SD and Mbal data as pre-configured display columns. You
Windows cannot directly print these windows, but you can copy the grid from them into
Excel. To do this you press the Copy button, located top centre of the Stream Data
window. As it is only the active tab that gets copied, you need to ensure that you
Version 6.0.1 - March 2014 Presentation of Mass Balance Results

have the appropriate tab selected for the type of data that you are intending to
report on.
This method may occasionally be useful if you are wishing to report the data for a
particular stream, but in general one of the other two methods below is probably
more practical.
Printing the Another alternative is that once you have the Configurable Stream Overview set
Configurable up according to your requirements, you can either print it directly or else export it
Stream to Excel for further manipulation before printing.
Overview When you use the Print function directly, the options for manipulating the format
of your report are somewhat limited and it is likely to span across several pages.
In most cases it is probably better to use the Export function and then print a
report from Excel.
There are two Export buttons - one is for exporting just the overview that is
currently displayed, while the other will export all of the overviews that have
been set up for this project. Note that this includes all the system configured
overviews as well as any that you may have created. The export function will
create a new Excel sheet for each of the existing overviews.
The copy grid option is also available from the Configurable Stream Overview
window and this may sometimes be useful as a quick way of getting the required
data into Excel for further manipulation.
Configure Probably the greatest flexibility for report production is afforded by JKSimMet's
and Print a
integrated Report generator. When you press the Report button ( ), a window
Report
similar to the illustration below will open.
From here you can create reports with complete flexibility regarding which
equipment items, streams and types of data that are to be included. There is also a
drop-down to allow you to choose the way your sizing data will be expressed in
the report.
Presentation of Mass Balance Results Version 6.0.1 - March 2014

Mass Balancing 265
For a mass balancing report, it is recommended that you place a tick in the
Summary check-box. When you do this, the formatting of the report will be
modified for easier comparison of values between streams. With the Summary
check-box ticked, the stream data will be arranged with the stream headings
across the page and the parameters down the page, grouped by data type. If you
have also selected equipment for the report, the equipment data will still be listed
down the page along the left-hand border, but it will have a lot less detail than in
the non-summary version.
6.6.3 Plotting Size Data Graphs
Plotting On the mass balancing window there is a graph of experimental data versus
Graphs of the balanced data, which provides a visual assessment of how much of an
Mass adjustment of the various data points was needed to achieve the balance.
Balancing
Results
For the sizing data it is possible to get a more detailed visual feedback on how
much adjustment was needed, by plotting a size distribution graph of both the
experimental and balanced data. A drop-down is provided to allow you to
select the format of the sizing data. This can be either cumulative % passing, %
retained or cumulative % retained. The data can be plotted for a number of
streams on the same chart, to allow comparisons.
An example of the graphing facility with the required data types in the process
of being selected from the drop-down, is shown in the screen grab below.
Once the streams to be displayed have been selected and the data format and
data types selected, you simply click on the Graph tab and the required chart
will appear in place of the graph configuration table. The screen grab below
shows a typical example in which the user has chosen to show the circuit feed
from the Learner Flowsheet plus the two products from the cyclone.
Version 6.0.1 - March 2014 Presentation of Mass Balance Results

It is also possible to make changes to the way this graph appears, using the
Format button near the top right of this window. If you click on this button, a
new window will open where you can make a number of changes to the chart
formatting. An example is shown below.
Any graph that you generate here can be easily inserted into an Excel or MS
Word report using the Copy button at top right.
Presentation of Mass Balance Results Version 6.0.1 - March 2014

Mass Balancing 267
6.7 Problems Related to Mass Balancing and Possible Solutions

There are, of course, many problems that may be encountered during mass
balancing. It is possible however, to point out some of the more common
problems and a description of these has been set out in the remainder of this
section. While the list below is not comprehensive, we hope that it will alert
you to some of the more significant pitfalls.
Errors, Warnings, Some problems detected by JKSimMet can produce error messages. In version
Faults 5 the errors had error numbers and were referenced via a key that could be
found in the help file. In version 6 it is no longer necessary to refer to a key
since the error explanations now appear in the error message window.
Graphical The graphing capability of JKSimMet is the most powerful way to examine
Analysis your data fit. Discontinuities in size data highlight poor data or a change in
size measurement technique. Graphical analysis also highlights any bias in
the data fit.
Different Sizing Be very wary of changes in size measurement technique e.g. from screens to a
Techniques Cyclosizer.
Different Assay Where assay techniques change between stream samples, as they sometimes
Techniques do for different assay ranges, there may be inherent biases within the assay
techniques. These will lead to biases within the mass balance.
Skill versus Mass Balancing is not a cut and dried procedure. The only way to acquire a
Practice useful skill level is to practise on a wide range of real data. JKSimMet offers a
user-friendly environment for what are really very complex and powerful
mathematical techniques.
Data Note that it is necessary to have enough feed and product data to achieve a
useful mass balance. This is very important. Generally you need to have
redundant data and the more of this you have, the better. If you have no
redundant data at all, then the mass balancing exercise reduces to just a
calculation i.e. there is only one solution to the balance. In this case the
internal checking that comes from having these extra data (and is also one of
the major advantages of mass balancing), will no longer be operating.
Without redundant data, there could well be a very large error in one of your
data points and you would have no way of ever being alerted to it.
Common Mass There are a couple of simple traps which can appear in many guises. If you
Balancing become aware of these now you may recognise them more easily when you
Pitfalls encounter them in the future. These are discussed in the two sub-topics that
follow.
6.7.1 The Middlings Problem
The Middlings Below we have a single unit flow diagram for a separation node where there
Problem is a middlings stream of assay m.
In this situation there are not enough assays to go around.

However, if we have two assays in each stream, we would write them out as
Version 6.0.1 - March 2014 Problems Related to Mass Balancing and Possible Solutions
simple equations and solve for two unknowns. However, if m really is a

middlings stream, it will be close to a in composition and very often recycled
back to it.
In this case, no matter how accurately we can sample and assay the streams,
we can only find out:
the ratio between flows b & c (if m goes elsewhere)
or
the flows in b and c if m is recycled.
The actual flow rate in m can be anywhere between zero and infinity.
However, there is a straightforward solution. Measure (or estimate) the flow
rate in stream m and input this flow rate as data.
The mass balancing module allows you to do this.
6.7.2 The Infinite Division Problem
The Infinite If one wishes to extract maximum information from a survey, it is not unusual
Division to assay on a two (or even three) dimensional matrix, for example, assay by
Problem size or assay by size by specific gravity. This subdivides the stream into even
smaller sub-groups. Each sub-group has an extra step of processing and an
increased relative error. Hence, we tend towards trying to solve for (0 - 0) / (0 -
0). This is not a useful numerical exercise.
The solution to this problem is straightforward, however.
You should first use the total assays where there are large differences, to
calculate the mass balance flow rate solutions. Once you have these flow
rates, fix them by selecting "Fixed" from the TPH Solids drop-down (in the
balance controls frame) and only then add in all of the smaller fraction assays
to the mass balancing problem.
Once the flow rates have been defined, the mass balancing module will be
more easily able to allocate the minimum adjustments required to make all of
the fractional assays consistent.
6.8 Metallurgical Accounting
Use in The day to day data collected from a mineral processing plant are rarely
Metallurgical consistent and will almost always contain redundant information. In general,
Accounting any two methods of calculation will yield different results. The challenge for
metallurgical accounting is to produce adjusted data that are both self-
consistent and as accurate a representation of plant performance as possible.
Consider a typical base metal concentrator with several products from several
circuits,
At each point marked , we have Au, Cu, Fe, Pb and Zn Assays. For the feed,
Problems Related to Mass Balancing and Possible Solutions Version 6.0.1 - March 2014
Mass Balancing 269
we have weightometer readings and for the concentrates we have load out
weights with stockpile surveys.
If we select an accounting period that is large compared with the circuit
residence time, we can carry out a mass balance over this complete data set. If
large adjustments are required, these may be an indication of problems in
either sampling or assay techniques. In this case you may need to select
smaller circuits for mass balancing in order to isolate and identify these
problems.
Once a consistent set of adjusted data is produced for each accounting period,
the sums of these sets will also be consistent.
If assays and flow rates are available on a short time scale, e.g. several times
per shift, these data can be balanced for each time period, printed to a file or
exported to most Windows spreadsheet or word processing packages using
copy and paste.
JKMetAccount For users with a serious interest in metallurgical accounting, the
JKMetAccount program was created to enable the Metallurgist or Plant
Manager to track the performance of a mineral processing plant over
time.Changes to a plant flowsheet, which can so often cause problems for a
spreadsheet based system, are easily accommodated by the JKMetAccount
software.
The major strength of this program comes from harnessing the power of the
JKMBal mass balance engine (and more recently a model based mass balance
engine), within a rigorous data management environment that is accessed via
a user friendly graphical interface. JKMetaccount also still provides for very
flexible reporting, as it utilises the formatting power of Excel within its report
production module.
With its rigorous data management advantage over a spreadsheet system, we
believe that JKMetAccount will in time become regarded as an indispensable
tool for modern mineral processing plants.
At the end of 2006, all rights to the JKMetAccount program were sold to the
large Brisbane based software development company Mincom, whom were
considered better able to handle the further development and marketing of
this product. Mincom have since been taken over (in July 2011) by ABB and
are now part of the ABB owned company Ventyx.
If you are interested in finding out more about JKMetAccount, further
information can be obtained either from the JKTech website (http://
www.jktech.com.au/commercialisation-case-studies) or directly from Ventyx,
whose contact details can be obtained from their website at http://
www.ventyx.com/.
6.9 References
LYNCH, A.J., 1977. Mineral Crushing and Grinding Circuits, (Elsevier,
Amsterdam), Chapter 7.
LYMAN, G.J., 1986. Application of Gy's sampling theory to coal, International
Journal of Mineral Processing, Vol 17:1-22.
GY, P.M., 1982. Sampling of particulate materials: theory and practice, 2nd Ed,
Version 6.0.1 - March 2014 Metallurgical Accounting

(Elsevier, Amsterdam), p 431.

MORRISON, R.D., 1976. A two stage least squares technique for the general
material balance problem, JKMRC Internal Report No 61
(unpublished)
References Version 6.0.1 - March 2014

Part
VII
7 Model Fitting
Model Fitting This section provides information about the model fitting capabilities of
JKSimMet V6.
7.1 Introduction to Model Fitting
Purpose This chapter describes how to use the JKSimMet model-fitting mode. Model
fitting allows JKSimMet to be fine-tuned to each specific plant and operating
condition, or even to particular ore types. It does so by adjusting selected
model parameters on the basis of systematic differences between measured
product data and simulation predicted product data.
The model fitting procedure can take into account any measured flow rates
and estimates of their accuracies.
Previously the determination of the model parameters was performed in
spreadsheet-based programs, involving complex formulae. This has been
very time consuming and potentially prone to error. As more companies are
becoming skilled in developing models, JKSimMet enables the fitting routines
to be standardised. The ability to use JKSimMet to fit the model parameters
greatly increases the efficiency and level of confidence in developing the
models; although a high degree of training is still required to ensure
reasonable results are obtained.
Overview For both plant designer and plant operator, model fitting is primarily
concerned with the collection of accurate experimental data, at either pilot or
full plant scale. The model fitting process provides a powerful means of data
examination or assessment as well as the compression of thousands of data
points into a few parameters.
The parameters characterise how a particular ore behaves in a particular
plant. This characterisation can be used to find the optimum plant settings
with respect to various criteria, or even to find an optimal plant configuration
to achieve stated objectives.
As with all data analysis or prediction processes, however, the quality of the
output is strongly dependent on the quality of the input. The computer jargon
for this phenomenon is GIGO or GARBAGE IN GARBAGE OUT. A serious
difficulty with all realistic simulation systems like JKSimMet is that they will
produce very plausible looking nonsense from rubbishy data.
Hence, just as the spreadsheet is not a replacement for the accountant,
JKSimMet is not a replacement for a metallurgist or process engineer. There is
no substitute for professional expertise or experience, especially in the
collection and analysis of large quantities of data. JKSimMet provides such a
professional with a tool of enormous power.
The general procedure for model fitting is:
Collect data;
Analyse data;
Optimise plant using models;
Adjust plant;

Model Fitting 273
Collect data to confirm

And start the cycle again.
7.2 Background to Model Fitting
Default The JKSimMet models are provided with a set of default parameters and, in
Parameters most cases, a range of parameter values.
For any real mineral processing operation, the best-fit parameters will almost
certainly be different from the default values provided with the system.
There are several classes of parameters used as model inputs:
Machine Firstly there are the machine dependent parameters. These are typically
Parameters dimensions and key operating adjustments.
Ore Parameters Then there are the ore dependent parameters. For example, the work index or
specific gravity or appearance function for a particular ore at a particular
energy.
Operating There are also the calculated or measured operating parameters. These
Parameters usually depend on a combination of machine and ore dependent parameters
and ore feed rates, etc. Examples are cyclone feed pressure and crusher power
draw.
Circuit Flow Process instrumentation often provides an estimate of solids and liquid flow
Rates of Solids rates in the circuit. An example might be the solids mass flow rate to a cyclone
and Water classifier. In some cases, such a flow can be treated as data. If it is
unmeasured, it may be varied until a best fit to the other data is achieved. In
this case, the flow rate effectively becomes a parameter.
Model Each model has a list of parameters that can be fitted. Each parameter to be
Parameters that fitted is selected from a menu for that model. These menus are listed for each
can be Fitted. of the models within the Model Descriptions 294 section.
7.3 How the Model Fitting Program Works

The model-fitting program works by calculating the differences between the
predicted and experimental data, and then deriving from these differences a
weighted sum of squares value (WSSQ). On its first iteration (step), the
program makes a small adjustment to each parameter in turn, with each
adjustment followed by an internal simulation to determine its affect on the
weighted sum of squares value. This step is used to estimate the magnitude
and direction of the adjustments to the parameters required to minimise the
WSSQ. On subsequent iterations, the program varies all the fitted parameters
simultaneously, noting the effect of the adjustments. This process is repeated
until the program is stopped for one of the following reasons:
A minimum WSSQ has been reached;
The maximum number of steps set by the user has been reached;
The adjustments made to the parameters are having no significant
effect on the weighted sum of squares value;
Operator intervention.
Whereas simulation uses given feed data and given model parameters to
Version 6.0.1 - March 2014 Introduction to Model Fitting

predict the product data, the model-fitting program uses the sum of the
squares of the differences between the predicted and the actual product data
to adjust the model parameters.
The difference between simulation and model fitting is represented
schematically below:
Schematic to Illustrate Difference between Simulation and Model

Fitting
7.4 Model Fitting as Applied in JKSimMet

Model fitting allows the simulation models present in JKSimMet to be tuned to
specific real world operating conditions. To do this, the user collects
experimental (stream) data and periodically engages in model fitting to
update parameters.
How the Model Fitting Program Works Version 6.0.1 - March 2014
Model Fitting 275
Model fitting consists of adjusting the model parameters so that the model
predictions line up as closely as possible with collected experimental data.
These data are collected from the real plant or circuit, and they are mostly data
associated with the circuit product stream or streams.
Any parameter within the comminution models can be incorporated into the
fitting routine. In general, the model parameters are within the comminution
machines themselves, while the data to be fitted against are within the
streams.
7.5 Preliminary Data Setup

The initial steps in performing the model fitting data analysis are similar to
those required for all previous functions.
7.5.1 Creating the Flowsheet
To create a new project, follow the procedure discussed earlier under the
topic Creating a New Project 178 . This will load a new project with a blank
flowsheet called FlowSheet1.
Lock the flowsheet once the flowsheet has been drawn, including labels given
to equipment and streams.
7.5.2 System Properties
The first step in model fitting for a given flowsheet is to check the system
properties defined for that flowsheet. First make sure that you have selected
the flowsheet you wish to deal with. Remember that you need to double-click
on a flowsheet from the list in order to select it. Next you should click on the
System Properties icon or select System Properties from the Flowsheet sub-
menu to open the System Properties window.
System In JKSimMet there are only two classes of system properties:
Properties Elements
Miscellaneous
In JKSimMet there are no predictive models that deal with the dispersion of
elemental flows around flowsheet nodes. Any elements that you enter as part
of the system properties will only be used within the mass balancing
function.
For the miscellaneous category, there are two built-in properties solids SG and
water SG. Both of these will have relevance for a number of the predictive
models. Generally the water SG will not vary greatly, but solids SG will have
more variation and changes here could have a substantial effect on the output
from models where gravity effects are important, such as the cyclone model.
Other aspects of the System Properties 192 window are discussed in the
chapter on Editing the Flowsheet Data.
7.5.3 Stream Specification
Click on the Stream icon or select Stream from the Flowsheet menu to open
Version 6.0.1 - March 2014 Model Fitting as Applied in JKSimMet

the Stream window. From here you can select individual streams. See
Entering the Data 237 under the chapter Learning Mass Balancing for more
detailed information.
For model fitting within JKSimMet, the user must ensure that sizing data has
been entered as part of the stream data for all streams associated with the
equipment item or items concerned.
For the models associated with these equipment items, the default values for
the parameters being fitted can be used as starting values.
7.5.4 Data Input
Feeder Units JKSimMet requires the user to enter data into the Feeder units, even though
this data has been previously used in the streams for the mass balance.
Ensure the following data has been entered for the feed stream(s):
TPH solids
% solids
Size distribution
Configurable In a similar manner to setting up the flowsheet for simulation, the user must
Equipment enter starting point parameter values for the equipment units. The addition of
Manager these data can be achieved via the Configurable Equipment Manager 153 or be
entering the data directly into the individual unit windows.
The Configurable Equipment Manager can be particularly useful where you
have multiple equipment units with the same associated process model.
Survey Data If you have survey data that has been entered into the survey data screen, the
task of getting your data into the various flowsheet streams can be efficiently
accomplished via the Transfer button on this Survey Data 175 window.
7.5.5 Mass Balance Prior to Fitting
It is generally recommended to balance experimental data prior to moving into

the model fitting routine. See the section on Mass Balancing 230 for more
details
Ensure the following steps have been performed:
Experimental Data Specification check to see that you have size fraction data
entered for all streams involved with model fitting.
Enter data in either the Configurable Stream Overview or the individual
stream windows.
Calculate ALL standard deviations, either by using the Automatic SD
Calculator or by manually entering values. The Automatic SD Calculator is
accessed from either the Configurable Stream Overview or from individual
stream windows.
Ensure standard deviations are present in the system for:
TPH Solids
TPH Water
Preliminary Data Setup Version 6.0.1 - March 2014

Model Fitting 277
% solids
ALL size fractions
Where no experimental data is present, ensure the standard deviation value is
set to Missing.
Run the mass balance using the hierarchical structure as discussed in the
Mass Balancing 230 section:
Adjust TPH solids and elements first until reasonable values have
been obtained, keep these as fixed for subsequent runs;
Adjust TPH water, using % solids as influence, then leave as unused
for subsequent runs;
Adjust size fractions (wt %)
Review results using the parity graph, Configurable Stream Overview and
individual stream windows to ensure realistic values.
7.5.6 The Model Fitting Window
Opening the Step 1 Open the Model Fitting window.

Model Fitting
The Model Fitting window within JKSimMet contains several frames. When
Window
first opened, either by clicking on the Model Fitting button ( ), or by selecting
Run Model Fitting from the Flowsheet menu, a window similar to the one
shown below will appear.
At the top left is a drop-down selection box for selecting the Model Fit Case. By
default, there is a system generated model fit case called Whole Circuit, which
as the name implies, encompasses all the equipment items in your flowsheet
that have associated models, plus their connecting streams.
The Whole Circuit model fit case cannot be deleted. However, you can add
(and/or delete) as many more model fit cases as you wish, so as to enable the
fitting of either individual equipment items or sections of the plant that
encompass any number of connected items.
Version 6.0.1 - March 2014 Preliminary Data Setup

Creating a New Step 2 Add a new model fit case for the ball mill only.
Model Fit Case
To add a new model fit case, you first click on the button at the end of the drop-
down (circled in the screen grab below).
After clicking on this button, a window labelled Simulate will open containing
a similar drop-down list at the top, this time labelled Simulation Select List.
From this window you can add new model fit cases as well as make any
changes needed to ones you have previously added.
A screen grab of this window is shown below.
Beneath the drop-down list there are two panels, the left-hand one showing a
list of equipment items and the right-hand one showing a list of the streams.
You will notice that when Whole Circuit is selected from the drop-down list, all
the equipment items and streams will be selected by default and you will not be
able to deselect any of them. To create a new select list (model fit case), click on
the New button (circled above) and then enter a name for the new list in the
dialog box that will then have opened (see below).
Setting up the In this case we will elect to fit the ball mill in isolation as our starting point for
New Model Fit model fitting the items on this flowsheet, so you could enter something like 'Ball
Case Mill Only' for the name. As a general principal, it is usually best to model fit the
equipment items individually before attempting to carry out model fitting on the
entire circuit. That said, in the case of a closed circuit ball mill configuration, it
is often better to fit the ball mill concurrently with the associated cyclone (see
ball mill model description 361 ). However, since our purpose in this example is
to demonstrate the more normal sequence, we will fit the ball mill first, followed
by the cyclone and finally the whole circuit.

Model Fitting 279
After pressing OK to name the new model fit case, you will be back on the
Simulate window where you can specify the equipment and streams that are to
be included. Here you will find that in addition to the Whole Circuit model fit
case, Ball Mill Only is now an additional option for selection from the drop-
down list. If you now select this item, you will see that initially there are no
equipment items or streams selected.
To set up the new model fit case, you should now select Ball Mill from the left-
hand panel. After doing this you will find that all of the input and output
streams for the ball mill will be automatically checked in the right-hand stream
selection panel. You can modify this selection if required. However, bear in
mind that the only streams you will have available in the Model Fitting window
when this model fit case is selected, will be the ones have been checked in the
Simulate window.
After setting up the model fit case, you should return to the Model Fitting
window. You do this simply by closing the Simulate window - via the corner
close button ( ). If Ball Mill Only was selected when you closed the
Simulate window, then this will also be selected on returning to the Model
Fitting window.
The model fitting window should now look similar to the screen grab below:

Selecting We will use the Ball Mill Only case for initial model fitting. However, to
Equipment illustrate a point we will now select Whole Circuit again. You will notice that
Items with the parameters appearing in the centre panel list will be appropriate for
Associated whatever equipment item you have clicked on in the equipment selection list at
Models and left. Note that when you click on a grey Equipment cell (or on a Model cell) you
Showing their will bring up the list of the appropriate parameters for the selected item of
equipment - you don't have to put a tick in the check-box next to the equipment
Parameters
item for it to be selected and to see the associated parameters. The check-box is
there simply to provide a means of quickly selecting the appropriate streams in
the Stream Error Selection list. When you place a tick in one of the equipment
item check-boxes, the appropriate streams will also be ticked. The streams that
get selected for error assessment by default will be the product streams from the
selected item of equipment.
You are not bound by this stream selection, but it does represent what would be
the normal choice of streams for use in assessing the veracity of the parameter
values, after each round of simulation. You can remove the tick for instance
from one of the product streams if you don't want the error in the simulated
values for this stream to influence the parameter fitting.
Selecting the Step 3 Select the streams that are to be used for the fitting process.
Streams for
If you now select Ball Mill from the Equipment Selection frame and place a tick
Fitting Error in its check-box, the program will automatically select the BM Product from the
Assessment Stream Error Selection frame. By default this frame should contain all of the
streams associated with the ball mill - the feed plus the water addition.
However, the default selection for stream error assessment will always be just
the product stream (or streams) from the selected item of equipment; in this case
the BM Product.
This means that fitting of the ball mill parameters will take place by minimising
the difference between the simulated values and the experimental values
associated with the BM Product stream.
Selecting Step 4 Select the parameters to be fitted.
Parameters for
Next you need to select from the central parameters list, the ones that you intend
Fitting to be dealing with for this round of fitting.
As you select each parameter from the top centre selection list, you will see that
the chosen parameters will immediately appear in the Parameter Selection
frame below. By default, each of the parameters that is added into the list in this
frame will have its check-box in the lower frame ticked, which means that it is
selected for fitting. You can however, uncheck these check boxes. If you elect to
do this, the parameter concerned will not be fitted, but the guessed value will be
used as a fixed value for the parameter concerned through each simulation
cycle of the fitting process. If on the other hand you were to de-select this
parameter from the top parameter list, then whatever value has been entered for
the parameter in the equipment model window will be the one used as the fixed
value through each round of simulation.
JKSimMet automatically inserts your initial estimate of the parameter value from
the equipment data window into the Guessed Value column. The Scale Factor is
also automatically set at 10% of the initial estimate. If you wish, these values
can be changed by highlighting the existing value and over-typing it with a new
one.

Model Fitting 281
Creating For each model fit case, a parameter list will automatically be saved and this
Parameter Lists will consist of whatever parameters you have chosen while this model fit case
was selected. However, in addition to this first parameter list, you can create
any number of extra parameter lists that you can then return to as required. Any
such lists you create will be automatically saved and they will be specific to that
particular model fit case.
Note that the definition of the parameter lists also includes the specification of
which streams are to be used for the model fitting error assessment.
Fitting the Ball You should next select Ball Mill Only from the Model Fit Case drop-down and
Mill Model then select all but the last of the parameters (Knot 4), that are associated with the
ball mill model. Note that the ball mill model is actually set via the equipment
window and in this case the perfect mixing model is the one that has been
selected.
There should now be 3 parameters listed in the lower Parameter Selection table.
Deselect the last of these three (Knot 3) by removing the tick from its check-box.
Then place a value (say 2 for example), into the Guessed Value field for this
parameter. This is not necessarily a realistic number to use for this parameter -
just an example to illustrate the principal.
Adjust Model Step 5 Adjust the settings for model fitting.
Fit Settings
The next step is to adjust the simulation settings for model fitting, if required.
The Settings frame looks like the screen grab below.
The Size Interpolation refers to how data associated with intermediate sizes;
that is sizes other than those actually entered, are to be calculated. The default
setting is Linear, but Spline interpolation may give better results under some
circumstances.
The Starting Condition drop-down is where you select the type of data that are
to be used for the feed to the circuit during each round of the fitting process.
Normally you would start from the experimental data but if you have doubts
about how representative the sample was and if balancing has changed the
values for this sample significantly, then you might want to start from the
balanced values.
Again, for the Error Condition, there is a choice of the data type with which to
compare the simulated values after each round of simulation. Once more the
first choice should probably be to use the experimental data, but if there are
doubts about the samples (in this case the products from the selected circuit),
then balanced data may be a better choice.
The Max Iterations figure here refers the maximum iterations allowed for each
round of simulation during the model fitting sequence. For simulations of a
circuit where there is no circulating load, (as is the case here, where we are

fitting the ball mill alone), only one or two iterations for each round of
simulation would be needed. The maximum iterations limit only becomes
important when you are fitting a larger circuit where there are one or more
circulating loads. Normally the default limit of 100 will be sufficient, but if your
circuit is having problems converging, then you may need to increase this limit.
Convergence refers to how close the simulated values have to be to whichever
data type has been chosen for the error condition, before the model fitting
process has deemed to have converged. The convergence limit value can
normally be left at the default setting.
Run the Ball Step 6 Run model fitting.
Mill Model Fit
Leave the default settings in place and press the Start button to run the model
fitting. A summary of the results will be shown in the Model Fitting Results
frame, which is immediately below the Settings frame.
Create A Step 7 Set up a model fit case for the cyclone.

Model Fit Case
Now that model fitting has been run for the ball mill by itself, you should create
for the another Model Fit Case, this time for the cyclone (call it Cyclone Only), using the
Hydrocyclone same procedure as was outlined above. After you have created this, select
Cyclone Only from the Model Fit Case drop-down. On doing so you will see that
there is now an item in the Equipment Data Selection frame (far right), which
was empty when we were fitting the ball mill parameters. This frame has an
item in it because the cyclone is selected and a cyclone is an example of an
equipment item that has an operational characteristic which can be measured
and is also predicted by the model. The characteristic we are talking about here
is the cyclone operating pressure. This means that in the case of a cyclone, the
difference between the measured and simulated cyclone pressure can be used in
the same way as the difference between measured and simulated stream
characteristics, to tune the parameters associated with the cyclone model.

Model Fitting 283
Run Cyclone Step 8 Run model fitting for the cyclone.

Model Fitting
After selecting the cyclone U/F and O/F streams plus the cyclone operating
pressure for the fitting error comparisons, you can again leave the settings at the
default values and run another fit. A screen grab of the Model Fitting window
after fitting the cyclone is shown below.
Run Fitting for Step 9 Run model fitting for the whole circuit.
Whole Circuit
Once the ball mill and the cyclone have been fitted separately, you can then run
the fitting process for the whole circuit. A screen grab of the Model Fitting
window after fitting the whole circuit is shown below.

7.5.7 Master Slave Fitting
Master/slave model fitting allows the same parameters to be fitted to two or

more units in a single test. The parameters fitted will have the same values for
the master and all the slave units. Master/Slave fitting can be used when
fitting survey data collected simultaneously from parallel units with the same
operating conditions. Alternatively, it can be used for survey data collected
sequentially from a single process unit, where it is expected that model
parameters will not be affected by any change in operating conditions.
Equipment The Master/Slave functionality is available in the model fitting dialog when
Selection two or more of the same equipment items use the same model, as shown
below.
In this case the eight cone crushers have the same model.
The choice of which equipment item to use as the master is not important as
all units will finish with the same parameter values. For this example Test 1 is

Model Fitting 285
the master equipment. The first step is to select the parameters in the master
equipment that you wish to use in the slave equipment. In this example the
parameters K1 - Constant, K1 - CSS(mm), K1 - Feed TPH, K1 - F80(mm), K2 -
Constant, K2 CSS(mm), T10 - Constant and Pow Prod Fact have been chosen,
as shown below.
Selecting Test 2 in the equipment list and then selecting Test 1 in the Master
drop down control gives the following selection options in the equipment
parameter list:
The user can now select the parameters chosen for fitting in the master
equipment as parameters for the slave equipment, in effect replacing those
parameters in the slave equipment.
As selected above, Test 2 will use the parameters from the master equipment
and none of its own.
Parameter With the eight parameters already chosen the parameter selection grid will

selection display the following:
The equipment parameters listed are the selected non slave parameters for
each equipment item. The equipment that uses the selected parameter as a
slave parameter is listed in the final column.
Once a piece of equipment has been set as a slave it cannot act as a master to
another equipment item. However, any equipment not set as a slave can be a
master to many other pieces of equipment as shown below where Test 1 is
also the master of Test 3, 4, 5, 6, 7 and 8.
7.5.8 Checking the Fit
During the execution of the fitting program the Model Fitting Results frame of
the Model Fitting window is continually updated as the iteration count
progresses. Assuming that the fitting reaches a satisfactory conclusion, the
standard deviations (SDs) of the parameters will be updated to their final
values when the fitting program stops.
There are various ways in which the user can judge whether the results are
good or bad:
One method is to compare the size (order of magnitude) of the parameter SDs
with that of their associated values. When the SD is small compared with the
value as a ratio, it is a good fit, when large, it is a poor fit.
The summary values in the Model Fitting Results frame also indicate the
success of the fit. Low values in the Residual, Error Sum, and Errors SD fields
indicate a good fit; large values, a poor fit. Moreover, in the case of these fields,
cross comparisons between fittings can be made. If these values are smaller in
the most recent run of the fitting than they were in the previous run, the fit is
getting better. If they are getting larger, you are going in the wrong direction.

Model Fitting 287
The engineer can also judge the relative success of the fitting by looking at the
stream data windows, with Weighted Error and Percentage Error versions of
the difference between calculated and experimental data being the most useful
indicators. These are displayed by selecting the appropriate item from the
Error drop-down list.
The graph plotting facility of JKSimMet allows the engineer to plot raw and
fitted sizing data on the same graph, as detailed in next section - Presentation
of Model Fitting Results.
The overview facility of JKSimMet allows key experimental and calculated
data for multiple streams to be viewed in a summary table. These overviews
are configurable by the user (see the topic under the JKSimMet Windows
section 157 for details).
7.5.9 Presentation of Model Fitting Results
There are two main ways to present the results of model fitting:
Printing data
Plotting graphs
We shall deal with these in turn.
Printing Model Given that model fitting concerns the experimental (raw) data and the predicted
Fit Results (fitted) data for streams (mainly), the results presentation should display these
two types of data for the streams concerned, in a manner that facilitates easy
comparisons.
The easiest method of printing data for the individual streams is to go to the
relevant stream data window and follow the steps below.
Step 1 Open the relevant stream data window by double clicking the
stream.
Step 2 Left-click on the Copy Grid icon in the top centre portion of the
stream data window to copy the required data.
Step 3 Open Excel, select an appropriate position for the top left corner of
the data grid to be pasted and then press the Paste button to insert
the data.
Step 4 Repeat Steps 1 to 3 for all the other streams whose data you want to
print.
These steps also apply to any other window that contains data you would like
to print, such as equipment data. In this case you would double-click on the
equipment item rather than on a stream to open the appropriate window.
Once these data have been inserted into an Excel spreadsheet, just use the Excel
facilities for setting out and printing a report.
The The Configurable Stream Overview window provides a convenient means of
Configurable looking at experimental and model fitted data on the screen and enables the
Stream user to design the layout so that it only shows the data that is currently of
Overview interest and only for the streams that the user has selected. These overviews can
Window also be printed, using the Print Overview button located on the Configurable
Stream Overview window toolbar. For more information on using the
Configurable Stream Overview, see under the topic heading Viewing the Data -

Summaries and Reports 213 .

The Reporting The Reporting feature provides a means of printing both stream and equipment
Feature data. The user can configure the report to show experimental and fitted data,
SDs and errors for any streams. (See the section Using the Reporting Feature 226
for more information on the this feature).
Plotting The graphs presenting model fitting results are once again, of stream data. They
Graphs of the involve experimental (raw) data, and predicted (fitted) data. The graphs are
Model Fitting configured on the Configurable Graphing window, which is opened by pressing
Results the Config Graph button ( ).
Step 1 Left-click on the Config Graph button on the main JKSimMet toolbar
to bring the Configurable Graphing window into view.
Step 2 For this exercise, you will create a new graph so click on the New
button (circled in screen grab below). Note that the default setting for
the graphing facility will normally have some data pre-selected, so at
this point you can either adjust the settings for this graph or else
create a new one.
Step 3 When you click on the New button, a dialog will open where you
can type in a name for your graph and also specify the type of graph
you require. For the type there are only the two options; Equipment
or Stream. In this case we will create a graph showing the new feed
plus the cyclone products.
Step 4 Move the cursor to the top row (where the row heading is Stream).

Model Fitting 289
When you click on this cell, (which should initially contain the word
"None"), a drop-down list will appear with all the available streams
from your flowsheet. Select Cyclone Feed from this drop-down.
Once you have selected the stream, you will find that all of the
previously grey cells below the stream selection cell will now be
white and editable. In fact they all contain drop-down lists through
which you can select the type of data to be plotted and also set up
the characteristics of the display for this data set.
Step 5 Select Cum% Passing from the drop-down list in the Format cell,
immediately below the cell for stream selection. Leave the Display
cell on the default of Show. The option of Hide is available to provide
you with the ability to temporarily remove any of the data sets you
have configured for plotting on the current graph.
Step 6 The cell in the Data row allows you to select individual data types or
combinations of data types. Select Exp & Fit from the drop-down list
to compare your fitted results with the experimental data.
Step 7 Leave the display characteristics of Line, Point and Colour at their
default settings.
Step 8 You can then select Cyc U/F for the next column and Cyc O/F for the
third column.

Step 9 Note that when you have multiple columns set up, you can set all
the Format and Data fields to the same values using the drop-down
lists immediately above the tabulated data.
Step 10 Once the columns of the grid have been set up, you can view the
graph by simply switching from the Stream tab to the Graph tab.

Model Fitting 291
7.5.10 Problems Related to Model Fitting and Possible Solutions
There are of course many problems that may be encountered during model
fitting. It is possible, however, to point out some of the more common mistakes,
so that you are aware of them.
Errors, Warnings, Some problems detected by JKSimMet will produce error messages. Generally
Faults these error messages will have a description of the problem that has occurred.
Skill versus Model fitting is not a cut and dried procedure. The only way to acquire a
Practice useful skill level is to practice on a wide range of real data. JKSimMet offers a
user-friendly environment for what are really very complex and powerful
mathematical techniques.
Initial Parameter As with all non-linear least squares programs, Model Fitting is sensitive to
Estimates initial parameter estimates. The default values and the supplementary
information provide a useful guide. However, trial and error may be necessary
to find the best estimates to use with a new circuit or new data.
Graphical The graph capability of JKSimMet is the most powerful way to examine your
Analysis data fit. Discontinuities in size distributions highlight poor data or a change
in measurement technique. Graphical analysis also highlights any bias in the
data fit.
Different Size Be very careful of changes in size measurement technique, such as from sieves
Measurement to Cyclosizer.
Techniques
No Apparent When nothing much seems to be happening in model fitting, a simple first
Progress check is to ensure that you have a reasonable Maximum Number of Steps
setting, and that the streams and parameters that you intend to include in the
fitting are selected with a tick in the Parameters section of the Model Fitting
window.
Data Note that it is necessary to have as much feed and product data as possible for
each of the unit Models to be tuned. Simulation requires only feed data, but
fitting must have some product data as well.
Not Enough Data Even when you have the necessary data to perform model fitting, it is essential

to ensure that there are enough readings to be useful for fitting; in general
terms, the more data the better.
SDs and The SD settings in the stream data window may be set so that they can cause
Emphasis such an over-emphasis on one parameter that the potential of the fitting is
compromised. Always try to make the SDs as good an estimate as possible.
Scale Factors The Scale Factor in the Parameters section of the Model-Fit window can also
be a source of problems. If the scale factor is too big the fitting may stop,
because any adjustment in the parameter produces such a large change that it
steps over the minimum of the sum of squares. On the other hand, however, if
the scale factor is too small, the fitting may stop because any adjustment
produces a change of so small a scale as to be judged insignificant, even
though you may not be close to a minimum point. So, be very careful with
scale factors. As a guide, perhaps a scale factor one-tenth of the magnitude of
the parameter estimate would be a reasonable place to start.
Parameter The last chapter 294 contains model descriptions, default values and a section
Problems on fitting for each specific model. The comments contained in these sections
may help to overcome any misunderstandings or other problems you may
have with the model parameters.
Large Weighted Examine the weighted errors carefully. These often indicate suspicious data
Errors points. A typical example is a screen top size that contains several times the
predicted weight, because the laboratory screen stack did not extend to a large
enough top size. Set the error to missing for this fraction to fix the problem.
Knot Positions Where spline functions are used, the knot values can usually be fitted, but not
the knot positions.
These models provide a fairly smooth response because of the use of spline
functions. A simple guide to knot positioning is that knots should be selected
wherever a bend is needed. After all, the spline function is a mathematical
model of a draftsmans spline curve - a thin strip of steel with screw positions
which are equivalent to spline knots.
7.5.11 References
GY, P.M., 1982. Sampling of Particulate Materials: Theory and Practice, 2nd
Ed. Elsevier, Amsterdam.
LYMAN, G.J., 1986. Application of Gy's Sampling Theory to Coal,
International Journal of Mineral Processing, 17, pp 122.
LYNCH, A.J., 1977. Mineral Crushing and Grinding Circuits, (Elsevier,
Amsterdam).
NAPIER-MUNN, T.J., MORRELL, S., MORRISON, R.D., & KOJOVIC, T. 1996.
Mineral Comminution Circuits Their Operation and Optimisation. JKMRC
Monograph Series in Mining and Mineral Processing 2. Series Editor T.J.
Napier-Munn, Julius Kruttschnitt Mineral Research Centre, University of
Queensland.

Part
VIII
8 Model Descriptions
In this chapter, details are provided for all of the models that are available in
JKSimMet. The models are grouped and described under the major plant
section headings.
This chapter contains:
A description of each model available in JKSimMet
Instructions for the use of each model
Key equations that constitute the mathematical basis of the models
A list defining the symbols used in the model equations
Any known limitations and restrictions
Any relevant references where the user could go for further information
Typical model parameter values, where appropriate.
There are a number of generic models included in JKSimMet which can be
used to describe the behaviour of a wide range of processes. For example the
mass re-allocation model can be used to describe any sort of device in which
the ore feed properties are changed, such as a reagent addition point or a ball
mill. Selection of parameters for these models will depend entirely on the type
of process being modelled.
Most of the process units available to the user when drawing the flowsheet can
be described by a number of models. Typically, a process unit will have a
specific model, developed for that particular device, and a number of generic
models. Selection of the appropriate model is at the users discretion and will
often depend on the available test data.
8.1 General Models

General Models This topic contains a description of all the general process models available in
JKSimMet that do not fit in one of the more specific process type category
headings below.
The splitter models described here provide splitters of varying complexity,
from a simple mass split into two products (810) or into three products (870),
independent mass splits of solids and water (811) and a split generating a
specific volume flow rate to one of the products (812).
8.1.1 Ore Feeder (1300)

Ore Feeder The ore feeder (called Feed) is a specialized piece of equipment that has a
single product. The feed unit allows you to set up the flowsheet ore SG and the
starting size distribution.
The size markers, i.e. the percent passing a particular size and the size at a
particular percent passing, can be set by double clicking on those fields in the
Totals tab. Note that while the flowsheet properties dialog allows you to set
global properties for Data Information blocks and for the tools such as
Simulation and Model Fit, these properties for the feeder and ports may be set
at different values for each.

Model Descriptions 295
8.1.2 Water Feeder Models (1251 & 1252)
Water Feeder This topic contains a description of the Water Feeder models available.
Models
8.1.2.1 Model Description - General
Equipment The Water Feeder is specialized equipment that is the source of water
additions to a flowsheet. The Water Feeder is characterized by the fact that it
has no feed streams and one product stream that is made up of water only.
The Liquid Feeder replaces the "Unit Feed Density" section of each model in
JKSimMet Version 4. The three models provided with the Liquid Feeder are
functionally identical to the three options for "Unit Feed Density". The
functioning of these models is described below.
There are two ways in which the Water Feeder can be defined:
1. Water Feeder Required % Solids Standard.
2. Water Feeder Water Addition Standard.
These model choices are only available for the Water Feeder equipment.
After opening the Equipment window for the Water Feeder equipment, click on
the Equipment model drop down list to access these choices. Then click on the
double arrow button to the right of the drop down list to open the model
window pertaining to the selected model.
8.1.2.2 Required % Solids - Standard Model
Model Overview The Water Feeder Required % Solids Standard model is used when water is
to be added so that the stream percent solids feeding a piece of equipment
equals that specified by the user.
This option allows the user to set a maximum % solids for the total feed to the
connected equipment.
If the feed % solids is higher than the "Required % Solids" then the liquid
feeder adds additional liquid to achieve the required % solids.
If the % solids value is already lower than required, the liquid feeder adds no
liquid. It does NOT remove liquid to achieve the required value.
Model Data Input Double click on the appropriate field in the table and type in the required value
for the parameter:
Required Percent Solids (%)
During simulation, JKSimMet calculates:
New Water Addition (m3/h)
such that the percent solids of the combined streams flowing into the
equipment to which the water is added, equals that specified by the user. The
other values in the table are also calculated by JKSimMet during simulation
and relate to the combined stream that flows into the equipment:
Solids Flow (tph)
Water Flow (m3/h)
Percent Solids (%)
Version 6.0.1 - March 2014 General Models

Volume (m3/h)
If during simulation the new water addition calculated by JKSimMet would be
negative, the new water addition value will be set to zero.
A typical Required % Solids tab for the Water Feeder is shown below.
Water Feeder a typical Required % Solids Standard tab
8.1.2.3 Water Addition - Standard Model
Model Overview The Water Feeder Water Addition Standard model is used when a user
defined volume of water is to be added.
Liquid Addition is the recommended mode for common use. The user specifies
the required liquid addition rate in cubic metres per hour.
This option has two more uses. The experimental liquid addition may be used
as a parameter in model fitting. That is, a model fit may use liquid addition as a
parameter when liquid flows were not measured or the measurement was
dubious. The "exp Liquid Addition" is subject to optional update after the model
fit, as are all other parameters.
Note that % solids or water flow from the circuit should be constrained by a
small SD value to provide a constraint on total water addition.
The third use of this option is for mass balancing of liquid additions.
The user provides the "exp New Liquid Addition" and an SD estimate for this
model. The other requirement is that the Liquid Feeder and Liquid are selected
on the Select Tab of the Mass Balance Tool.
The balanced liquid addition is returned to the Calc* field of the Liquid Feeder.
If you wish to use this value for fitting or simulation, copy it into the appropriate
Exp value.
Model Data Double click on the appropriate field in the table and type in the required value
General Models Version 6.0.1 - March 2014

Input for the parameter:
New Water Addition (m3/h)

The other values in the table are calculated by JKSimMet during simulation and
relate to the combined stream that flows into the equipment unit to which the
water is added:
Solids Flow (tph)
Water Flow (m3/h)
Percent Solids (%)

Volume (m3/h)
A typical Water Addition tab for the Water Feeder is shown below.
Water Feeder a typical Water Addition Standard tab
8.1.2.4 Model Limitations
Two Water Feeders with the Required % Solids Standard model selected
cannot be used to add water to a single water addition point on a flowsheet.
This is because the Required % Solids model calculates the volumetric flow of
water to be added by taking into account the percent solids of all of the streams
that combine to flow into the equipment to which the water is added. If there
are two Water Feeders with the Required % Solids model adding water to one
equipment item, the amount of water added by each water feeder to obtain the
required percent solids of the combined equipment feed cannot be calculated.
8.1.2.5 References
No relevant references.

8.1.3 Hydrocyclone Models (200, 201)
Hydrocyclone This topic contains a description of the Hydrocyclone models 200 and 201.
Models (200 and
201)
8.1.3.1 Desciption
The model is based on the concept of a reduced efficiency curve, which in turn
is developed from the actual efficiency curve and the corrected efficiency curve
for the classifier treating a particular ore. The important concept is that the
reduced efficiency curve is a characteristic function of an ore and is
independent of the dimension or operating conditions of the cyclone. A
typical set of efficiency curves for a cyclone is shown in the first figure 298 of
the next section.
The model consists of a series of equations which are described below. At
least one cyclone test on a particular ore is required to provide data for the
calculation of constants in the equations.
8.1.3.2 Equations
The model consists of a series of equations, which are described below.

Pressure - The pressure-throughput relationship can be expressed as:
Throughput
Relationship Q = KQ2 Dc2 (P/ p
)0.5 (Do/Dc)0.68 (M200.1)
where
KQ2 = KQ1 (Di/Dc)0.45 ( )-0.1 (Lc/Dc)0.2 (M200.2)
The proportionality constant, KQ1 , is a function of the feed material and the
diameter of the cyclone. For cyclones of Krebs design, treating identical feed
solids, the dependence on cyclone diameter may be empirically represented by
the equation
KQ1 = KQ0 Dc-0.1 (M200.3)
where KQ0 depends on feed solids characteristics (eg. specific gravity) only.
Classification For normal industrial operation, the classification size can be related to the
Size variables according to the equation
Relationship
d50c/Dc = KD2 (Do/Dc)0.52 (Du/Dc)-0.47 0.93
(P/{ p
g Dc})-0.22 (M20
0.4)
where KD2 is related to the minor design variables Di, Lc and q by
KD2 = KD1 (Di/Dc)-0.5 (Lc/Dc)0.2 ( )0.15 (M200

.5)
and KD1 may be written as
KD1 = KD0 (Dc)-0.65 (M200

.6)
KD0 depends on feed solids characteristics only (such as size distribution and
specific gravity).
(Note that the classification sizes for specific minerals within the feed stream
can be estimated using the following formula:
where FeedSG is the mean feed solids density, d50c is the overall corrected d50 ,
MineralSG is the density of the specific mineral of interest, and d50c(m) is the
corrected d50 of the mineral of interest.)
Recovery to Water recovery (Rf) and volume pulp recovery (Rv) to underflow are related to
Underflow the major variables by:
Relationships
Rf = Kw2 (Do/Dc)-1.19 (Du/Dc)2.40 (P/{ p
g Dc})-0.53 ( )0.27 (M200.7)
and
Rv= Kv2 (Do/Dc)-0.94 (Du/Dc)1.83 (P/{ p

g Dc})-0.31 (M200.8)
Further, the effects of inlet diameter, cone angle and cylinder length have been
evaluated as
Kw2 = Kw1 (Di /Dc)-0.50 ( )-0.24 (Lc/Dc)0.22 (M200.9)
and
Kv2 = Kv1 (Di/Dc)-0.25 ( )-0.24 (Lc/Dc)0.22 (M200.10

)
Here Kw1 and Kv1 are constants also depending on feed solids characteristics.
The current data indicate that Kw1 and Kv1 are independent of cyclone
diameter for geometrically similar cyclones treating identical feed solids.
Small quantities of viscosity modifiers such as clay, can have a marked effect
on these variables.
Efficiency Curve The efficiency curve used in this model is given below:
Relationship
Eo(d/d50c) =
(M200.
C.(1+ . *.d/d50c) (exp( ) - 1)/(exp( . *d/d50c) + exp( ) - 2) 11)
When is 0, * is 1 the above equation reduces to
Eo(d/d50c) = C.(exp( ) - 1)/(exp( .d/d50c) + exp( ) - 2) (M200.12)
The shape parameter determines the initial rise, while determines the
slope at larger values of d (d d50c). Both and are normally constant for
given feed solids, while C and d50c vary with cyclone dimensions and
operating conditions. The parameter * is determined, for given values of
and , by the condition that

Eo.(1) = C/2 (M200.13)
* is calculated iteratively in the model.

The first two figures below show the effects of and on the shape of the
efficiency curve.
Modified An alternative to the standard efficiency curve is available with the
Efficiency Curve Nageswararao Fines hydrocyclone model.
With this model the user can specify the value of the reduced efficiency curve
(ie. fraction reporting to overflow) at 33% and 66% of the d50c size.
The curve is fixed (by definition) at the 100% point for zero size and at the
d50c. A cubic spline curve is used to describe the efficiency curve for sizes
below the d50c point. For sizes larger than the d50 , a log-normal distribution
curve is used. The log-normal curve is determined so that there is no
discontinuity in slope at the d50c point.
The third figure below shows how the modified efficiency curve works. The
user needs to specify (or model fit) the values of the curve at 33% and 66% of
the curve only.
The other parameters used by the model are used in the same way as the
standard Nageswararao model.
The Nageswararao-Fines model is useful for describing asymmetric efficiency
curves where a long 'tail' exists for either coarse or fine material.
Interactions The interactions of variables within a cyclone are complex. Refer to Summary
Table 305 section for a summary of interaction dependencies.
Scaling Facilities for scaling the operation of the hydrocyclone are built into the
model.
Figure M200.1 - Effect of Alpha on Reduced Efficiency Curve

Figure M200.2 - Effect of Beta on Reduced Efficiency Curve
Figure M200.3 - Efficiency Curve for Nageswararao-Fines Model
8.1.3.3 Symbols
Symbols Symbol Meaning

reduced efficiency curve sharpness parameter
reduced efficiency curve hook parameter
* reduced efficiency curve calculated parameter
C 100 - Rf or recovery of water to overflow, %
Dc cyclone diameter, m

Di diameter of circle with the same area as cyclone inlet, m
Do diameter of circle with the same area as vortex finder, m
Du diameter of circle with the same area as spigot, m
Eo (d) percentage of feed material of size d reporting to overflow
g gravitational acceleration
KD constant in the classification size relationship
KQ constant in the volume pulp recovery relationship
Kv constant in the volume pulp recovery relationship
Kw constant in the water recovery relationship
Lc length of cylindrical section, m
P feed pressure at inlet, kPa

Q cyclone throughput, m3/hr
Rf recovery of water to underflow, %
Rv volumetric recovery of feed pulp to underflow, %
d mean size of particle, mm

d 50c size of a particle in feed which has equal probability of going to
underflow or overflow, due to centrifugal action, mm
Cv volumetric fraction of solids in feed slurry
Cv Cv
p density of feed pulp, tonnes/m3

cone full angle, degrees
8.1.3.4 Restrictions
Restrictions As the feed becomes coarser, d50c tends to decrease even when all the other
variables are kept constant. The effect of size distribution of the feed
material becomes insignificant when the feed consists of mainly 53 mm
particles, and also when the proportion of 53 mm particles is less than
25% of the feed solids.
The analytical form used does not provide a perfect representation for the
reduced efficiency curve. As a result the model often tends to predict fewer
coarse particles in the overflow than occur in real operation, however, the
magnitude of the error is considered to be small.
Viscosity variations due to changes in pulp density are largely accounted
for by the model. Viscosity variations caused by variable quantities of
slimes affect the parameters in quite a systematic way.
As viscosity (or slimes fraction) increases, the cut size becomes coarser, the
water split to overflow is reduced, and the cyclone pressure drop becomes
larger. However, the reduced efficiency curve remains relatively constant
until the onset of roping.

The model may be used to estimate operation during roping:

o the cut size will become 5 to 10 times larger (ie. multiply KD0 by 5 to 10
times
o the efficiency curve will become an inefficiency curve with an value
typically of 0.1 - 0.2.
o water split and pressure drop are relatively unaffected although a small
drop in pressure is often claimed. This may result from a reduced
volume of solids to overflow.
The onset of cyclone roping is difficult to predict. In general 50% solids by
volume is a practical underflow limit. However, very coarse underflow may
achieve higher density and finer ones somewhat lower density as detailed
below.
JKSimMet will warn you that roping is likely if either of the density limits
(detailed below) are exceeded.
Cyclone Roping If the cyclone feed density is less than 35% solids by volume, the SPOC
Constraint constraint (Laguitton 1985) is claimed to predict onset of roping.
Vol % solids in U/F = Limiting Vol % solids (~56) + 0.2 (Vol % Solids in Feed -
20)
The limiting % solids is defined as the onset of roping at a volumetric feed
density of 20%.
In tabular form:
Table M200.1 - Cyclone Roping Conditions
at sg 2.7 at sg 4.0
Feed Underflo Feed Underflo Feed Underflow

Density w Density Density w Density Density Density
% by Volume % by Weight % by Weight
5 53 12.4 75.3 17.4 81.8
10 54 23.1 76.0 30.8 82.4
15 55 32.3 76.7 41.4 83.0
20 56 40.3 77.5 50.0 83.6
25 57 47.4 78.2 57.1 84.1
30 58 53.6 78.8 63.1 84.7
35 59 59.2 79.5 68.3 85.2
Empirical Industrial experience demonstrates that a coarse underflow will remain in

Constraint spray discharge at a higher density than a fine underflow. This is intuitively
reasonable in terms of slurry viscosity but difficult to predict.
Plitt et al (1987) have developed an empirical relationship based on Lynch
(1965) data and others.

Vol % Solids in U/F = 62.3 *
This approach puts a 50% solids by volume limit on an underflow with 50%
passing 100 m and 60% at a P50 of around 200 m. This function decreases
sharply with size dropping to 45% solids by volume at a P50 of 80 m and
40% at a P50 of 60 m.
In tabular form:
Table M200.2 - Cyclone Roping Conditions - Accounting for Coarseness
Roping onset Underflow % Solids % Solids

% Solids by Vol. 50% passing at sg 2.7 at sg 4.0
(mm)
35.2 50 59.4 68.5
39.0 60 63.3 71.9
45.9 80 69.6 77.2
50.5 100 73.4 80.3
53.9 120 75.9 82.4
58.6 170 79.3 85.0
60.0 200 80.2 85.7
61.3 250 81.0 86.4
The two effects are probably competitive to some degree. Further, each
operation has a 'comfort limit' on cyclone underflow density which may be a
good deal lower than the above limits.

8.1.3.5 Printouts
Nageswararao
(Model 200)
Nageswararao -
Fines (Model 201)
8.1.3.6 Summary
Summary of the Table M200.3 - Effects of Variables on Cyclone Operation

Effects of
Variables on Variable Resultant Effect on Parameter
Increased
Cyclone Q d R R
Operation 50c f v
Dc increase (0.57) increase (0.82) decrease (-0.4) decrease (-0.55)
Di increase (0.45) decrease (0.5) decrease (-0.5) decrease (-0.25)

Do increase (0.68) increase (0.52) decrease (-1/19) decrease (-0.94)
Du - decrease (-0.47) increase (2.4) increase (1.83)
Lc increase (0.2) increase (0.2) increase (0.22) increase (0.22)
p increase (0.5) decrease (-0.22) decrease (-0.53) decrease (-0.31)
- increase (0.93) increase (0.27) -
p decrease (-0.5) increase (0.22) increase (0.53) increase (0.31)
decrease (-0.1) increase (0.15) decrease (-0.24) decrease (-0.24)
Note: The numbers listed in brackets are exponents for dependence of the
parameter on the variable.
Examples of the effects of and on reduced efficiency curves are given in the
figures in the Model Equations 298 topic. The * parameters used in the model
are calculated.
8.1.3.7 Fitting the Cyclone Model (200)
Parameter Menu
Pressure Data If you wish to predict cyclone pressure accurately at other conditions you will
need at least one accurate pressure measurement and a set of at least two out
of three of the feed, underflow and overflow samples.
If pressure data are not available, an approximate pressure can be estimated
from the manufacturers published data.
The calculated pressure is used in the equations for classification size and
recovery to underflow. Hence, the cyclone pressure is an important
measurement.
The measured or assumed pressure data must be entered on the Performance
Data tab of the cyclone equipment data window. If an accuracy estimate is
available, use it to calculate the standard deviation. If not, use 10% of the
pressure value.
The capacity constant KQO can be calculated from the cyclone flow rate and
the cyclone dimensions. (Refer to equations M200.1-M200.3).
Typical values of KQO are in the range 300-600. The scale factor for fitting
should be 100.
To make the pressure observation available to the fitting calculation, it must
be selected with a tick on the Equipment Data tab of the Model Fit dialogue
window
Classification Equations M200.4 to M200.6 define the cut size. KDO is typically a small
Size (KDO) number - say 0.001 to .00001. Therefore, a scale factor of 0.0001 is usually
suitable.

Water Split % to The actual water split to overflow (Cal WS) is fitted rather than the two
O/F (Cal WS) parameters, KV1 and KW1 , which are defined by a single water split.
When model fitting a single set of cyclone data, ALWAYS fit Cal WS. A good
starting point is 50% with a scale factor of 5.
After fitting, the calculated values of KV1 and KW1 are displayed on the
cyclone equipment data window (Model Parameters tab).
Efficiency Curve The reduced efficiency curve is an "S" shaped function as shown in the figure
( and ) in the Model Equations 298 topic.
Typical values of range from 0.5 to 4. Beyond 5, the efficiency curves become
very sharp and larger numbers are not significant. A good initial estimate is
2.0.
The factor modifies the "S" curve to add an additional "hook" - or a negative
portion to the actual efficiency curve. A typical value is zero. However, a
poor fit at fine sizes can be tested by trying values of of 0.01 to 0.5. Fitting of
is available but not recommended. A scale factor of 0.1 is suitable once a
good initial estimate has been found by trial.
If the efficiency curve is a poor fit at coarse sizes, try the alternative fines
modified or spline efficiency curve models.
Master/Slave Multiple sets of cyclone data can be model-fitted using the Master/Slave
Fitting facility, with one important provision. The water split (Cal WS) cannot be
fitted using Master/Slave fitting.
Fit KD0 , KQ0 , and Cal WS for each data set independently, and determine the
average values of KV1 and KW1 for each cyclone data set from the fit. Use the
average values of KV1 and KW1 in each cyclone data set. Use Master/Slave to
fit KD0 , KQ0 , and (if required) , over all data sets.
8.1.3.8 Fitting the Nageswararao Fines Model (201)
Parameter Menu
The comments in the topic above apply equally to Model 201 except for the
Efficiency Curve parameters a and b which are replaced by Eff @ 0.33 (of d50c)
and Eff @ 0.66 (of d50c).
Typical values are 0.85 and 0.65 respectively.
8.1.3.9 References
DE KOOK, S.K., 1956, Symposium on recent developments in the use of

hydrocyclones - a review J. Chem. Metal. Min. Soc. S.Afr., Vol.
56:281-294.
KAVETSKY, A., 1979. Hydrocyclone modelling and scaling. JKMRC report to
AMIRA, November.

KELSALL, D.F., 1953. A further study of the hydraulic cyclone. Chem. Eng.,
Sci., Vol. 2:254-273.
LAGUITTON, D. (Ed), 1985. The SPOC Manual Simulated Processing of Ore
and Coal, CANMET EMR Canada, Ch. 5.1 (Part B).
LYNCH, A.J. 1965. The characteristics of hydrocyclones and their application
as control units in comminution circuits, AMIRA Progress Report
No. 6, University of Queensland (unpublished).
LYNCH, A.J. and RAO, T.C., 1965. Digital computer simulation of
comminution systems. Proc. 8th Comm. Min. Metall. Congr., Aust.,
N.Z., Vol. 6:597-606.
NAGESWARARAO, K., 1978. Further developments in the modelling and
scale-up of industrial hydrocyclones. Ph.D. Thesis (unpublished).
University of Queensland.
PLITT, L.R., FLINTOFF, B.C. and STUFFCO T.J., 1987. Roping in
hydrocyclones. 3rd International Conference on Hydrocyclones,
Oxford England, Elseveir, pp21-23.
YOSHIOKA, N. and HOTTA, Y., 1955. Liquid cyclone as a hydraulic
classifier. Chem. Eng. Jpn., Vol. 19:632-640.
8.1.4 Narasimha-Mainza Cyclone Model (221)
8.1.4.1 Description
Like the Nageswararao model, the Narasimha-Mainza model is based on the

concept of a reduced efficiency curve, which in turn is developed from the actual
efficiency curve and the corrected efficiency curve for the classifier treating a
particular ore.
The model consists of a series of equations which are described below. At least
one cyclone test on a particular ore is required to provide data for the
calculation of constants in the equations.
The form of the equations was given by Narasimha (2009). The exponents differ
slightly from those reported in his thesis, as the model has since been refitted
with a larger data set.
8.1.4.2 Equations
The model consists of a series of equations which are described below.

Pressure - The pressure-throughput relationship can be expressed as:
Throughput
Relationship

(
M
2
2
1
.
1
)
where
(M221.1)
The proportionality constant, KQ0 , is a function of the feed material and

depends on feed solids characteristics (e.g. specific gravity) only.
fv is the volume concentration of solids in the feed.
Classification For normal industrial operation, the classification size can be related to the
Size variables according to the equation
Relationship
(M22
1.3)
where:
(M22
and: 1.4)
(M22
f38 is the mass percentage of -38m particles in the feed.
1.5)

Recovery to Water recovery (Rf) to underflow is related to the major variables by:
Underflow
Relationships (
M
2
2
1
.
6
)
where:
and:
(
M
2
2
1
.
7
)
(
M
2
2
1
.
8
)
Efficiency Curve The efficiency curve used in this model is identical to that used in the
Relationship Nageswararao model
( equations M200.11, M200.12 and M200.13), but with the given by:

(
M
2
2
1
.
9
)
8.1.4.3 Symbols
Symbols Symbol Meaning

reduced efficiency curve hook parameter
C 100 - Rf or recovery of water to overflow, %
d mean size of particle, mm

d 50c size of a particle in feed which has equal probability of going
underflow or overflow, due to centrifugal action, mm
Dc cyclone diameter, m
Di diameter of circle with the same area as cyclone inlet, m
Do diameter of circle with the same area as vortex finder, m
Du diameter of circle with the same area as spigot, m
Eo (d) percentage of feed material of size d reporting to overflow
f38 mass percentage of -38 m particles in the feed

g gravitational acceleration
i angle of inclination of the cyclone, degrees
Kd0 constant in the classification size relationship
KQ0 constant in the volume pulp recovery relationship
K 0 constant in the relationship
Kw0 constant in the water recovery relationship
Lc length of cylindrical section, m

P feed pressure at inlet, kPa

Q cyclone throughput, m3/hr
Re Reynolds Number
density of feed fluid, tonnes/m3
f
density of feed pulp, tonnes/m3
p
density of feed solids, tonnes/m3
s
R recovery of water to underflow, %
f
cone full angle, degrees
Vi inlet velocity
8.1.4.4 Printout
Narashima-
Mainza
(Model 221)

8.1.4.5 Restrictions
Restrictions For the Nageswararao model, as the feed becomes coarser, d tends to
50c
decrease even when all the other variables are kept constant. The effect of size
distribution of the feed material becomes insignificant when the feed
consists of mainly 53 mm particles, and also when the proportion of 53 mm
particles is less than 25% of the feed solids.
For the Narasimha/Mainza model, it is not known if this effect exists.

However, it is likely that there is still a feed size effect on d .
50c
The analytic form used does not provide a perfect representation for the
reduced efficiency curve. As a result the model often tends to predict fewer
coarse particles in the overflow than occur in real operation, however, the
magnitude of the error is considered to be small.
Viscosity variations due to changes in pulp density are largely accounted

for by the model. Viscosity variations caused by variable quantities of
slimes are also accounted for by the model.
The model may be used to estimate operation during roping:
the cut size will become 5 to 10 times larger (i.e. multiply K by 5 to 10

D0
times
the efficiency curve will become an inefficiency curve with an a value

typically of 0.1 - 0.2.
water split and pressure drop are relatively unaffected although a small
drop in pressure is often claimed. This may result from a reduced volume
of solids to overflow.
The onset of cyclone roping is difficult to predict. In general 50% solids by

volume is a practical underflow limit for vertically mounted hydrocyclones.
However, very coarse underflow may achieve higher density and finer
ones somewhat lower density as detailed below. The Narasimha/Mainza
model does incorporate the effect of angle of inclination and this will affect
the roping point.
JKSimMet will warn you that roping is likely if either of the density limits
(detailed below) are exceeded.
Cyclone For vertically mounted hydrocyclones, if the cyclone feed density is less
Roping than 35% solids by volume, the SPOC constraint (Laguitton 1985) is claimed
to predict onset of roping. The effect of angle of inclination incorporated in
Constraint
the model is NOT included in this prediction of roping.
Vol % solids in U/F = Limiting Vol % solids (~56) + 0.2 (Vol % Solids in
Feed -20)
The limiting % solids is defined as the onset of roping at a volumetric feed
density of 20%.
In tabular form:
at sg 2.7 at sg 4.0

Feed Underf Feed Underfl Feed Underf

Den low Densit ow Densit low
sity Densit y Density y Densit
y y
% by Volume % by Weight % by Weight
5 53 12.4 75.3 17.4 81.8
10 54 23.1 76.0 30.8 82.4
15 55 32.3 76.7 41.4 83.0
20 56 40.3 77.5 50.0 83.6
25 57 47.4 78.2 57.1 84.1
30 58 53.6 78.8 63.1 84.7
35 59 59.2 79.5 68.3 85.2
Empirical Industrial experience demonstrates that a coarse underflow will remain in

Constraint spray discharge at a higher density than a fine underflow. This is
intuitively reasonable in terms of slurry viscosity but difficult to predict. The
effect of angle of inclination incorporated in the model is NOT included in
this prediction of roping.
Plitt et al (1987) have developed an empirical relationship based on Lynch

(1965) data and others.
Vol % Solids in U/F = 62.3

This approach puts a 50% solids by volume limit on an underflow with 50%
passing 100 m and 60% at a P50 of around 200 m. This function
decreases sharply with size dropping to 45% solids by volume at a P50 of 80
m and 40% at a P50 of 60 m.
In tabular form:
The two effects are probably competitive to some degree. Further, each
operation has a 'comfort limit' on cyclone underflow density which may be a
good deal lower than the above limits.

In preparing the Narasimha/Mainza model for inclusion in JKSimMet,

Co JKTech has conducted a series of comparisons with the older Nageswararao
mp model. In most cases, the responses to changes in operating variables are
aris similar between the two models. However, the effect of D on d is quite
i 50c
on different. The reason for the difference is that in Narasimha/Mainza, the
wit major effect of on D on d is in the calculation of Reynolds Number (Re)
i 50c
h
which depends on inlet velocity (Vi) which depends in turn on D .
Na i
ges Nageswararao does not consider Re, the effect of which is very strong in
wa Narasimha/Mainza and outweighs the direct effect of D which is similar in
i
rar both models. The validity of this major change in response is currently
ao being investigated by CFD modelling.
8.1.4.6 Summary
Summa
ry of the
effects
of
variable
s on
cyclone
operatio
n
Examples of the effects of a and b on reduced efficiency curves are given in the
attached Figures A2.1 and A2.2. The b* parameters used in the model are
calculated.
8.1.4.7 Fitting the Cyclone Model 221
Parameter
Menu

Pressure Data If you wish to predict cyclone pressure accurately at other conditions you will
need at least one accurate pressure measurement and a set of at least two out
of three of the feed, underflow and overflow samples.
If pressure data are not available, an approximate pressure can be estimated
from the manufacturers published data.
The measured or assumed pressure data must be entered on the Performance
Data tab of the cyclone equipment data window. If an accuracy estimate is
available, use it to calculate the standard deviation. If not, use 10% of the
pressure value.
The capacity constant K can be calculated from the cyclone flowrate and the
Q0
cyclone dimensions. (Refer to equations A2.14-A2.15).
Typical values of K are in the range 100 - 600. The scale factor for fitting
Q0
should be 100.
To make the pressure observation available to the fitting calculation, it must be

selected with a tick on the Equipment Data tab of the Model Fit dialog window
Classification Equations A2.16 to A2.18 define the cut size. KDO is typically a small number
Size (KDO) - say 0.001 to .05. Therefore, a scale factor of 0.001 is usually suitable.
Water Split % to Equations A2.19 to A2.21 define the recovery of water to the underflow. K
W0
U/F (KW0 ) is typically in the range 0.01 4.0. Therefore, a scale factor of 1.0 is usually
suitable. The model is particularly sensitive to this parameter so it may be
necessary to try several different starting estimates for model fitting to be
successful.
Efficiency Curve The reduced efficiency curve is an "S" shaped function as shown in the figure
( and ) M200.1.
Equation M221.9 defines the alpha parameter. Ka is typically in the range 1
0
to 80. Therefore, a scale factor of 1.0 is usually suitable.
Typical values of a a range from 0.5 to 4. Beyond 5, the efficiency curves

become very sharp and larger numbers are not significant. A good initial
estimate is 2.0. a is calculated from Equation M221.9.
The b factor modifies the "S" curve to add an additional "hook" - or a negative
portion to the actual efficiency curve. A typical value is zero. However, a poor
fit at fine sizes can be tested by trying values of b of 0.01 to 0.5. Fitting of b is
available but not recommended. A scale factor of 0.1 is suitable once a good
initial estimate has been found by trial.
If the efficiency curve is a poor fit at coarse sizes, try the alternative models.
Master/Slave Multiple sets of cyclone data can be model-fitted using the Master/Slave
Fitting facility.
Use Master/Slave to fit K , K , K K and (if required) b, over all data
D0 Q0 W0 a0
sets.

8.1.4.8 References
LAGUITTON, D. (Ed), 1985. The SPOC Manual Simulated

Processing of Ore and Coal, CANMET EMR Canada, Ch. 5.1 (Part
B).
NARASIMHA, M., 2009. Improved Computational And Empirical
Models Of Hydrocyclones, PhD Thesis, University of Queensland
(unpublished)
PLITT, L.R., FLINTOFF, B.C. and STUFFCO T.J., 1987. Roping in
hydrocyclones. 3rd International Conference on Hydrocyclones,
Oxford England, Elseveir, pp21-23.
8.1.5 Screen Models (215, 230 & 235)
Screen Models This topic contains a description of the various screening models.
8.1.5.1 Kavetsky Single Deck Screen Model (230)
Kavetsky Model This topic contains a description of the Kavetsky Single Deck Screen model.
8.1.5.1.1 Model Description
Mechanistically a screening process can be regarded as a series of trials, as a

result of which particles of a particular size have a probability of entering the
fine product. This concept of defining the screening efficiency in terms of a
number of trials (or bounces) is the basis for a screen model.
A typical efficiency curve for a vibrating screen is shown in the figure below.
There are three regions on the curve:
A Typical Efficiency Curve for a Vibrating Screen
the region describing the above-aperture size material (region A),

the region describing the below but near aperture size material in which the
probability of passing through the aperture is directly dependent on particle
size (region B),
the region describing the ultra-fines that adhere to the coarse particles (region
C).
Region B of the efficiency curve is the important region for modelling purposes,
and it can be described by the equation (Whiten and White 1977).
E(x) = exp[-TRN.fo.(1-x/d)k] (A3.1)
where E(x) is the fraction of particles in the feed of size x which enter the coarse
product, d is the screen aperture; fo the fraction open area, TRN is the efficiency
parameter and k is a minor parameter used for precise fitting purposes.
Typically, the value of k is about 2. The performance of the screen in region C
can only be determined experimentally since it will be dependent on local
conditions such as the moisture content of the ore which causes small particles
to adhere to large particles. For design purposes it is necessary to make a
reasonable assumption about the shape of the curve in region C and this
assumption is made by the design engineer based on knowledge of local
conditions.
The typical dependence of the efficiency parameter, TRN, which is analogous to
the number of trials, on the feed rate is shown in the figure below for different
materials used for the screen deck.
The dependence of the screen efficiency parameters on the feed rate for
rubber and steel decks
The explanation of the above figure is that when the feed rate to screens with
rubber decks is low the particles move independently, accumulate energy, take
large bounces and have little opportunity to pass through the screen aperture.
An increase in feed rate causes an increase in inter-particle collisions, reduction
in particle energy and bounce lengths, and an increase in number of trials.
Hence, the screen efficiency increases. A further increase in feed rate causes
more particle interference, a decrease in the number of trials due to particles not

reaching the screen surface, and a decrease in screening efficiency.

With steel screens, however, the coefficient of restitution is low and particles do
not accumulate energy. Particle bounces are small and high efficiencies occur at
low feed rates. As the feed rate increases the inter-particle interference increases
and this reduces the number of trials and the screening efficiency.
Model A better understanding is required of the relationship between particle shape,
Limitations aperture shape and screen efficiency, and also of screening performance in the
difficult area between dry and wet screening. The first is a problem of
optimization of existing screens, the second is a problem of plant operation.
8.1.5.1.2 Model Equations
Region B of the screen efficiency curve 317 is described by equation A3.1 318 .
E(x) = exp (- TRN * P/T) (A3.2)
where
P = fo*((1-fs) (1 - x/d)2 + fs*(1 - x/d))T (A3.3)
and
fs = 1 - (W/L) (A3.4)
In region A
E(x) = 1.0 (A3.5)
In region C an adjustment is made using the submesh factor (SF). This
adjustment transfers some of the submesh material in the undersize stream to
the submesh fraction of the oversize stream, that is to account for the small
particles that adhere to the larger ones.
The important operating parameter is feed rate per unit screen width (FW)
and this function is approximated by several straight lines as shown in Figure
A3.2.
The number of trials TRN is related to operating parameters by a set of
regression equations of the following form.
Ln(TRN) = A + B * FW + U * P1 + V * P2 (A3.6)
FW < FW1
Ln(TRN) = C + D * FW + U * P1 + V * P2 (A3.7)
FW1 < FW < FW2
where
C = A + (B-D) * FW1 by continuity (A3.8)
and
Ln(TRN) = C + D * FW2 + U * P1 + V * P2 (A3.9)
FW > FW2
SF is also related to operating parameters by a regression equation
SF = E + F * PSF + G * TSF (A3.10)
Fines Factor The fines factor is used to describe the "piggyback" effect of fines on coarse

material.
The material coarser than the "fines critical size" is considered in terms of its
notional surface area.
and SF* Area is the t/h of fines which are carried into the oversize product.
Moisture For damp ores, the behaviour of moisture can be very important. There are
Behaviour sometimes several kinds of moisture. The only one of interest to this model is
in the fines, that is, fractions finer than the "Moisture Split Critical Size XM".
All of the feed moisture is assumed to be carried in material finer than this
size. It is then allocated across the coarse and fine products in proportion
with how the material finer than XM is allocated.
Scaling The model allows scaling of screen length by linear scaling of the number of
trials parameter, TRN.
Scaling of screen width is accomplished within the normal model structure as
FW is feed rate per unit width.
Aperture, fraction open area and slot shape are also included as normal
model parameters.

8.1.5.1.3 Single Deck Model Printout
8.1.5.1.4 Symbols
Symbol Meaning
xi size of particles in the ith size fraction
E(x) fraction of particles in the feed of size x which enter the coarse
product
X1, X2 lower and upper screen sizes at fraction being considered
X3 a critical size - if required - close to screen aperture. However V
is usually zero
X4 sub-mesh screen size, i.e., the smallest sieve in the series
TRN efficiency parameter (number of bounces or trials)
fo fraction open area
T total area of screen
W width of apertures
L length of apertures
fs fraction slot = 1- (W/L)
d maximum size of particle than can pass through the screen, ie.

aperture size
FW solids feed rate/unit width of screen
P1 % of feed of size x such that X1 < x < X2
P2 % of feed < size X3
SF submesh factor
PSF % of feed < size X4
TSF tonnes/hour feed of size , X4
XF fines factor critical size
XM moisture split critical size
A Regression constant
B Regression constant
C Regression constant
D Regression constant
E Regression constant
F Regression constant
G Regression constant
U Regression constant
V Regression constant
8.1.5.1.5 Know n Restrictions
Accurate application of the screen model requires data from the screen to be
simulated for parameter fitting. For simulation of screens for which data are
not available, data for a similar screen type with similar feed may be used.
using data from operations with markedly different screens or feeds will not
provide useful results.
The same square root of two series of screen sizes should be used for both
fitting and simulation.
The regression equations of the screen model make it quite complex and more
difficult to handle than most JKSimMet models.
For most processing plants only the tonnage dependence is required. That is
the values of U and V can be left at zero. For wire mesh screens often equation
A3.5 is adequate on its own.
Where there are large variations in the fitted submesh factor (SF) try the
dependencies of equation A3.9 as detailed in Sub Mesh Factor Modelling.
However, a constant SF is often adequate.
In a situation where you really want to tune a screen and are prepared to
collect a lot of accurate data, contact JKTech for assistance with the parameter
and regression fitting.
8.1.5.1.6 Parameter Fitting the Screen Model
Parameter Menu

Ap Length
Ap Width
OA %
A int (TRN)
B*FW (TRN)
D*FW (TRN)
U*P1 (TRN)
U*P2 (TRN)
E int (FF)
F*PSF (FF)
G*PSF (FF)
XF
XM
The basic concept of a number of trials is quite simple. However, the extensive
correction factors and sectionalised curves make this quite a difficult model to
fit.
The model fitting program can process only one set of flowsheet data at a time.
However, one flowsheet may contain many measured sets of screen data.
Clearly, the flow rate and near size dependencies require several sets of data
to define the screen efficiency v feed rate curves 318 .
To describe any particular set of screen data, only a number of trials TRN
(parameter 22) and a submesh factor SF (parameter 23) need to be found.
Good initial estimates for these parameters are 5 and 0.1 respectively.
However, both TRN and SF are calculated variables in this model. Therefore,
we need to fit them as regression parameter A (Ln TRN) and regression
parameter E with FW1 set to a larger value than any anticipated screen feed
rates per unit of width and with B, V, U, D, F and G all set to zero.
Master/Slave Master/Slave model fitting allows the secondary dependencies on the
Fitting parameter menu to be established when multiple sets of data are available.
Setting up Master /Slave fitting is detailed in section 5.6.5.
Parameter dependencies are discussed in A3.7.
However, fitting of multiple data sets is complex and assistance from JKTech
consultants is strongly recommended if you intend to tackle this aspect of the
fitting process.
Aperture Length Where screen data do not provide precise aperture and wire dimensions, the
and Width screen aperture can be fitted to the data.
Note that for slotted screens, effective aperture length depends on the shape of
the particle because the size data are measured using square mesh screens.
Selection of Feed Screen performance can be affected by the feed size distribution. This is
Size Parameters usually a secondary dependence compared with feed rate. However the
X1 to X4 model does allow it to be incorporated. X1 and X2 are the upper and lower
sizes of a critical size fraction (or fractions). If a particular range of sizes in
your feed data is highly variable use X1 and X2 to bracket it.
Set X3 to the screen aperture; or the average screen aperture, if you are going to
fit several screen mesh sizes.
Set X4 to say - 2 or 3 times the submesh top size. The finer part of a size
distribution has most of the surface area and will tend to dominate surface

carryover.
Traditional screen design techniques relate a different fines factor to half of
the screen aperture. You can use X3 set to half the screen aperture to
approximate this dependence if there are large variations in fines in the feed.
Similarly, a traditional approach would use a near size dependence of
aperture size to half aperture size and X1-X2 can be set to estimate this
dependence.
8.1.5.1.7 Regression Model Parameters
Trials versus This is the important dependence.

Feedrate Fit each of the data sets available. This will give you a set of TRN values at
each fitted feed rate. You may also have a set of fractions between P1 and P2
at each TRN value.
The next step is to plot up (TRN) versus feedrate. Any graphing package eg
MS Excel, can be used. Select FW1 and FW2 to let you describe the curve
accurately in three sections. An alternative method is to print out your graph
(with a full grid) and rule on several line sections to suit. Their slopes and
intercepts will provide B and A and D and C respectively.
A multiple linear regression program can also be used - if you are adept with
such programs. Most spreadsheet programs (eg. Lotus, MS Excel) have built-
in multiple linear regression functions).
Critical Size If your Trials (TRN) versus feedrate data are erratic and your data are a good
Dependencies fit (less than 2 stream SD with Whiten weights), then it is worth trying P1 and
P2 dependencies.
Use a multiple linear regression program to fit ln (TRN) against feedrate, P1
and P2 and divide into separate data sets using your estimates of FW1 and
FW2.
You can impose the continuity constraint by correcting equations 6 and 8
ln(TRN) values by equation 7.
If you have a constrained non-linear fitting program which can handle
multiple equations, you can fit FW1 and FW2 as well. However, you will
need lots of good data.
Submesh Factor This is the other important dependence. For many operations, SF is small and
Modelling more or less constant. However, for operations with damp ore, it can be
crucial to a good model.
Once again, plot your best fit SF values against the calculated PSF and TSF
values from the parameter screens and draw a linear regression line against
any one variable. Print out the graph with a fine grid for this slope (for G) and
the intercept E. points.
Running the Input your estimated values back into the screen menu and import to each of
Screen Model your data sets. Try a simulation and check agreement on product streams.
Expect to make errors in this procedure the first few times.
Master/Slave For up to 10 data sets, Master/Slave fitting provides an excellent way of
Fitting estimating these dependencies for good data. You can add secondary
dependencies one at a time to test for a significant reduction in the sum of
squares.

Hint : Only the undersize and a flowrate is needed for a full screen fit.
8.1.5.1.8 References
WHITEN, W.J. and WHITE, M.E., 1977. Modelling and simulation of high
tonnage crushing plants, XII International Mineral Processing Congress,
Brazil, Volume II, 148-158.
WHITEN, W.J., 1984. Models and control techniques for crushing plants,
Control 84, Mineral/Metallurgical Processing, (Editor, J A Herbst), Publishers
- AIME, New York, 217-225.
8.1.5.2 Double Deck Screen Models (215 & 235)
The Double Deck Screen models (215 & 235) are simply two consecutive
applications of the Single Deck Screen models. Model 215 consists of
consecutive applications of the Simple Efficiency Curve Model (210) while
model 235 consists of consecutive applications of the Kavetsky Single Deck
Screen Model (230). The operation of the Kavetsky Single Deck Screen Model
is described fully in the previous topic.
8.1.6 Eff. Curves (210, 211, 212, 213, 203 & 240)
Efficiency These models (210, 211, 203) use simple efficiency curves to describe the
Curves operation of any classification device. For the filter model (240), the user
simply sets the U/F pulp density and the model redirects all the remaining
water out in the effluent stream.
8.1.6.1 Simple Efficiency Curve (210, 212)
Simple This topic contains a description of the Simple Efficiency Curve model.
Efficiency Curve
8.1.6.1.1 Model_Description
The model is simply an efficiency curve with a fixed d50c and a fixed water
split to fine product. Refer to the figures in the Hydrocyclone model
description 298 for efficiency curve shapes. A typical DSM screen has an
value of 4 and a value of zero.
The model can be used to approximate many classifiers. Therefore the default
parameter values should be used with caution.
Relationship Eo.(d/d50c) =
C.(1+( . *d/d50c)) (exp( ) - 1) / (exp( . *.d/d50c) + exp( ) - 2)
When is 0, * is 1 and the above equation reduces to:

Eo.(d/d50c) = C.(exp( ) - 1) / (exp( .d/d50c) + exp( ) - 2)
given feed solids. The parameter * is determined, for given values of and ,
by the condition that:
Eo(1) = C/2
* is calculated iteratively in the model. C is the fractional water split to the
fine product.
Scaling This form of the model does not permit scaling.
8.1.6.1.3 Fitting the Simple Efficiency Curve
Parameter Menu
This is a simple model to fit as it has no scaling capabilities. Fit the water
split, alpha and d50c. See the comments regarding fitting Beta in the cyclone
model description 306 .
For DSM Screens, initial estimates of 4 for alpha and 50% for the water split
should be adequate for most data sets. An initial d50c estimate of half of the
actual screen aperture is appropriate
8.1.6.1.4 Simple Efficiency Curve Printout
8.1.6.2 Simple Efficiency Curve - Water & Fines (211, 213)
Simple This topic contains a description of the Simple Efficiency Curve - Water &
Efficiency Curve Fines model.
- Water & Fines
8.1.6.2.1 Model Description
The model is also an efficiency curve with a fixed d50c as described above for
Model 210 with the added feature of allowing the fines and water splits to be
different.

Efficiency Curve The efficiency curve used in this model is the same as that described in A4.2.2
Relationship above except that C (fractional water split to fine product) is replaced in the
equations with a separate parameter F (fractional split of fines to fine
product):
Eo.(d/d50c) = F(1+( . *.d/d50c)) (exp() - 1) / (exp(*d/d50c) + exp( ) - 2)

Eo.(d/d50c) = F(exp( ) - 1) / (exp( .d/d50c) + exp( ) - 2)
The shape parameter determines the initial rise, while a determines the
given feed solids. The parameter * is determined, for given values of and , by
the condition that:
Eo.(1) = F/2
* is calculated iteratively in the model. F is the fractional fines split to the

fine product.
The water split is calculated directly from C, the fractional water split to fines
product.
8.1.6.2.3 Fitting the Simple Efficiency - Water & Fines
Parameter Menu
This also is a simple model to fit as it has no scaling capabilities. Fit the water
split, the fines split, alpha and d50c. See the comments regarding fitting Beta
in the cyclone model description 306 .

8.1.6.2.4 Simple Efficiency Curve (Model 211) Printout
8.1.6.3 Splined Efficiency Curve (Model 203)
Splined This topic contains a description of the Splined Efficiency Curve model.
Efficiency Curve
8.1.6.3.1 Splined Efficiency Curve (Model 203) Description
The model is also a simply an efficiency curve but the analytic form of the
curve used in Models 210 and 211 is replaced by a four knot spline curve.
8.1.6.3.2 Splined Efficiency Curve (Model 203) Equations
Efficiency Curve The efficiency curve in this model is provided by specifying four pairs of
Relationship coordinates through which a smooth curve (piecewise cubic spline function)
is constructed. Fine end of the curve is specified by the water split as in Model
210.
8.1.6.3.3 Fitting the Splined Efficiency Curve (203)
Parameter Menu
This also is a simple model to fit as it has no scaling capabilities. Fit the water
split and the four efficiency values at the knots on the spline curve. It is
important to remember to set the size values for the knots before attempting
model fitting.
Even though it seems incorrect, it is possible for the fitted efficiency values to
be greater than 1 or less than 0. Sometimes, model fitting arrives at values at
the ends of the curve which are outside the 0 1 range in order to achieve the
best shape for the curve inside the 0 1 range. This is due to the properties of

the spline curve for which the values at the ends of the curve have an effect on
the shape of the curve in the centre region.
The simulation model code truncates the efficiency values to be less than 1
and greater than 0.
The combination of these two features, control of the shape of the centre of the
curve and truncation at 0 and 1 ensures that the model predictions are
sensible.
8.1.6.3.4 Splined Efficiency Curve (Model 203) Printout
8.1.6.3.5 Symbols for Splined Efficiency Curve Model (203)
Symbol Meaning Equivalent JKSimMet

Parameter
Reduced efficiency curve

Alpha
sharpness parameter.
Reduced efficiency curve dip

Beta
parameter.
Parameter for describing the

* Beta*
reduced efficiency curve.
C Water split to fines product. WS%Fines
F Fines split to fines product FI%Fines
Size of particle in the feed which

d50c has equal probability of going to D50c
fine or coarse product.
8.1.6.3.6 Know n Restrictions
Range of Validity The highly simplified form of these models means that extrapolation away
from the conditions at which the parameters were determined will
significantly decrease the accuracy. If a wide range of data is available, it may
be possible to use Model 251 330 which has a variable cut point.

8.1.6.4 References
LYNCH, A. J., 1977, Mineral crushing and grinding circuits, (Elsevier,

Amsterdam), pp 124-126.
8.1.7 Eff. Curve Variable D50c (Model 251)
Efficiency Curve This chapter describes the Efficiency Curve Variable D50c model.
- Variable D50c
8.1.7.1 Model Description
This model is an extension of the Efficiency curve (Fixed D50c) model to

include a regression relationship for d50c. The water split to the fine product
remains fixed.
8.1.7.2 Model Equations
d50c For normal operation the classification size d50c can be related to the operating
Relationship variables according to the equation:
Log10 (d50c) = W * log10 (SW) + X * FW * C / 100 + Y * FPS + Z (A5.1
)
Relationship Eo.(d / d50c) = 100.C.(1+( . *.d / d50c)) (exp( ) - 1) / (A5.2)
(exp( . *.d/ d50c) + exp( ) - 2)

Eo.(d/d50c) = 100.C.(exp( ) - 1) / (exp( .d / d50c) + exp( ) - 2) (A5.3)
slope at larger values of d (d close to d50c). Both and are normally constant
for given feed solids. The parameter * is determined, for given values of
and , by the condition that:
Eo.(1) = 100.C / 2
* is calculated iteratively in the model.


8.1.7.3 Efficiency - Variable d50c (Model 251) Printouts
8.1.7.4 Symbols
Symbol Meaning
reduced efficiency curve dip parameter
W,X,Y,Z regression constants in the d50c equation
d50c size of particle in the feed which has equal probability of going
to fine or coarse product
C % water split to fine product
SW slot width (mm)
FW volume flow rate of water in the feed (m3)
FPS % solids in the feed
8.1.7.5 Known Restrictions
As Model 251 is based on a regression equation, extrapolation beyond the

scope of the data used in the regression will decrease accuracy significantly.
Effect of the Log The relationship between d50c and Slot Width is defined in Log space. This
Relationship means that the multiplier coefficient W will have a different effect for slot
widths less than and greater than 1.0 mm. For slot widths less than 1.0 mm a
multiplier greater than 1 will make the calculated d50c value smaller than the
slot width. However, for slot widths greater than 1.0 mm, the effect is
reversed.This can cause unexpected results when changing slot width.
Screen Wear DSM screens are sensitive to wire wear condition. The screens are usually
reversed on a regular basis. If possible, test data should record the wear
condition. If this is not possible, test at both new and worn to obtain a range
of likely operation.

8.1.7.6 Fitting
Parameter Menu
W * Slot
X * FPS
Y * FdWater
Z (int)
Sharpness
Dip
C
This is a simple model to fit as it has no scaling capabilities. Fit the water
split, and d50c. See the comments regarding fitting in the cyclone model
description (Appendix A2).
Initial estimates of 4 for a and 50% for the water split should be adequate for
most data sets.
An initial d50c estimate of half of the actual screen aperture is appropriate.
Multiple Data If the data cover a range of feed rates, feed percent solids, slot widths and
Sets screen widths, proceed as follows:
Fit each data set for a, C and d50 .
Refit with average a and C set constant. That is, force all the variation into
the cut size.
Use Master/Slave fitting to fit the separation size equation (A5.1) for W, X,
Y and Z.
Note: If the slot width does not have a strong effect on d50c, then the data are
very questionable.
8.1.7.7 References
LYNCH, A. J., 1977, Mineral crushing and grinding circuits, (Elsevier,

Amsterdam), pp 124-126.
8.1.8 Simple Combiner Model (800)
Simple This topic contains a description of the Simple Combiner model.

Combiner Model
Equipment The Simple Combiner model is available for selection for the Pump, Pump
Sump, Sump, Ball Mill, Tower Mill and Stockpile equipment. After opening the
Equipment window for the equipment, click on the Equipment model drop down
list to access the model options. Next click on the double arrow button to the
right of the drop down list to open the model window pertaining to the selected
model.
Model Overview For the Simple Combiner model, the mass in the particle classes of two or more
incoming feed streams is combined to produce the mass in the particle classes
in a single product stream of the combiner (Equation M800-1):

(M800-1)
The mass of water in the feed streams is also combined to produce the mass of
water in the Simple Combiner product stream.
Prerequisite There are no prerequisite system properties for this model for the Standard
System Properties input option, however the Volume output warning option requires the
Mineralogy system property to be added as a property in the particle class
definition table in Stream Specification.
Model Data Input The information required by JKSimMet to calculate the mass in a single product
stream using the Simple Combiner model is outlined below.
There are two options for the Simple Combiner model accessed via a drop
down menu on the screen:
1. Standard
2. Volume output warning
Standard Option The Standard model option requires no parameter input and has no prerequisite
stream properties, (see window below). The number of particle classes in all
feed and product streams is equal and the mass of a particular particle class is
conserved across the equipment unit.
Simple Combiner Model Standard Option

Volume Output The Volume output warning option alerts the user when the flow rate of the
Warning Option streams entering the combiner equipment exceed the volume capacity of the
equipment. When using this option, JKSimMet will report a warning to the
user at the completion of simulation when the Simple Combiner output flow
exceeds the Maximum Product Volume flow (m3 /hr) specified.
The Volume output warning option for the Simple Combiner model is shown
below.

Simple Combiner Model Example of Volume Output Warning Option
8.1.8.2 Symbols
Symbol Meaning
Mp feed stream s mass in particle class p in an incoming feed stream, s, to the
combiner
Mp product mass in particle class p in the single product stream of the

combiner
No relevant limitations.
8.1.8.4 References
8.1.9 2 Way Simple Splitter Model (810)
2 Way Simple This topic contains a description of the 2 Way Simple Splitter model.
Splitter Model
Equipment The 2 Way Simple Splitter model is available for selection for the 2 Product
Splitter, Hydrocyclone, Flotation Cell, Flotation Column and Jameson Cell.
After opening the Equipment window for the equipment, click on the Equipment
model drop down list to access the model options. Next click on the double
arrow button to the right of the drop down list to open the model window
pertaining to the selected model.

Model Overview The feed to this model is split into two streams with size distributions, particle
classes and pulp densities identical to the feed. The controlling parameter is
the Fraction Split to Top Product. The top product is the upper product on the
equipment icon and is marked with a T. The parameter range is 0.0 to 1.0.
The 2 Way Simple Splitter model in JKSimMet combines the mass in the
particle classes of the feed stream and splits this mass according to a defined
ratio into the particle classes of its product streams.
A splitter is characterized by the fact that its combined feed composition is
equivalent to the composition of each individual product stream, that is, the
ratio of particle classes in the feed and product streams is equal, and the total
mass in a particular particle class is conserved across the unit.
Prerequisite This model can be used regardless of the properties that have been added as
System Properties properties in the particle class definition table in Stream Specification.
Model Data Input The information required by JKSimMet to calculate the mass in each particle
class in each of the product streams using the 2 Way Simple Splitter model,
and the models used to perform these calculations, are outlined below.
The user defines the fraction of the feed stream split to the top product, .
Double click on the appropriate field to input the required value for Fraction split
to top product. This fraction is used during simulation to determine the mass in
each particle class in the product streams, Mpproduct stream 1 or 2 (Equations M810-1
and M810-2).
This ratio is used in a similar manner to determine the mass of water in the two
product streams.
(M810-1)
(M810
-2)
The 2 Way Simple Splitter model is shown below.

Example of 2 Way Simple Splitter Model
8.1.9.2 Symbols
Symbol Meaning
Mp feed stream s mass in each particle class in a feed stream s
Mp product stream mass in each particle class in a product stream
fraction of the feed stream split to the top product
This model makes no assumptions about the process used to separate. It is a

splitter only; the fraction split data must be entered by the user. There is no
relationship between feed or equipment unit conditions and the model output.
8.1.9.4 References
8.1.10 2 Way Volumetric Splitter Model (812)
2 Way This topic contains a description of the 2 Way Volumetric Splitter model.
Volumetric
Splitter Model
Equipment The 2 Way Volumetric Splitter model is available for selection for the 2 Product
Splitter, Flotation Cell, Flotation Column and Jameson Cell. After opening the
Equipment window for the equipment, click on the Equipment model drop down
list to access the model options. Next click on the double arrow button to the

right of the drop down list to open the model window pertaining to the selected
model.
Model Overview The feed to this model is split into two streams with size distributions and
particle classes identical to the feed. The controlling parameters are the
Fraction Split to Top Product (Water) and Fraction Split to Top Product
(Solids). The top product is the upper product on the equipment icon and is
marked with a T. The parameter range is 0.0 to 1.0.
The 2 Way Volumetric Splitter model in JKSimMet combines the volume in the
particle classes of any feed streams and splits this volume into the particle
classes of its product streams. Instead of entering a split ratio, in this model the
user defines the volumetric flow to the top product.
A splitter is characterized by the fact that its combined feed composition is
equivalent to the composition of each individual product stream, that is, the
ratio of particle classes in the feed and product streams is equal, and the total
mass in a particular particle class is conserved across the unit.
Prerequisite This model can only be used if the Mineralogy property has been added as a
System Properties property in the particle class definition table in Stream Specification.
Model Data Input The information required by JKSimMet to calculate the volume in each particle
class in each of the product streams using the 2 Way Volumetric Splitter model,
and the models used to perform these calculations, are outlined below.
The user defines the volumetric flow rate to the top product. Double click on
the appropriate field to input the required flow rate for Volumetric flow rate to top
product (m3 /h). This value is used during simulation to determine the volume in
each particle class in the product streams (see Equations M810-1 and M810-2
334 ), where the split ratio, , is equivalent to the defined top stream volume
flow divided by the stream volume flow in the combined feed streams. If the
defined top stream volume flow is greater than the combined feed stream
volume flow, JKSimMet sets the split ratio to 1.0.
This ratio is used in a similar manner to determine the mass of water in the two
product streams.
The 2 Way Volumetric Splitter model is shown below.

Example of 2 Way Volumetric Splitter Model
8.1.10.2 Symbols
Symbol Meaning
split ratio, equivalent to the user defined top stream volume
flow divided by the stream volume flow in the combined
feed streams

splitter only; the volumetric flow rate to the top product must be entered by the
user. There is no relationship between feed or equipment unit conditions and
the model output.
8.1.10.4 References
8.1.11 Water & Solids 2-Way Simple Splitter (813)
Water and Solids This topic contains a description of the Water and Solids 2-Way Simple
2-Way Simple Splitter model.
Splitter
Equipmen The Water and Solids 2 Way Simple Splitter model is available for selection for the
t DSM screen, 2 Product Splitter, Rake Classifier, Spiral Classifier, Spiral Separator,
Hydrocyclone, Flotation Cell and Flotation Column. After opening the Equipment
window for the equipment, click on the Equipment model drop down list to access the

model options. Next click on the double arrow button to the right of the drop down list
to open the model window pertaining to the selected model.
Model This model is a variation on the 2-way simple splitter model. The feed to this model is
Overview split into two streams with size distributions and particle classes identical to the feed
but the water in the feed is split in proportions different from the solids split to the two
products. The controlling parameters are the Fraction Split to Top Product (Solids) and
Fraction Split to top product (liquid). The top product is the upper product on the
equipment icon and is marked with a T. The parameter range is 0.0 to 1.0.
The water and solids 2 Way Simple Splitter model in JKSimMet combines the mass in
the particle classes of the feed stream and splits the solids mass according to a defined
ratio into the particle classes of its product streams and the liquid .. ratio.
Prerequisi This model can be used regardless of the properties that have been added as properties
te System in the particle class definition table in Stream Specification.
Properties
Model The information required by JKSimMet to calculate the mass in each particle class in
Data each of the product streams using the water and solids 2 Way Simple Splitter model,
Input and the models used to perform these calculations, are outlined below.
The user defines the fraction of the feed stream solids split to the top product, and
the feed stream liquid to the top product . Double click on the appropriate field to
input the required values for Fraction split to top product solids and liquid. These fractions
are used during simulation to determine the mass in each particle class in the product
streams, Mpproduct stream 1 or 2 (Equations M813-1 and M813-2) and the mass of liquid in
the product streams.
The liquid ratio is used in a similar manner to determine the mass of water in the two
product streams.
(M8
13-
1)
(
M
8
1
3
-
2
)

The Water and Solids 2 Way Simple Splitter model is shown below.
8.1.11.2 Symbols
Symbol Meaning
Mps feed stream s mass in each particle class in a feed stream s
Mps product stream mass in each particle class in a product stream
Mpl feed stream l liquid in feed stream s
Mplproduct stream liquid in product stream

8.1.11.4 References
8.1.12 3 Way Simple Splitter Model (870)
3 Way Simple This topic contains a description of the 3 Way Simple Splitter model.
Splitter Model

Equipment The 3 Way Simple Splitter model is available for selection for the 3 Product
Splitter equipment item. After opening the Equipment window for this item, click
on the Equipment model drop down list to access the model options. Next click
on the double arrow button to the right of the drop down list to open the model
window pertaining to the selected model.
Model Overview The feed to this model is split into three streams with size distributions, particle
classes and pulp densities identical to the feed. The controlling parameters are
the Fraction Split to Top Product and the Fraction Split to Bottom Product. The
top product is the upper product on the equipment icon and is marked with a
T. The parameter range is 0.0 to 1.0.
This model can be used regardless of the properties that have been added as
properties in the particle class definition table in Stream Specification.
Model Data Input The information required by JKSimMet to calculate the mass in each particle
class in each of the product streams using the 3 Way Simple Splitter model, and
the models used to perform these calculations, are outlined below.
The user defines the fraction of the feed stream split to the top product, top, and
the fraction of the stream split to the bottom product, bottom. Double click on the
appropriate fields to input the required values for:
Fraction split to top product
Fraction split to bottom product.
On data input, JKSimMet calculates:
Fraction split to middle product.
These fraction split ratios are used during simulation to determine the mass in
each particle class in the product streams (Equations M870-1, E870-2 and E870-
3).
The fraction split ratios are also used in a similar manner to determine the mass
of water in the three product streams.
(M870-1)
(M870-2)
(M870-
3)
The 3Way Simple Splitter model is shown below.

8.1.12.2 Symbols
Symbol Meaning
Mp feed stream mass in each particle class in an incoming feed stream
Mp product stream mass in each particle class in the product stream
top fraction of the feed stream split to the top product
bottom fraction of the feed stream split to the bottom product

8.1.12.4 References
8.2 Comminution Models

This section describes the various comminution circuit models and contains:
a description of each comminution model available in JKSimMet
key equations forming the mathematical basis of the models
known limitations and restrictions
some guidance and restrictions for parameter fitting

typical model parameter values, where appropriate

There are a number of generic models included in JKSimMet that can be used
to describe the behaviour of a wide range of processes. For example, the
simple efficiency curve model can be used to describe any sort of classification
device, such as a cyclone or a spiral classifier. Selection and fitting of
parameters for these models will depend entirely on the type of process being
modelled.
Most of the process units available to the user when drawing the flowsheet
can be described by a number of models. Typically, a process unit will have a
specific model, developed for that particular device, and a number of generic
models. Selection of the appropriate model is at the user's discretion and will
often depend on available test data.
Note that all model parameters have default values and a permitted range.
The default value and range can be viewed by double clicking on the
parameter value. These values are not currently editable by the User.
8.2.1 Crusher Models (400 and 405)
Crusher Models This chapter describes the crusher models.
8.2.1.1 Model Description (Anderson/Awachie/Whiten)
The crusher model considers the crushing process as two components:

the selection of particles for breakage, and
the breakage of the particles so selected.
Selection Clearly, whether or not a particle is selected will depend principally upon its
size relative to the closed-side setting (CSS) of the crusher and the extent of
choke feeding. The size distribution of the daughter products of breakage will
depend principally upon the initial size of the particle and upon its physical
properties.
New feed entering the crusher is classified (or selected). Some material,
predominantly the finer fraction, bypasses the breakage process entirely and
reports directly to the product. The remainder is broken, and the daughter
fragments are then recycled to the classification step. The new fine fraction
exits via the product, and the coarser material is re-broken.
Perfect Mixing If we think of a crusher as a stage-wise breakage process, then we can model it
Model in terms of a steady state balance.
Version 6.0.1 - March 2014 Comminution Models

Schematic Representation of the Crusher Model
A schematic representation of the crusher model is given in the above figure.

Mass balance equations may be written about each node as:
x = f + ACx (A6.1)
x = p + Cx (A6.2)
where x is a vector representing the amount in each size fraction in the crusher
f is the feed size distribution vector

p is the product size distribution
vector
C is the classification function, a
diagonal matrix describing the
proportion of particles in each size
interval entering the crushing zone
A is the appearance function, a lower
triangular matrix giving the
relative distribution of each size
fraction after breakage.
Combining (A6.1) and (A6.2) results in the Whiten crusher model equation:
p = ( I - C ) * ( I - AC ) -1 * f (A6.3)
where I is the unit matrix.

Since the feed and product are expressed as size distributions, and the
properties of the internal classification and breakage mechanisms are
expressed with respect to particle size intervals or mean sizes, it is convenient
to represent these quantities as vectors and matrices respectively.
Since f is known and p is the desired output, the problem resolves itself into
obtaining estimates of C and A for a particular machine and feed material.
These values can then be manipulated by simulation to explore the effects of
changing machine parameters, material characteristics or operating conditions
upon the product size distribution.
An important limiting factor in crusher operation is the power drawn by the
machine. This model permits estimates of power draw to be made for a given
condition, so that the simulations can be constrained by power requirements
(by the user). The power draw can be normalised to experimental data or
estimated from data for similar crushers in the Supplementary Parameters
Comminution Models Version 6.0.1 - March 2014

Manual. Note: a single particle breakage test of the ore is required for either
type of power estimate.
p = (I - C) * (I - A * C)-1 * f
Selection Where C is the classification function (a diagonal matrix) and where C(x) is the
probability of selection for breakage of a particle of size x and is defined as:
C(x) = 1 (A6.4)
for x > K2
i.e. all particles are broken

C (x) = 1 - [ (K2 -x)/(K2 -K1 ) ] ^ K3 (A6.5)
for K1 < x < K2
C(x) = 0 (A6.6)
for x < K1
i.e. no particles are broken

(x = mean particle size)
An example of the classification functions is given in figure A6.2.
Classification Function, c
The model equations are developed by non-linear regression analysis of

survey data collected over a wide range of operating conditions, followed by
multiple linear regression of the fitted parameters against the operating
conditions. The general form of these relationships is:
K1 = A0 * Crusher gap - A1 * Throughput + A2 * Feed coarseness
K2 = B0 * Crusher gap - B1 * Throughput + B2 * Feed coarseness
K3 = C0 (generally held constant at a value of 2.3)
First For many crusher types performance can be estimated by setting K1 to the
Approximation closed side setting, K2 to the open side setting (or K1 plus eccentric throw).
Both K1 and K2 will decrease with particle interference as the crusher
throughput increases to choke feeding.

The breakage severity (t10) will also increase (see A6.6 and equation A6.11).
The model allows for inclusion of minor variables where more detailed data
are available The equations in the model are of the form:
K1 = A0 * CSS + A1 *TPH + A2 * F80 + A3 LLen + A4 (A6.7)
K2 = B0* CSS - B1 * TPH + B2 * F80 + B3 * LHr + B4 * ET + B5 (A6.8)
K3 = C0 (usually 2.3) (A6.9)
Where:
CSS Closed side setting
LLen Liner Length
ET Eccentric Throw
LHr Liner Hours
TPH Crusher Feed Rate
F80 Crusher Feed 80% passing size
P80 Crusher Product 80% passing size
Note that only closed side setting and crusher throw will normally be used.
The other relationships require a very detailed experimental database.
8.2.1.3 Ore Breakage Characterisation
Andersen The Andersen model uses the results of JK breakage testing of coarse particles
Breakage Model to predict both breakage and crusher power consumption. This model has
been extensively tested on cone crushers (mostly operating as secondary
crushers) over a broad range of ore types. When the model was developed,
only the pendulum device was available for single particle breakage tests.
However, the JK Drop Weight test is now used as it provides for a wider range
of energies and particle sizes.
The first step is to use the JK breakage test to characterise ore breakage over a
range of input and absorbed energies. The absorbed energy (per unit mass of
particle) is referred to as the specific comminution energy.
8.2.1.4 Breakage Distribution Parameter
A typical size distribution of product from the JK breakage tester is given in the
figure below. This product size distribution may be adequately described by a
one parameter (t) family of curves (Awachie (1983); Narayanan and Whiten
(1983)). The parameter t10 is defined as the cumulative percent passing one tenth
of the geometric mean size, Y, of the test particle. The parameter is shown in the
figure below, together with other tn values - t2 and t4,- which are defined in a
similar manner to t10. Using the tn values (n= 10, 2, 4, 25, 50 and 75), the whole
of the size distribution may be fully described.

Typical pendulum product size distribution
The tn values (n = 10, 2, 4, 25, 50 and 75) for the product size distributions for
nine pendulum tests on hard rock ores from four major crushing operations at
different sites were determined and a 'best-fit' spline curve was drawn through
all of the tn data using a JKMRC multiple spline regression package, MSR. This
breakage distribution information may be conveniently stored as a three
dimensional spline relationship between the breakage distribution parameter,
t10 ( a measure of the amount of breakage or reduction), the cumulative percent
passing a particular relative size, and the relative size, tn, of the particle being
broken. Using the t10 spline knots 10.0, 20.0 and 30.0, Table A.6.1 gives the
cumulative percent passing the relative sizes t75, t50, t25, t4, and t2 i.e. the
cumulative percent passing the Y/75 size (etc), where Y is the size of the original
particle being broken as shown in Figure A6.4. The distribution for any
intermediate value of t10 is determined by spline interpolation.
SIZE RELATIVE TO INITIAL SIZE
T75 T50 T25 T4 T2
Breakage Cumulative Percent Passing

Parameter t10
10.0 2.8 4.0 5.5 22.2 51.4
20.0 5.6 7.2 10.7 43.4 80.8
30.0 8.9 11.3 16.4 60.7 93.0
Appearance Function Data

The relationship between t10 and the remainder

of the product size distribution
8.2.1.5 Breakage Parameters
Breakage parameters can be established from regression analysis of the same

data as the classification equations.
t10 = D0 * Crusher Gap + D1 * Throughput D2 * Feed Size (F80) + D3 (A6.10
)
This equation shows the intuitively expected dependence on the crusher gap,
throughput and feed size distribution.
The "feed coarseness" factor is somewhat application dependent. That is, it
will be influenced by crusher liner profile and effective slope as well as closed
side setting and gap.
First Typical cone crusher operation for secondary and tertiary crushers will be at a
Approximation t10 of 15 to 20. For a lightly loaded crusher (size control on a primary jaw
crusher) will operate at a t10 of 5-10. A high reduction crusher (toothed roll or
choke fed tertiary) may achieve a t10 up to 25.
8.2.1.6 Crusher Power Predictions
Energy - Size The JK breakage test also provides important information on the specific
Reduction comminution energy (kWh/t) required for a fixed size reduction, quantified by
Relationship the breakage distribution parameter t10, for each particle size broken.
The specific comminution energy, Ecs, defined as the amount of energy

available for breakage, is derived as the energy absorbed from the drop weight
on impact. This energy has been found to have a linear relationship with the
breakage distribution parameter, t10, but is also dependent on the test particle
size. This relationship is ore-specific and is used to characterise ores and
compare the crushing energy requirements of different ores.
Figure A6.5 shows the energy - size - size reduction relationship derived from
a JK breakage test for a fine-grained, siliceous copper ore.

Energy size reduction relationship
This information as used in the crusher model program in the spline form is
tabulated below. The energy required for a given reduction increases with a
decrease in particle size.
In Model 400, provision is made for data for three particle sizes. In Model 405,
the matrix is extended to accept data for five particle sizes to match the data
available from the JKTech Drop Weight Test.
Reduction Particle size mm

parameter
t10 14.50 20.63 28.89
% Specific comminution energy kWh/t
10.0 0.35 0.30 0.25
20.0 0.80 0.70 0.50
30.0 1.2 1.0 0.80
Energy-Size Reduction Relationship (Spline Form) Model 400
Reduction Particle size mm

parameter
t10 14.50 20.63 28.89 41.10 57.80
% Specific comminution energy kWh/t
10.0 0.35 0.30 0.25 0.20 0.15
20.0 0.80 0.70 0.50 0.40 0.30
30.0 1.2 1.0 0.80 0.60 0.40

Energy-Size Reduction Relationship (Spline Form) Model 405

Power Prediction A power prediction method has been developed using energy size-reduction
Method information from the pendulum test (Andersen & NapierMunn, 1988) and is
also applicable to the Drop Weight test.
Using the ore-specific energy-size-reduction relationship from the pendulum
test, the breakage function, B the classification values Ci (from the parameter
fitting or model regression equations, the model calculates the total energy
required to reduce the feed size distribution to the product size distribution as
if all the feed was broken in the pendulum or drop weight testing device, i.e. it
defines the energy which would have been used by the breakage device to
achieve the same degree of breakage observed in the crusher. The sum of the
products of the amount of material selected for breakage in each size fraction,
Ci*xi (tonnes) (from equation (A6.3)), and the Ecs (kWh/t) for each size at the
breakage parameter value t10 (determined from the parameter fitting or model
regression equation (A6.11)), is the total comminution energy calculated by the
model, Pcalc (kWh).
This total model-calculated energy is then regressed against the actual power
draw observed during the plant surveys on a particular crusher using multiple
linear regression analysis, resulting in a simple equation of the form given
below.
Pobs = E1 * Pcalc + E2 (A6.11)
where Pobs is the observed crusher power draw (kW)

Pcalc is the model calculated comminution energy(kWh)
E1 is a constant dependent on the efficiency of the crusher
E2 is a constant of similar value to the 'no-load' power draw
The constant included in the regression equation adequately accounts for the
crusher machine power draw (the power required to overcome machine
frictional losses), or 'no-load' power draw as it is commonly termed. This 'no-
load' power appears to vary slightly with throughput and is a function of both
plant power factor and drive motor efficiency.
Feed rate (t/h) and feed coarseness are usually less significant variables and a
satisfactory model can be obtained by absorbing these effects into the constant
term. These variables are implicitly included in the pendulum power
calculation.
The power regressions developed may be used to predict the power
requirements of crushers operating on different ores after determining the
relationship between the breakage parameter, t10, test particle size, and the
specific comminution energy, Ecs, for the ore under investigation. The
pendulum test should be conducted on representative ore particles over the
range of the crusher feed size. Where a specific mathematical performance
model of the form of equations A6.7 to A6.10 has been developed from
extensive plant surveys, the power draw may then be predicted for different
operating conditions.
In a design situation, given the feed and the desired product size distributions,
the t10-size-Ecs relationship for the ore to be processed must be obtained from
the pendulum test and this information used in the model to calculate the total
comminution energy required. The crushing power requirements can then be

determined for a similar crusher from a power regression of the form of

equation A6.11 obtained from another site.
8.2.1.7 Crusher Model (400/405) Printout
8.2.1.8 Symbols
Symbol Meaning

f feed size distribution (vector)

p product size distribution (vector)
A appearance function (matrix)
C classification function (diagonal matrix)
I unit matrix
K1 size below which C = O
K2 size above which C = 1
K3 exponent in the equation for C
CSS closed side setting (mm)

TPH tonnes/hour feed
F80 coarseness of feed, e.g. 80% - 25.4mm
t10 breakage distribution factor
Pcalc total power consumed in size reduction using the pendulum (from
laboratory tests results)
Ai regression constant
Bi regression constant
Ci regression constant
Di regression constant
Ei regression constant
This is the most general of the crusher models developed at the JKMRC. It has
been extensively tested for large (7ft) cone crushers. The model provides an
excellent description for individual results for many types of crusher, e.g., jaw,
roll, toothed roll, hammer mill etc., but has not been extensively tested on these
other crusher types.
The feed coarseness relationships are usually based on scalped feed oversize
variations. They could well be different from variations in scalping screen
aperture. This interaction is a subject for continuing investigation.
For power calculations large particles are apparently softer (see Table A6.2).
The drop weight test is not suitable for particles of diameter larger than 63mm.
Hence, using specific comminution energies derived on smaller particles will
tend to overestimate required pendulum power.
There is also a physical flow limit for most types of crushers. For crushers
which cause a considerable increase in volume, this limit is important. Hence
for cone or 'Gyra disk' types, check the simulated flowrates against the design
tables for that type of crusher and the corresponding bowl and mantle.
Typical flowrates are available from standard references such as Mular and
Bhappu (1978), Chapter 11.
8.2.1.10 Fitting the Crusher Model
The model fitting subsystem only analyses one data set at a time. Hence the
actual parameters adjusted are the constant terms in each of the equations

A6.7, A6.8, A6.9 and A6.10.
That is, A4 for K1
B5 for K2
and D3 for t10
Parameter
Menu
There are two distinct levels of use of the crusher model. The different uses
require different fitting strategies.
Limited Data One data set allows a (somewhat approximate) estimate of product size for
small variations in closed side setting.
For one data set:
fit A4 and B5
with A0 = 1.0, and B0 = 2.0 and (for cone crushers) K3 = 2.3.
Set other A and B values to zero.

Similarly for the breakage function:
fit D3
D0, D1 and D2 are set to zero.

Note that one data set does not provide useful information about power
dependencies.
Extensive Data The model is much more useful with a range of data. This means 5 to 10 data
sets covering a range of crusher settings, feed rates and (if possible) feed sizes.
JKTech can undertake breakage tests to characterize an ore as shown in Figure
A6.3 and Table A6.1 and to determine the size single particle breakage/power
as shown in Figure A6.5 and Table A6.2.

HP Grinding Note that the value of K3 is generally 2.3 for cone, jaw and gyratory crushers
Rolls only. For other types of crushers, such as grinding rolls and hammer mills, it
(and Others) is advisable to fit K3 also, with 2.3 as a good initial estimate
8.2.1.11 Regression Modelling
The procedure is very similar to that for the screen model. Hence, an efficient
test program can be designed to gather screen and crusher data together.
Fit each test using only constant terms, A1 , with all of the other regression
terms set to zero.
Use the ore Specific Appearance and Power Data measured by JKTech, or use
the defaults (average of 4 ore types). Measured oretype data should give more
accurate results for breakage and are essential for realistic power estimates.
Each data set produces estimates of K1 , K2 , K3 and A and B.
Set K3 = 2.3
Use a multiple linear regression package to fit each estimate to the measured
variables. If any coefficients plus or minus their estimated errors bracket zero,
try a refit without that variable included. If the error of prediction improves
(i.e., gets smaller), omit the variable by setting its model coefficient to zero.
8.2.1.12 Model Testing
Import each feed and product into the model and simulate to check each set.
This is quite a complex model and it is not difficult to make errors.
If any data sets are seriously in error, try to track down the reason. Check the
calculated K1, K2, and t10 against your fitted estimates. When all else fails (or
much earlier, if you prefer), ask JKTech, who will be happy to assist.
As soon as you have reasonable parameter estimates, you may use Master/
Slave fitting on up to ten data sets at a time to test secondary crusher model
dependencies.
8.2.1.13 References
ANDERSEN, J. A., 1989. M.Sc. Thesis, University of Queensland,

(unpublished).
ANDERSEN, J.A. and NAPIER-MUNN, T.J., 1988. Power prediction for cone
crushers, Mill Operators' Conference, Cobar.
AWACHIE, S.F.A., 1983, Development of crusher models using laboratory
breakage data, PhD Thesis, University of Queensland.
MULAR A. L. & BHAPPU, R. B. 1978, Mineral Processing Plant Design.
WHITEN, W.J., 1984, Models and control techniques for crushing plants,
Control 84, Minl./ Metall.Process (Am.Inst.Min.Engrs. Annual Meet.,
Los Angeles, USA, February), 217-225.
8.2.2 Rod Mill Model (410)
Rod Mill Model This chapter describes the workings of the Rod Mill model.

The rod mill model is based on the concept of stages of breakage. A stage of
breakage has three components:
selection
appearance
classification.
That is, each stage is equivalent to breakage, screening and recirculation.
The mill is considered as a number of segments in order. Each segment is a
stage of breakage.
Diagrammatically a stage of breakage may be considered as:
A representation of the breakage process in a rod mill
Eliminating m and q by matrix algebra yields
pj = (I-C) . (A.S +I-S) . [I-C(AS+I-S)]-1 . fj

or
pj = X . fj
since AS and C are assumed constant for all stages.
Stages of If there are v stages of breakage in the mill then:
Breakage

p = (X) v f (A7.1)
or
p = XXX ... f for v times
Non-integer numbers of stages can only be calculated by interpolation.
Once A, S and C are known, any particular operating condition can be
represented by a value of v.
Feed Rate The key dependence is the variation of stages of breakage v with mill feed
rate F.
Experimentally:
F (v)1.5 = MC
where MC is the mill constant.
The mill constant can also be scaled as detailed later.
Appearance The default Appearance Function is the modified Rosin-Rammler equation:
Function
A(x,y) = (1-e-x/y)/(1-e-1 )
Where A(x,y) is the proportion after breakage of particles of initial size y
which are smaller than size x. The appearance A is made up of vectors of the
differences in x for the specified screen interval. For specific ores, JKTech can
measure the appearance function. A range of appearance functions for
various ores is given with the ball mill model description in Appendix A8.
Classification The classification function C is a diagonal matrix which provides a simple
Function classifier. Each diagonal element gives the proportion of that size fraction
returned to the breakage stage for rebreakage.
The usual values are (for a v2 size distribution)
1.0, 0.5, 0.25, 0.125, 0.063 and so on.
Hence, each stage of breakage in a rod mill will eliminate the top size fraction
from the product.
Selection Function The selection function, S is a diagonal matrix. It gives the proportions of
each size fractions which are selected for breakage.
S is represented by three parameters XC, SL and IN as shown in the figure
below, and is calculated by:
Si = SL * Size + IN for Size i > XC
Si = SL * XC + IN for Size i < XC
and limited if Si > 1.0 then Si = 1.0
and if Si < 0.0 then Si = 0.0
An example of a selection function is given in the figure below.

Graph of a rod mill selection function
Scaling The rod mill model is scaled by modifying the mill constant according to
dimensions and operating conditions described below:
Mill Size FACTA = (DSIM /DFIT )2.5 * LSIM /LFIT
These scale factors only apply for rod mills with normal length to diameter
ratios, that is, 1.2 < simulated L/D < 1.6 and L 7m.
Media Load Load Fraction (i.e. volume of mill occupied by charge and media at rest after
grinding out)
FACTB = [(1 - LFSIM ) * LFSIM ] / [(1 - LFFIT ) * LFFIT ]
Note 30% < LF < 45%

Critical Speed Fraction Critical Speed
FACTC = CSSIM /CSFIT
Note 50% < CS < 80%

These factors are applied to the Mill Constant MC of the original mill to
estimate the mill constant of the simulated mill.
MCSIM = MC * FACTA * FACTB * FACTC
The required number of stages of breakage is
VSIM = (MCSIM /FSIM )2/3
Feed Size Coarseness of feed (90% passing size)

FACTD = ln (F90 FIT /F90 SIM ) / lnv2
VSIM = (MCSIM /FRSIM )2/3 + FACTD
Ore Hardness Work Index

FACTE = - 0.8 ln (WISIM /WIFIT )
FACTF = ln [(S(I)FIT /(1-S(I)FIT )] + FACTE

FACTG = exp (FACTF)

S(I)SIM = [FACTG/(1+FACTG)]
8.2.2.3 Rod Mill Model Printout
Rod Mill Printout Showing Default Values
8.2.2.4 Symbols
Symbol Meaning
f feed size distribution (vector)
p product size distribution (vector)

A appearance function (step matrix)

C classification function (diagonal matrix)
S selection function (diagonal matrix)
Si element of selection function S from size i
v number of stages of breakage of original mill
vSIM v for simulated mill
F90FIT 90% passing size for fitted mill feed
F90SIM 90% passing size for simulated mill feed
MCSIM mill constant for simulated mill
MC mill constant for original or fitted mill
SL slope of selection function
IN intercept of selection function
XC Size below which selection function is constant
DSIM diameter of simulated mill
DFIT diameter of fitted mill
LSIM length of simulated mill
LFIT length of fitted mill
LFSIM load fraction of simulated mill
LFFIT load fraction of fitted mill
CSSIM fraction critical speed of simulated mill
CSFIT fraction critical speed of fitted mill
WISIM work index of ore for simulated mill
WIFIT work index of ore for fitted mill
Note: The fitted mill is the rod mill which provided the
experimental data.
Scaling Note the restrictions for scaling in the section on Model Equations.
Change in Feed The number of stages of breakage is calculated from the feed solids mass
Pulp Density flow. No account is taken of water in the feed. It is assumed that rod mills
operate at 75 to 85 percent solids in the feed.
Effect of Feed There is some doubt about the adjustment of number of stages of breakage
Size according to feed coarseness. Data from some operations exhibit an effect
while data from others do not. If the particles are large enough and strong
enough to resist a rod impact, the dependence is reasonable.
The scaling effect can be eliminated from open circuit operation by setting
F90FIT (parameter 16) equal to F90SIM (parameter 80).
Mill Speed This dependence is reasonable from 50-80% of critical speed at industrial
mill feed rates.

8.2.2.6 Fitting the Rod Mill Model
Parameter
Menu
Because the rod mill model is dependent on feed conditions, it is difficult to

fit in closed circuit until the parameters are very good estimates. Therefore,
mass balance a closed circuit rod mill first. Then fit the discharge using the
mass balanced feed rate and sizing. (Use Whiten SDs for the product size
distribution). If an ore specific breakage function is available, it should be
used. the mill constant (MC) and the three selection function parameters can
be fitted.
For fitting, set the simulated and original mill dimensions etc. to the same
values.
Check the experimental feed 90% passing size and input it. Use a measured
work index if available - an approximate one if not.
This model is fussy about initial estimates and some trial and error may be
needed. These guidelines will help for many cases.
If you are new to the rod mill model use the rod mill example in Chapter 3
and graph the output to get a feel for how XC, SL and IN interact and change
the shape of the product curve.
Set XC to about half of the top size of the mill feed and MC to 2000. Assume a
selection value of 0.1 at XC and 1.0 at the feed top size. Calculate slope and
intercept to suit. Try a simulation with these values. If the product
distribution is approximately the right shape, (plot as cumulative percent
passing both simulated and experimental products) fit the rod mill constant.
If the shape is very different, increase the assumed selection value for a
steeper product slope and proceed when the slope is similar.
If the fitting program finds a reasonable minimum, - that is, the mill constant
error is less than 20% - change the MC estimate to the new value and fit the
slope. If the sum of squares decreases, update the SL guess to the fitted value
and fit XC and IN also.
8.2.2.7 References
LYNCH, A.J., 1977. Mineral crushing and grinding circuits, (Elsevier,

Amsterdam), 51-60.
8.2.3 Perfect Mixing Ball Mill (Model 420)
Perfect Mixing A new feature introduced with Version 5.2 was the extension of the ball mill
Ball Mill Model model to include a grate discharge option. Ball mill power is now calculated
for both overflow and grate discharge options (using the Morrell Power
Model) and is displayable in an information block.

This model considers a ball mill as a perfectly mixed tank with contents
described by a vector size distribution s.
The product vector p is produced by a discharge rate di for each size fraction,
where D is a diagonal matrix of rates, that is:
p = D*s (A8.1)
Within the mill, two factors control breakage. The first is the rate of selection
of each size for breakage. The second is the way in which the selected
particles are broken (or appear) in the mill contents.
Selected = R * s
where R is a diagonal matrix of rates.
Appearance = A * s
where A is a triangular matrix of breakage (appearance) functions
(distributions).
At steady state, the mill feed minus the material selected for breakage plus the
material from breakage minus the material discharged must equal zero. This
can be written as:
f - R*s + A*R*s - D*s = 0 (A8.2)
Discharge Rates For overflow mills and most of the operational range of grate discharge mills,
the discharge elements can be approximated by:
Di = Di* 4 * v / (d2 * l) (A8.3)
where Di* is close to unity

v is the total volumetric mill feed rate
d and l are mill diameter and length
A typical discharge function is given in Figure A8.1.
Typical graph of mill discharge function
Breakage Rates Breakage rates tend to increase rapidly with particle size, with the increase
tapering off at the feed top size.

Typical graph of breakage rate factor
Appearance The appearance function A is ore dependent, and can be measured using the
Function drop-weight testing technique developed at the JKMRC. A table of
appearance functions for a variety of ore types and the associated operating
work indices is given in section A8.7. The standard Broadbent-Calcott
appearance function is also included.
Considering equation 8.1 as the elements of each vector and matrix yields:
(
i A
fi - Ris i + A ij R js j - D is i = 0 8.
j=1 4
)
and:
pi = Dis i (A8.5)
Substituting for si yields:

i
A ij
fi - pi + j=1 pj- pi = 0 (A8.6)
Rj
Dj
where feed and product are related by R/D for a particular breakage function.
Equation A8.3 can be used to scale for feed rate and mill dimensions.
In general, the mill contents s is not known and it is not possible to separate
the R/D* ratio into its components. The R/D* function is represented
internally by a cubic spline function (that is, by a smooth curve). A number of
spline knots (generally between 2 and 4) on the 1n(R/D*) function are fitted.
Scaling Scaling of the ball mill model is achieved by modifying the fitted R/D*
function according to dimensions and operating conditions as described
below.
Mill Diameter The mill diameter d is scaled.

FACTA =
Note: This factor is in addition to a direct volume effect which is built into the
model.
Load Fraction The load fraction LF is the volume of mill occupied by charge and media at
rest when the load is ground out.
(1 - LFSIM ) . LFSIM
FACTB =
(1 - LFFIT ) . LFFIT
Fraction Critical Fraction critical speed is scaled by:
Speed
FACTC =
55% < CS < 78%

Work Index The Work Index is scaled by:
FACTD = 0.8
Ball Size Scaling By assuming that the reduction mechanisms of impact and attrition occur in a
ball mill, the following relationships can be derived from theoretical
considerations.
Impact breakage Db3
Attrition breakage 1/Db
where Db = ball top size diameter.
Impact breakage is assumed to predominate above a certain size xm whilst
attrition is the main reduction mechanism at sizes below xm. The size xm is
assumed to be equivalent to that at which maximum breakage occurs. Size xm
can be related to ball diameter as follows:
xm = K * Db2
where K is the maximum breakage rate factor.

The value of K has been found to be of the order of 4.4 E-04. K can be
calculated from the formula above if the value of xm is known. The graphing
facility within JKSimMet allows easy graphing of the breakage rates to
determine this value.
xm (fit) and xm (sim) are both calculated. The smaller of the two is denoted
xm (small) and the larger as xm (large) .
The above relationships are used to scale R/D* values at each spline knot to
account for ball size effects.
The scaling factor for ball size effects depends on the knot position size.
for knot position size < xm (small)

1
Db SIM Db FIT
FACTE
1 Db SIM
Db FIT
for knot position size xm (large)
2
Db SIM
FACTE
Db FIT
For knot positions between xm (small) and xm (large) linear interpolation is
used.
The effect of ball size is shown in the diagram below.
R/D* Relationship with Ball and Particle Size
Scaling These factors are applied to each fitted 1n (R/D*) knot as follows:
Calculation
R/D*SIM = R/D*FIT FACTA FACTB FACTC/FACTD FACTE
Scaling Using Where characteristic breakage functions have been measured (i.e. pendulum
Breakage tested) for both ores, these breakage functions may be used to predict
Functions performance. Note that it is not valid to scale this way from the default
breakage function.

8.2.3.3 Ball Mill Model Printout
Ball Mill Model Printout Showing Default Values
8.2.3.4 Symbols
Symbol Meaning
f feed size distribution vector
p product size distribution vector
s mill contents size distribution vector
A appearance function lower matrix
R breakage rate function diagonal matrix
D breakage discharge function diagonal matrix
D* normalised discharge function
R/D* SIM normalised R/D ratio for simulated mill
R/D* FIT normalised R/D ratio for fitted mill
dSIM diameter of simulated mill

d FIT diameter of fitted mill
LSIM length of simulated mill

v volume flow rate of feed
LFSIM load fraction of simulated mill
LFFIT load fraction of fitted mill
CSSIM fraction critical speed of simulated mill
CSFIT fraction critical speed of fitted mill
WISIM work index of ore for simulated mill
WIFIT work index of ore for fitted mill
Db ball diameter (top size)
DbSIM ball diameter for simulated mill (top size)
Db FIT ball diameter for fitted mill (top size)

K maximum breakage rate factor
Change in It is known that the coarse end of the R/D* function does vary with gross
Coarseness of changes in the amount of coarse material in the feed stream. As the amount of
Feed coarse material in the feed is decreased, the relevant R/D* values increase.
This limitation is not considered significant for changes of less than plus or
minus 50% in the amount of coarse material in the feed.
Critical Speed The critical speed dependence is approximately valid for 55-78% of critical
Range speed and incorrect outside of that range.
Predicting Rates If the ball mill model does not produce any of a coarse fraction (i.e. none in the
at 'Missing Sizes' mill discharge) then the effective rate of grinding is 'infinite'. One way to
overcome this problem is to size the mill contents and expand to the perfect
mixing model used for the SAG mill model.
This is usually not experimentally convenient. Some more practical
approaches are to:
Test the mill at maximum tonnage with coarse feed. If there is any coarse
material in the discharge, the actual rates can be estimated.
Use a set of rates and knot values from the supplementary information for a
similar mill feed sizing and fit with Work Index alone the first time.
Transfer the coarse rate values from calc to exp, return the Work Index to its
original value and refit the two smaller rates. This procedure should give
reasonable answers with a coarser feed. Work is proceeding on improving
the ball mill model in this area.
High Mill The perfect mixing mill model only takes account of pulp density variations
Viscosity or Pulp as variations in mill volume. Therefore, higher pulp density will always
Density predict higher grinding rates. In practice, the rates do improve until pulp
viscosity begins to interfere with ball action and rates decrease rapidly. This
onset is difficult to predict as it is highly ore type dependent. However,
effective mill operation of greater than 50% solids by volume is unlikely and
improbable at greater than 60% solids by volume.
Ball Size Scaling The ball size scaling relies on the R/D* function exhibiting a maximum. If
there is no maximum in the fitted R/D* function, increasing the ball size will
give optimistic results.
Wide Range Size The mill model assumes a constant breakage function for all size fractions.
Data This assumption simplifies the model but experimental evidence suggest
strongly that partial breakage increases in severity with decreasing size -
down to some limiting size. Therefore, if more than (say) twenty size fractions
are considered, an apparent minimum rate may be produced in the finer
ranges. This phenomenon is more likely to be an artefact of an incorrect
assumption than to have any physical significance. Research work continues
in this area.

8.2.3.6 Fitting the Perfect Mixing Ball Mill Model
Parameter
Menu
The ball mill model is well-behaved for model fitting. It can be fitted in closed
circuit with the cyclone model with generally better results than by fitting
each model to mass balanced data. Hence a good closed circuit fit will also
provide a good mass balance estimate of circulating load.
R/D* Spline Use three knots for normal grinding conditions and four knots for a wider
Knots than usual size range (such as SAG mill discharge or a very fine product).
Knot Positions To determine an appropriate set of knot positions divide the number of size
fractions covering the feed size distribution by the number of knots plus one.
This will give about equal log size spaces from both ends and between knots.
Knot Estimates Estimates for the function values at the knot positions are provided as ln(R/
D*) values. A simple ascending series provides a good first estimate, for
example:
0.5, 1.5, 2.5
Work Index, If you have several sets of data, use an operating Work Index for each
Load Fraction (calculated from mill feed rate, mill power, feed and product 80% passing
sizes). If the major variation is hardness only, then the average knots can be
used.
The calculated R/D* values are displayed on the unit data entry screen.
There should be a smooth increase with size. Sometimes the curve will have a
maximum at the coarse end. If there are any sudden changes or ups and
downs, try adjusting the knot positions.
There will often be a bump at a change in size measurement technique, such
as the transition from screen sizing to Cyclosizer sizing.
Systematic deviations can sometimes be removed by adjusting a knot towards
the largest deviation.
Graph When nothing else works, plot the experimental feed and product on a coarse
Cumulative scale (say 0-30%) percent retained against log size. If there are any large
Simulated and discontinuities, check your data very carefully, and repeat your sampling if
Experimental possible.
Product
Master/Slave The perfect mixing ball mill model is well suited to fitting of multiple data
Fitting sets. The ln(R/D*) knot values can be fitted simultaneously for a number of
surveys. Ensure that you use the same knot positions, and number of knots,
for each mill in your master/slave fitting test.
8.2.3.7 Table of Appearance Functions
This table shows ore-specific appearance function values determined from

single particle breakage tests using JK breakage testers pendulum or drop-
weight.

Ball milling circuits from which the samples were collected
Massiv Massiv Porphy Porphy Massive

Size e e ry Hard ry Soft Sulphid
Interval Sulphid Sulphid e Fine
(Cu) (Cu)
e e
(Pb-Zn)
Coarse
(Ni)
(Pb-Zn)
1 0.0591 0.0505 0.08586 0.05220 0.1128
2 0.1052 0.0974 0.1248 0.09919 0.1490
3 0.1318 0.1276 0.1387 0.1288 0.1497
4 0.1295 0.1278 0.1278 0.1284 0.1250
5 0.1127 0.1128 0.1076 0.1129 0.09885
6 0.0927 0.09469 0.08722 0.09423 0.07866
7 0.07486 0.07810 0.06960 0.07727 0.06289
8 0.06082 0.06428 0.05540 0.06339 0.04943
9 0.05005 0.05316 0.04428 0.05239 0.03842
10 0.04166 0.04424 0.03574 0.04364 0.03003
11 0.03462 0.03666 0.02899 0.03623 0.02376
12 0.02723 0.02880 0.02278 0.02847 0.01865
13 0.02054 0.02171 0.01743 0.02146 0.01448
14 0.01537 0.01623 0.01325 0.01604 0.01120
15 0.01144 0.01207 0.01004 0.01192 0.00864
16 0.00849 0.00894 0.00758 0.00883 0.00664

1
Operating Work Index
12.8 9.0 13.6 12.2 15.9
Ball milling circuits from which the samples were collected
Quartzit Porphy Massiv Massive Standar

Size e ry Soft e Sulphid d
Interval Sulphide Sulphid e Functio
USA
Low e n
(Pb, Zn,
Grade (Cu)
(Cu, Pb, Cu)
(Cu) Zn)

1 0.09514 0.0501 0.1171 0.1081 0.193

3
2 0.1322 0.0970 0.1537 0.1442 0.157
3 0.1417 0.1273 0.1522 0.1472 0.126
4 0.1267 0.1276 0.1247 0.1253 0.101
5 0.1049 0.1128 0.09723 0.1006 0.082
6 0.08477 0.0948 0.07685 0.08050 0.066

1
7 0.06778 0.0783 0.06131 0.06444 0.053

2
8 0.05371 0.0645 0.04810 0.05076 0.043

1
9 0.04244 0.0533 0.03729 0.03958 0.035

6
10 0.03379 0.0443 0.02911 0.03103 0.028

8
11 0.02709 0.0367 0.02303 0.02459 0.022

7
12 0.02127 0.0288 0.01810 0.01929 0.018

8
13 0.01637 0.0217 0.01407 0.01496 0.015

7
14 0.01254 0.0162 0.01089 0.01155 0.012

8
15 0.009565 0.0121 0.00841 0.00888 0.010

1 3 8
16 0.007279 0.0089 0.00648 0.00682 0.008

68 3 5
Operating Work Index
14.1 10.2 14.1 13.5
8.2.3.8 References
LYNCH, A.J., 1977. Mineral crushing and grinding circuits, (Elsevier,

Amsterdam), 309-312.
WHITEN, W.J., 1976. Ball mill simulation using small calculators, Proc.
Australas. Inst. Min. Metall., 258, 47-53.
MORRELL, S. 1992. Ball size effects in ball mills. Chapter 2, End of project

report, AMIRA/JKMRC Project P9J. "Simulation and Automatic

Control of Mineral Treatment Processes".
8.2.4 SAG Mill (Model 430)
AG and SAG This chapter contains a description of the AG and SAG Mill models.
Mill Models
The JKMRC has been involved in the development of a model of autogenous

and semi-autogenous grinding for many years. The first model to provide
useful predictions was the Leung model (Leung, 1987). It used ore-specific
breakage functions obtained off-line using a laboratory test procedure. It has
largely been superseded by the Variable Rates model( see Appendix 11).
However, because of its relative simplicity, the Leung model provides a good
introduction to SAG mill modelling.
Caution: The Leung model scales on volume. This is irrelevant for
optimisation but is important for scale up from pilot to full scale mills of more
than 8 to 9m in diameter.
The power model (Morrell, 1991) was added in 1992.
The Leung model has the general structure shown in Figure A9.1. The
appearance function has two components:
high energy corresponding to impact breakage, determined from the twin
pendulum single particle breakage apparatus, and
low energy corresponding to an abrasion mechanism, determined from
laboratory tumbling tests.
In both cases the functions are obtained off-line on representative samples of
ore and do not rely on being simultaneously back-fitted to operating data. The
energy levels at which the high energy appearance function is determined are
based on the mean energy in the mill, which is related to mill diameter.
Discharge rates are determined as the product of the rate at which the load is
presented to the grate, dmax, and the classification at the grate (which is
represented by a simple classification function). The model iterates to select a
value of dmax equal to the fraction of mill occupied by material of a size less
than the grate size, which in turn is assumed to be a simple power function of
feed rate expressed as a proportion of mill volume.
The model predicts product size distributions and mill loads from a known
feed size and tonnage for a given mill and feed ore. Ball charge is
incorporated through the assumption that balls are equivalent to mill load
particles of equal mass.
Average breakage rates are provided as defaults for both the autogenous and
SAG mill models. Note that these rates are different and are based on a
limited data set.
Usually, breakage rates will be model fitted to plant data.
Limitations / This model is a significant development of earlier models, and has been
Cautions shown to be successful in describing operating data on full scale autogenous

and SAG mills. Its scale-up capability is limited to mills up to 8 to 9m in

diameter from pilot mills of up to 2m. The dependency of the model
parameters on operating conditions such as mill speed, percent solids, grate
open area, liner characteristics and pulp rheology was not well established
when this model was developed. Most of these issues are addressed in the
Variable Rates model(A13)
The Leung model is based on data from mills operating at approximately 70%
of critical speed and 60-70% solids by weight in the feed.
Autogenous Mill Model Structure
8.2.4.2 Equations - Particle Breakage
Particle This description follows the structure shown in figure A9.1.

Breakage
The model assumes that each size fraction experiences only one energy level
of breakage. (The reality will certainly be a distribution of energy levels).
High Energy The relationship between the amount of breakage and the input energy is
Breakage described by
t10 = A (l - e - b Ecs ) (A9.1)
where t10 is the percentage of the broken particle which will pass through a
screen of one tenth the size of the original particle, and Ecs is the energy
absorbed per unit mass during breakage measured in kWh/t.
A and b are the parameters which characterize this equation for a particular
ore. A is usually taken as 50. Parameter b is derived from a drop-weight
breakage test of closely sized ore particles. Required sample size varies

according to ore variability. However, as a guide, about 50 kg of 50 mm

material is needed.
Low Energy One or more 3 kg samples of 50 mm natural ore are tumbled for 10 minutes in
Breakage a small dry mill at 70% of critical speed. The products of each run are sized
and t10 is measured for each run.
Where 50mm material is not available, other sizes are used and adjusted
using a simple linear model.
The t10 data are fitted to
t10 = a0 + a1 * mean size + a2 * sample mass + a3 * time. (A9.2

)
The actual value of the abrasion parameter ta is one tenth (scale factor only)
of t10 :
based on top size of 50 mm, mass 3 kg and time 10 minutes.

Low Energy The size distributions produced by ores tested to date have a similar shape.
Appearance This shape can be scaled to the ta factor that is the percentage passing one
Function - tenth of the original particle size.
Abrasion
A cubic spline function is used for smooth interpolation.
A 100mm particle is chosen as an example as particles of this size will
typically undergo abrasion rather than crushing breakage. Parameter ta is
taken as 1.0 to make the scaling obvious.
size (mm) % passing
t value scale* 100 100
t1.25 2.687*ta 80 2.687
t1.5 1.631*ta 67 1.631
t10 1.0*ta 10 1.0
t100 0.9372*ta 1 0.9372
t250 0.8070*ta 0.4 0.8070
t500 0.6365*ta 0.2 0.6365

The example shows that most of a 100 mm particle remains unbroken.
This value of t is assumed to be equal for all size fractions.
Breakage Energy As the charge provides the grinding media, the level of available energy is
related to the coarse fraction of the mill charge.
The average size of the top 20% of the charge is used as the highest energy
reference level.
1/11 (A9.3)
S20 = (p100 * p98 * p96 ... p80)
and the potential energy at the full height of the mill
E1 = 4/3 . . (S20 )3 g D (A9.4)

where D is mill diameter in metres. An assumption due to Austin et al (1984)

is used to relate other energy levels to E1. Austin et al provided a rationale for
energy levels in mills to be related by
E particle 1/(x)1.5 (A9.5)
where x is particle diameter.

Hence, the energies experienced by smaller sizes are scaled using this
relationship. This allows an Ecs to be calculated for each size and t
calculated from equation (A9.1).
High Energy Once the energy of breakage is known, the distribution the particle breaks
Appearance into can be described by a cubic spline surface.
Function
spline knots t = 0.0 10.0 30.0 50.0
(Crushing
Breakage) function values for
t2 0.0 50.53 92.49 96.47
t4 0.0 23.33 61.58 82.86
t10 0.0 10.00 30.00 50.00
t25 0.0 4.975 15.62 25.88
t50 0.0 3.064 9.412 14.71
t75 0.0 2.325 6.893 10.32

For example, for a 50 mm particle, a t of 30 would produce this distribution.
% passing Size (mm)
50 100
t2 25 92.49
t4 12.5 61.58
t10 5 30.00
t25 2 15.62
t50 1 9.412
t75 0.67 6.893

Combined As noted earlier, the abrasion distribution does not vary with particle size
Appearance while the crushing breakage is highly dependent on particle size.
Function
Hence, abrasion will tend to dominate for coarse particles and impact for
fine particles (from equation (A9.5)).
To generate an appearance function for each size fraction, the high and low
energy appearance functions are combined proportionally.
a = (tLE * aLE + tHE * aHE) / (tLE + tHE) (A9.6)

where
aLE and aHE = low and high energy appearance functions,
tLE and tHE = low and high energy t values
Equations (A9.1) to (A9.6) combined with the two tables of spline knots
yield a complete appearance function (that is how each component will
break) for each size in the mill load.
Breakage To predict a product from the mill contents and the appearance function
Rates requires only a rate of selection for breakage for each size fraction of the mill
load.
These rates will be inherently scaled because the mill load will be
constrained by mill dimensions and the mill diameter (if the energy versus
breakage assumptions are correct). These rates will certainly vary if mill
speed is changed but this dependence is not included in the Leung model.
To describe these rates, a five knot spline function is used.
Best fit values to data are tabulated.
Spline knots (mm) ln (Rate of ln (Rate of

Breakage) Breakage)
Autogenous SAG
0.250 2.63 2.176
4.00 4.04 4.444
16.0 3.32 3.577
44.8 1.98 2.753
128 3.37 4.082

These are the default values in each model.
These rates are fitted to customize the model to any particular operating
mill.
SAG Mill The ball charge is approximated by a distribution of equivalent weight
Modification particles added to the mill load for the high energy breakage calculation
(equation (A9.3)). That is, only the appearance function will be varied by
the addition of balls.
This completes the description of the Breakage area of the model.
8.2.4.3 Equations - Mass Transfer and Discharge
Classification The mill grate is modelled as a very simple classifier. When this model was
developed the relationship between the classification, discharge and the
operating conditions was not well defined. Hence, the classifier/discharge is
assumed to be constant- for other than minus grate size hold up. A simple
form is used.
D=1 x < xm (A9.7)
D = [ ln(x) - ln(xg) ] / [ ln(xm) - ln(xg) ] xg > x > xm

where xm is the particle size below which it will always pass through the
grate if presented to it - that is, behave like water. xg is the size of the grate
through which the largest particles will pass through.
Pebble Port Pebble port allows a small discharge rate of substantially coarser particles.
Modification This modification affects the classification curve as shown below.
Pebble Port Effect on Classification Curve
xp is the notional size of the pebble port
fp is the notional fraction open area of the pebble ports compared with the
fraction of grate open area.
Typical values for fp are 2 to 5% ie. 0.02 - 0.05. While this modification gives a
good description of pebble product, the areas are notional only and in fact
reflect relative discharge rates.
Discharge Rate The quantity of pulp discharged will depend on the quantity per unit time
presented to the grate multiplied by the classification function.
d = dmax * D
where dmax is the fraction of the load presented to the grate per unit time and
D is the classification function.
The water is assumed to follow the sub mesh particles.
The actual value of D is found iteratively.
The required value satisfies the following empirical mass transfer law
(Austin, 1976).
Mass Transfer The value of dmax is adjusted until the model prediction matches the required
"Law" one. That is, until it lies on the operating line of
L = m1 Fm2 (A9.9)
where
m1 = 0.37
m2 = 0.37
L is the fraction of the active volume of the mill occupied by minus grate size
material and F is the total volumetric feed rate per minute divided by the

active volume of the mill.

Perfect Mixing The perfect mixing model at steady state provides the structure to combine the
Mill Model various components of the model. It relates the different parts in the following
manner.
(
A
fi - ri s i + - di s i = 0 9.
1
0)
p i = di * s i (A9.11)
where fi, s i, ri, di and pi are feed rate, contents, breakage rates, discharge rates
and product rate vectors and a ij is the combined appearance function.
The form of equations (A9.10) and (A9.11) allows both the mill load and the
product to be calculated for any mill load and discharge rate adjusted until
equation (A9.9) is satisfied.
Calculation sequence:
1. Calculate breakage rates
2. Calculate volume of below grate size material in the mill, L
3. Calculate discharge rate
4. If error is acceptable exit else make correction to Dmax
Mill Load This model is unusual because it uses an internal port to describe the mill
contents. This port is accessible from the model properties drop down or from
the model window. It does not appear as stream equipment.
Scaling This model is inherently scaled for mill diameter and volume. This scaling
optimistic in capacity as mill diameter is increased. It is reasonable for mills of
up to 8 to 9 m diameter.
8.2.4.4 Prediction of AG/SAG Mill Power Draw
The Grinding The gross power draw of the mill is that drawn by the mill motor(s), ie metered
Mill Power power. It is assumed that this has two components, viz
net power, ie. the power delivered to the charge
no-load power, ie. the power to overcome drive train and bearing losses.
The gross power can, therefore, be represented by the following equation
Gross Power Draw = No-Load Power + Net Power (A9.12)
The gross power draw is calculated from the fraction critical speed, ball SG
and ball and rock porosity. These data are provided by the user. The
calculations use pulp load data generated by the model calculations.
The model data entry screen section for the power calculations include the
'net power adjustment factor'. This is a calibration constant which varies
slightly from mill to mill depending on mill liner configuration and other
factors.
Users are strongly recommended to leave this value set at 1.21. Other values

should not be used unless a comprehensive range of load vs power data are
available.
Net Power Draw From photographic evidence, the charge shapes shown in Figure A9.2 were
assumed to occur in grate discharge mills.
Simplified AG/SAG Mill Charge Shape
By considering an element in the charge of cross sectional area r ds d and

Len, the torque inertia of the element can be represented by the following
equation.
Torque Inertia of Element = g Len r2 cos d dr (A9.13)
Power can be defined in terms of torque ( ) and rotational rate (N) as follows:
Power = 2 N (A9.14)
For grate discharge mills, by integrating between the limits s
and T
and
between ri and rm the net power (Pnet) is given by:
rm S (A9.15)
2
Pnet = 2 gLen N r r cos d .dr
ri T
No-Load Power The no-load power draw (i.e. that drawn by the mill when completely empty),
is associated with various electrical and mechanical energy losses. The main
ones are motor, gearing and bearing losses. None of these are fixed over the
full mill operating range. Some, however, may have a fixed component. For
example, bearing losses due to friction will be dictated by the mill's dead
weight (though even this will vary as liners and lifters wear), and the mill
charge weight which will clearly vary with grinding condition.
To determine the relationship between no-load power and mill design
parameters, data from pilot and industrial mills ranging from 1.7 to 7.2 m in
diameter were analysed. However, these no-load powers are difficult to
measure precisely. The problems are power factor effects at low loads and
achieving a completely empty mill. The parameter Diam3Len N was

regressed against no load power and found to provide a good fit (Figure A9.3).
The relationship developed was as follows with N converted to the fraction of
control speed:
No Load Power (kW) = 2.62 (Diam2.5 Len )0.804

Hence, this equation estimates the likely indicated no-load power for an
installed mill.
Indicated vs Fitted No-Load Power
Power The most recent JKMRC database currently includes power data from 63
Calculation different mills. Details are shown in Table A9.1.
Accuracy
Ball Mills SAG AG Mills

Mills
Diameter (m) 0.85-5.34 1.80-9.59 1.8-9.50
Belly Length Inside Liners 1.52-8.84 0.59-7.95 0.59-5.18

(m)
Length/Diameter Ratio 1.00-1.83 0.33-1.50 0.33-1.0
Percent of Critical Speed (%) 60-83 48-89 72-75
Ball Filling (Vol %) 20-48 3-25 0
Total Filling (Vol %) 20-48 7-38 10-31
Specific Gravity of Ore 2.6-4.6 2.6-4.1 2.7-4.6
Number of Mills 38 20 5
Number of Data Sets 41 28 7
Power Draw (kW) 6.8-4100 14.8-7900 12.5-

5500

The power model has been applied to this database and was found to give
excellent results. The standard deviation of the relative error of the model was
calculated to be 6.5% for gross power..
The model therefore requires a knowledge only of mill dimensions and speed,
ball charge, volume occupied by balls and pulp, and the ore specific gravity.
Full details of the model are given in Morrell (1991).
Because of the industrial database, the prediction of gross power is the most
reliable.
Restrictions This power model assumes the SAG mill grate and pulp lifters do not limit
pulp throughput. For a large diameter mill (say > 7m) in closed circuit with
hydrocyclones or fine screens, this assumption may not be justified. A build
up of fine slurry in the mill will remove some of the charge imbalance and
reduce the actual power draw.

8.2.4.5 SAG Mill Printout
SAG Mill Printout

8.2.4.6 Symbols
Symbol Meaning
aij fraction of size j which breaks into size i
A Ecs model parameter

b Ecs model parameter
d max discharge rate at xm
di discharge rate of size i
fi feed rate of size i
Ecs Energy absorbed per unit mass during breakage in each size
fraction
E1 particle potential energy at full height of mill
F volumetric feed rate/mill volume

HE High Energy
LE Low Energy
L mill volume fraction of minus grate size
m1, m2 mass transfer parameters
si mill contents of size i
rj rate of breakage out of size j
S average size of top 20% of mill load

20
t10 percentage which passes through a screen aperture of 10%
of the original size.
tp percentage which will pass through a screen of aperture
original size /p
ta abrasion parameter
xi particle size
xg grate size (mm)
xm size below which all will pass through the grate (mm)
g gravitational constant
charge density
r radial position of element
angular position of the element
Nr rotational rate at a radial distance r
rm mill radius
ri charge surface radius (see Figure A9.2)
s angular position of the shoulder

r angular position of the toe

Diam mill diameter (m)
Len mill length (m)
fraction of critical speed.
The model is not valid outside a range of 55% to 75% solids by weight in the
feed.
Mill speed is assumed to be 70% of critical or close to it. However for small
changes in speed (~ 5%) a good approximation can be made by multiplying
the rate at each knot by the relative change. That is, for +5% (ie. 70% increased
to 73.5% critical) multiply by 1.05 or add ln (1.05) to the logarithm of the knot
value. This assumes the number of impacts per mill revolution will not
change. In reality more speed will give more lift and a slightly higher
breakage energy.
The classification model is very simple and only dependent on grate size. The
xm parameter is driven by slurry viscosity. For viscous ores, xm may be up to
1mm. For clean ores (hard rock, clay free) 0.1-0.2mm is typical.
This model has been tested against a large number of full-scale operations
and a very wide range of pilot plant test data. The model has provided good
predictions for design (Morrison, Kojovic and Morrell 1989) over a wide range
of ore types.
Detailed comparison with pilot plant data has highlighted areas where the
model assumptions are not a sufficiently good approximation. Known areas
to treat with caution are as follows.
The assumption that grinding rates are constant at a given ball load is not
true when
there are large variations in mill feed sizing
the mill is taken from open circuit to closed circuit.
Operating Limits The model is numerically stable at any mill load (equation (A9.9)). Real world
mills typically operate with maximum loads of 30 to 35% by volume of charge.
However, they may be limited by motor power at much lower loads. There is
usually a limit on ball load of 5 to 10% because of mechanical or power
constraints.
It is the engineer's responsibility to check these parameters against the limits
for a particular mill.
Feed Sizing The auto/SAG model 'forms its load' from the mill feed. If the mill feed size
distribution is smooth (ie. a reasonably straight line on a Rosin-Rammler
plot), simulated variations in feed sizing give sensible results. If the coarse
end of the feed distribution is artificially adjusted for the feed is preclassified
in some way, then the S20 assumption that the load can be treated as a single
number becomes unjustified. Hence artificially adjusted top sizes will cause
the model to predict wide variations in performance.
(While these variations are excessive, it should be noted that real auto mills
are also sensitive to feed top size).

Similarly, if those fractions that limit throughput (notional critical size) are
prescreened from mill feed, the model will be optimistic about increased
throughput.
(Once again, real SAG mills will also achieve much higher throughputs).
However, predictions for recycle crusher are quite realistic.
If mill operation is closed with a fine classifier (DSM screen or hydrocyclones)
there is usually an increase in the observed grinding rates at 4mm. This
means a typical SAG mill may have some 'free' grinding capacity for particles
a few millimetres in diameter. Where the simulated mill is operating in closed
circuit with a screen, the circulating load will tend to vary more (and the mill
load less) with changes in hardness and feed sizing than the real mill.
However trends will be correct and overall product sizing should be close.
Mill Power Accurate measurements or estimates of mill dimensions, speed and ball and
pulp load are required for the power calculation. Ensure that all data used
are accurate.
Ball Size Effects Ball effect is estimated by generating an equivalent load of ore particles. As
the top 20% of this load is used to find S20, only the top one or two ball sizes
can have any 'impact' on this calculation. Manipulating the finer ball sizes
(ie. < half top size) have very little effect. In practice, it does change the fine
grinding rates.
Ball Load Effects These have been investigated in some detail at pilot scale. In general, the
harder the ore (low b and low ta) the less the grinding rates are affected. A
soft ore however follows the accepted wisdom that increasing ball load will
produce a coarser product. This may well be because the increased number of
balls are now breaking the ore particles in the load which were doing the fine
grinding.
Discharge Rates Considerable work has been carried out by Morrell (1990) on factors affecting
discharge rates. These effects are also summarised in Morrell and Morrison
(1989). See A11 for details.
Overall, discharge rates will only become a limiting effect in very high
viscosity ores. In this case, operation at a lower pulp density is recommended.
The SAG mill is an effective pump and the charge will remain relatively 'dry'.
Mill Liner Effects The SAG mill model is valid for correctly designed traditional 'high/low' lifter
type action. Wave liners or short lifters do not provide enough lift to achieve
the default rates. If poor lift is combined with poor discharge, the mill only
produces abrasion with a very fine product at a correspondingly low
throughput.
Further The JKMRC now has a substantial database of SAG/auto mill surveys and
Developments breakage characteristics. This data base has been used to develop the wider
range variable rates AG/SAG model described in Appendix 11
Mill Load Limits The autogenous and SAG mill model does not include an explicit maximum
for the mill load. However, a warning will be flagged if the total load (ie. balls
and pulp) exceeds 40% by volume. If the total load exceeds 60% by volume an
error will be flagged and the model calculations will be stopped.
8.2.4.8 Fitting the Autogenous & SAG Mill Models
XG

XM
Rate 1
Rate 2
Rate 3
Rate 4
Rate 5
Parameter Menu
These models are complex and calculation intensive. However, any
computer which is suitable for MS Windows 95/98/NT should be
adequate for AG/SAG model fitting.
In the unlikely event that the fit is slow, the Select list may be used to
restrict the scope of calculation or to fix recycle streams as feed
streams.
Initial Values Use the grate width and 100 m as initial estimates for xg and xm.
The default breakage rates for auto and SAG will provide a good guess
for each knot value.
Ore Type Parameters For accurate results, these are best derived from tests carried out on
representative samples at JKTech.
For an existing operation, the values provided in the volume of
supplementary information provide some guide to possible values.
Mill Load If a reasonable estimate of load mass and sizing is available, then fitting
with a range of A and b values may provide a way of estimating these
values - that is - use the values which give the best fit for ratio work.
Mill Load is fitted by inputting it as raw data into the dummy product
stream. If you only have a total mill load estimate (eg. from bearing
pressure), set the size fraction SDs to zero and the load SDs
appropriately. Subtract the weight of balls from this load for a SAG mill
and input it on the model screen.
Closed Circuit If the mill is being operated in closed circuit with hydro-cyclones, it is
Operation better to reduce m1 from 0.37 to 0.25. This seems to provide a better
approximation of the mass transfer response for a large recirculation of
material finer than grate size.
Knot Positions The spline knot positions are better left where they are for the 'normal'
range of SAG mill feed sizings, 80mm < F80 < 250mm. However for very
fine auto mill feeds, the limiting size fraction will also be finer and it may
help to scale down all the knots. That is, reduce them by the same ratio.
An alternative is to simply fix the larger knots at their default values.
Hint: If the closed circuit simulation gives a very different circulating
load, check carefully for size biases in the fit or in the data itself.
Master/Slave Fitting The Master/Slave fitting can be used with multiple sets of SAG/auto
data. Ensure that you are using the same knots positions for each mill in
the test. Similarly, each survey data set to be fitted simultaneously
should have been collected with the same grate and pebble port size, and
ball load.

8.2.4.9 References
AUSTIN, L.G., LUCKIE, P.T. and KLIMPEL, R.R., 1984. The process
engineering of size reduction: Ball Milling, S.M.E/A.I.M.E., NEW
YORK: 561pp.
AUSTIN, L.G., WEYMONT, N.P., PRISBREY, K.A. & HOOVER, M., 1976.
Preliminary results on the modelling of autogenous grinding. 14th Int.
A.P.C.O.M. Conf. The Penn. State Uni.: 207-226pp.
LEUNG, K., 1987. An energy based ore specific model for autogenous and
semi-autogenous grinding. Ph.D. Thesis, unpublished, University of
Queensland.
LEUNG, K., MORRISON, R.D. and WHITEN, W.J., 1987. An energy based ore
specific model for autogenous and semi-autogenous grinding. Copper
87. Chilean Institute of Mining Engineers, Santiago, Chile.
MORRELL, S. 1990. Simulation of bauxite grinding in a semi-autogenous mill
and DSM screen circuit. MEng Thesis, University of Queensland
(unpublished).
MORRELL, S. and MORRISON R.D. 1989. Ore charge, ball load and material
flow effects on an energy based SAG mill model. SAG Conference,
University of British Columbia, Vancouver.
MORRELL, S., NAPIER-MUNN, T.J. and ANDERSEN, J. 1992. The prediction
of power draw in comminution machines. Comminution-Theory and
Practice, K. Kawatra (ed), SME, Chapter 17, pp. 235-247, 1992.
8.2.5 Size Converter Model (490)
Size Converter This chapter contains a description of the Size Converter model.
Model
8.2.5.1 Introduction
The model provides a product size distribution with a user specified P80. This
is achieved by adjusting the feed size distribution finer or coarser as required.
The model is useful when there is no process knowledge of upstream
comminution devices, or when a size distribution of a particular size is
required for sensitivity analysis.
8.2.5.2 Model Details
The feed to the model is adjusted by moving it sideways on a Cum % Passing

v size plot until the product P80 matches the specified P80 as closely as
possible.
8.2.5.3 Fitting the Size Converter
There are no fittable parameters in this model.

The model is limited in its ability to generate a product which is coarser than
the feed by the coarsest screen available in the feed combiner and product
ports. It is always wise to plot and inspect the graph of the feed and product
to ensure that the shape of the distribution is reasonable.
8.2.6 Variable Rates SAG Model (435)
Variable Rates This chapter contains a description of the Variable Rates SAG model.
SAG Model
The Leung AG/SAG model (A9) typically requires a full scale plant or pilot
mill survey combined with ore breakage testing to generate a set of grinding
rates. However research in the mid 1990s using a large database of pilot and
full scale milling tests has lead to the development of a correlation between
model grinding rates and mill operating conditions. A further correlation
between mill feed sizing and ore breakage characteristics has also been
developed. These two correlations now allow mill performance to be predicted
for a wide range of mill sizes and operating conditions. Hence the model can
be used to evaluate optimisation strategies in existing plants and to
investigate (and compare) grinding circuit configurations at the pre-feasibility
stage thus reducing the cost of pilot testing.
The underlying model is still identical with that developed by Leung et al
(1987) except that
grinding rates have been related to mill diameter and operating conditions,
and
A model that includes grate geometry (but does not incorporate pulp lifter
capacity) now describes slurry holdup.
This approach was reported by Morrell and Morrison, 1996.
If you are new to SAG mill modelling, it is strongly recommended that you
work through Appendix 9 (the Leung model) before attempting to use the
Variable Rates model.
The VR model interface has been slightly revised for Version 5 mostly to make
recycle effects easier to specify.
8.2.6.2 Scaling Approach
A large proportion of AG/SAG model users either carry out pilot scale tests
and wish to predict full scale operation or carry out full-scale tests and wish
to predict performance at different operating conditions. The variable rates
model has been implemented to facilitate this scaling process as in the rod
and ball mill models. The variations in rates also depend on recycle and feed
sizing. Hence, this model allows the user to select appropriate streams for
recycle data.
For model fitting, the original and simulated cases will usually be identical.
This is considered in detail in section A11.6.

8.2.6.3 Slurry Holdup Model
The transport of slurry through the mill is described by a function which

relates the hold-up of slurry, grate design, grate open area and mill speed to the
volumetric discharge rate through the grate (Morrell and Stephenson, 1996):
Jp = k Q 0.5 -1.25
A-0.5 0.67
D-0.25 (A11.1)
where
Jp fractional slurry hold-up
D mill diameter (m)

A total area of the grate apertures (m2 )
f fraction of critical speed
Q volumetric flowrate out of the mill (m3 /hr)
mean relative radial position of the grate apertures
ri ai
=
rm ai
ai open area of all holes at a radial position ri
rm radius of mill inside the liners
Classification by the grate is related to the effective grate aperture by a

simplified classification function. For illustrative purposes a conceptual view
of the weighted radius model is shown in Figure A11.1.
Weighted Radius For Two Grate Designs
8.2.6.4 Variable Rates Model
Relationships between the operating conditions and changes in the breakage

rate distributions within the JKMRCs pilot mill database (Mutambo, 1993)
were developed. These results were augmented with results from full-scale
mill data in cases where the pilot mill database contained little or no variation
in the parameter of interest e.g. mill speed. To indicate the extent of the pilot

mill database, Table A11.1 summarises its details.
Range
New Feed F80 (mm) 35-140
Ball load (%) 0-12
Recycle load (%) 0-500
No. different ores 16
No. tests 52
Pilot Mill Database Details

The breakage rate distribution is described within the model using cubic
splines (Ahlberg, 1967). This gives rise to five breakage rate values each of
which relate to a particular particle size and which together characterise the
entire breakage rate distribution. The five standard particle sizes chosen are
0.25, 4, 16, 44 and 128mm which have associated with them breakage rates
which are labelled R1, R2, R3, R4 and R5 respectively.
Characterisation of the Breakage Rate Distribution

These rate curves exhibit a characteristic shape. The coarser (R5 and R4) rates
relate to abrasive breakage while the finer rates R1 and R2 exhibit similar
characteristics to those of coarse ball milling, ie. predominantly impact
breakage. The pronounced dip in the rates at R3 is associated with the critical
size which may limit mill throughput by building up to excessive levels.
Typically it is in the 25-75mm range and varies with particular combinations
of feed sizing, breakage characteristics and the magnitude of the breakage
energy developed in the mill.
To determine the relationship between operating conditions and the breakage
rate distribution, the breakage rates R1-R5 were regressed against operating
conditions. The resultant equations were of the following form:

Ln (R1) = (k11 + k12 Ln(R2) - k13 Ln(R3) + JB (k14 - k15 F80) - DB )/Sb (A11.
2)
Ln (R2) = k21 + k22 Ln(R3) - k23 Ln(R4) - k24 F80 (A11.
3)
Ln (R3) = Sa + (k31 + k32 Ln(R4) - k33 Rr ) /Sb (A11.
4)
Ln (R4) = Sb(k41 + k42 Ln(R5) + JB (k43 - k44 F80 (A11.
5)
Ln (R5) = Sa +Sb(k51 +k52 F80 + JB (k53 -k54 F80) - 3DB ) (A11.
6)
where:
Sa rpm scaling factor
= Ln (simulated mill rpm/23.6)

Sb fraction of critical speed scaling factor
= simulated mill fraction of critical speed/0.75

DB ball diameter scaling factor
= Ln (simulated ball diameter/90)

JB % of total mill volume occupied by balls and associated voids
Rr recycle ratio
(tph recycled material_-20+4mm) /

(tph new feed + tph recycled material -20+4mm)
F80 80% passing size of new feed (mm)
kij regression coefficients
The regression coefficients for equations (A11.2) - (A11.6) are given below and
are based on the JKMRC current database at mid 1996. As more data are
collected and our understanding of the various factors increases, these
coefficients are likely to be modified.
j k1j k2j k3j k4j k5j

1 2.504 4.682 3.14 1.057 1.89
1 4
2 0.397 0.468 0.333
0.40 0.01
3 0.597 0.327 0.171
2 4
4 0.192 0.008 0.001
4.63 0.47
5 4
5 0.002 2 3
-- --
-- 0.00
2
--
--
Regression Coefficients

It can be seen from the equations that the finer size rates are functions of the
rates of the coarser sizes. Hence R1 is a function of R2 and R3 etc. The rates
can be considered as falling into 2 groups which represent the grinding media
and product size fractions. Hence the grinding media group contains the
rates R4 and R5 (related to particles >30mm) the magnitude of which affect
the throughput. The product group incorporates rates R1, R2 and R3 (related
to particles < 30mm) and the magnitude of these affects the final product size.
It is of particular note that the rates are interrelated in a complex manner and
are best understood by graphing the entire breakage rate distribution.
8.2.6.5 Effect of Key Parameters
The variable rate model allows the effects of a number of key parameters to be
considered independently.
It is worth mentioning that original does not provide a basis for scaling in
this model as it does in rod and ball mill models. It provides a marker to
allow the user to see how much the rates have varied from the original case.
Ball Load The effect of changing ball load on the breakage rate distribution is illustrated
in Figure A11.3.
Effect of Ball Load on Breakage Rate Distribution
The resulting relationship is as expected in that by increasing the ball load the
breakage rates increase at coarser sizes but reduce at finer sizes. This has the
effect of predicting higher throughputs at coarser grinds as the ball load is
increased. However, it is commonplace to operate at too high a ball charge
often because of historical experience with softer, oxidised, surface ore. As the
ore becomes harder it may well be possible to replace balls with ore as
grinding media for more power effective operation.

Makeup Ball No significant dependence of the breakage rates on ball size was found in the
Size pilot mill database. The sag model does account for ball size changes in terms
of the energy provided during impact. It does this by changing the mean
grinding media-size, which in turn changes the energy level of the mill. This
energy-level term is used to determine the specific energy of impact. As the
ball size is increased, therefore, the specific energy increases and hence for a
given impact event a finer product size distribution occurs. However, as the
ball size is increased the number of grinding media per tonne of charge will
decrease. As the breakage rate is related to the number of impacts provided by
the grinding media then a reduction in the breakage rate may be expected to
occur. To account for this a ball scaling factor is used. Figure A11.4
illustrates the effect of the ball size correction factor on the breakage rate
distribution.
It should be emphasised that it is usually argued that a coarser ball size will
give a higher throughput but with a coarser grind. In practice, experiments
with full-scale mills are sometimes inconclusive and mill operators see little or
no effect when experimenting with ball size. This may be due to the counter-
effect of reduced numbers of balls providing higher breakage energies when
increasing ball size. The model predicts such a response by increasing the
breakage energy and reducing the breakage rate. In some instances the one
effect may outweigh the other, in which case a response will be noted. Over
some ranges of ball sizes, however, little or no effect will be seen.
Predicted Effect of Changing Ball Size

Feed Size F80 The effect of F80 was found to be the most difficult one to evaluate as it
Effects for SAG interacted with the ball charge level. At relatively high ball charges (10% or
Milling more) high F80 values were detrimental as evidenced by the reduction in the
breakage rates illustrated in Figure A11.5.
Effect of F80 on Breakage Rate Distribution - (SAG mill)
Feed Size F80 However in the case of autogenous grinding the pattern is different. In this
Effects for case a higher F80 promotes breakage in the coarser size fractions (Figure
Autogenous A11.6). This is to be expected when it is considered that in autogenous
Milling milling large rocks are required to break ore in the R5 size range (128mm). As
the F80 increases, this will typically result in more coarse rocks in the charge
able to break R5-size ore and hence R5 will increase. In SAG mills running
with higher ball charges, the rock component of the grinding media plays a
lesser role in dictating the breakage rate and contributes more to the rock
burden which has to be ground down. Feeds with F80 values and hence
more coarse feed rocks, can thus be expected to reduce the breakage rate.
Caution needs to be exercised, however, as it has been found that the F80 is
not always a good indication of the feed size distribution. This is particularly
noticeable with autogenous mills whose performance may fluctuate
considerably yet maintain a reasonably constant F80. In such cases the
distribution changes systematically with performance and that typically
higher proportions of 25-50mm material in the feed result in lower feedrates,
ie. less sub-grate size material is present in the feed and more near size
material has to be broken.

Effect of F80 on Breakage Rate Distribution - (AG mill)
Effect of Recycle Recycle loads broadly fall into 2 categories viz.:

Load
1. Coarse recycles from trommels, vibrating screens and recycle crushers
which typically comprise only -20 + 4 mm material and have P80 values of
the order of 8 - 12mm,
2. Fine recycles from hydrocyclones and DSM screens which are
predominantly 4 mm material and have P80 values of the order of 0.2 - 0.5
mm.
It has been found that the amount of recycled material in the -20 + 4 mm size
range is inversely related to the amount of breakage that this material is
subjected to. This can be explained if one considers that these rocks are
broken by coarser rocks and balls whose frequency does not appreciably
change with changes in recycle load. However as the amount of recycled -20
+ 4 mm rock increases, the amount of this size material in the load will
increase. As the breakage rate in a given size class is related to the ratio of the
number of coarser rocks and balls to the number of rocks in the given size
class, then increasing the -20 + 4 mm recycle will result in a drop in the
breakage rate in this size range (R3 size = 16 mm). The changes in the
breakage rate distribution as the coarser recycle increases is illustrated in
Figure A11.7. Interestingly, recycle of fine material ie. 4 mm did not correlate
with any of the breakage rates. This may be related to the breakage mode of
this material which is believed to be dominated by attrition.
Where the material has been recycle crushed, it is considered to have similar
properties to new feed and is not included as -20 +4 mm recycle.

Effect of Recycle Load on Breakage Rate Distribution
Recycle Control For the most part, the Version 5 model is identical with the Variable Rates
in V5 SAG model in Version 4. There are, however, a couple of important
differences which relate to control of recycle of 20 +4mm material on the
grinding rates.
As for V4, the User inputs new feed rate tonnes per hour and 80% passing
size for Simulated and Original mills.
Recycle Options In Version 4, there are two implied switches.
The first is Fixed Recycle. If the User inputs a Fixed Recycle tonnage, all
simulations will use this value to calculate the recycle ratio.
Version 5 uses this implied switch as well i.e. the fixed recycle tonnage value
is set to zero to allow for simulated recycle.
The second implied switch in Version 4 is to select one (or more) recycle
streams from the flowsheet. In version 5, this switch is now explicit as Use
Recycle in Calculations. If this switch is set to one, the actual recycle is now
calculated by the model as the difference between 20 +4mm in new feed
(specified by the user) and in the total feed to the SAG mill.
Hence the User uses the Ore Feeder size marker to estimate % -20mm and % -
4mm and enters the difference into the appropriate field on the SAG model.
Comment. The effect of recycle has always been difficult to model and it also
the subject of current research. It provides some compensation for recycle
material survivors being likely to be somewhat harder than new feed
particles in the same size fraction.

However, if the recycle stream is crushed, new flaws will be generated and the
original feed properties retained. Therefore it is recommended that Use
Recycle . be turned off when a recycle crusher is used, with the following
note of caution. If K1 is larger than 4mm, a proportion of recycle crusher feed
will not be crushed. The bypassed 20 +4mm can be compensated for by
iteratively adding the new 20 +4mm in the crusher product to the new feed
% of 20 +4mm.
Excessive fine recycle may make this model unstable. However, excessive fine
recycle will often make real AG/SAG mills unstable and it a consequence of a
realistic model.
Mill Speed/Mill The breakage rate is related to the number of size reduction events per particle,
Diameter per unit time and is hence a frequency. This in turn must be related to the
frequency with which the mill rotates (rpm). A scaling factor is therefore
applied to account for changes in the rotational rate. For a given fraction of
critical speed the rpm decreases with mill diameter0.5 and hence this scaling
factor will also change with mill diameter. All else being equal, therefore, a
larger diameter mill will have a lower breakage rate than a smaller unit.
However it is pointed out that the JKMRC model inherently scales on the basis
of breakage energy which it relates to mill diameter. Therefore, whereas a
larger diameter mill will have a lower breakage rate it will have a higher
breakage energy.
In a given mill as the rpm changes, apart from the rotational rate, the shape of
the grinding charge will also change in line with the fraction of critical speed
(Morrell, 1996). Typically as the fraction of critical speed increases the charge
is subjected to increased lift and hence impact breakage is enhanced. It is at
the expense of attrition breakage which is normally associated with cascading
motion and which is prevalent at lower speeds. To account for these effects a
further scaling factor is applied which is based on the fraction of critical
speed. Figure A11.8 illustrates the predicted changes in the breakage rate
distribution as speed is changed.

Predicted Effect of Changing Speed on the Breakage Rate Distribution
Mill Power The variable rates model allows the user to specify the conical slope inside the
liners of each mill end. The mill power estimate includes the conical ends
(Morrell, 1996).
8.2.6.6 Parameter Fitting - Variable Rates Model
Parameters
Fitting Single Model fitting the variable rates model is quite similar to fitting the Leung
Data Sets model (A9). The defaults for the original mill grinding rates are all set to zero,
ie. the intercepts of the rate equations (Table A11.2) are included in the model.
Hence the fitted rates indicate how far the measured mill is operating from
typical conditions. The recommend strategy is to first fit xg and xm with
the grinding rate intercepts set to zero. If the mill has pebble ports, set the
initial pebble port size to the largest measured particle in the mill discharge. If

the xg and xm fit is plausible, add the pebble port size (PPSize). Use the
measured open areas for pebble ports and grates and the measured weighted
radius/mean relative radial position for the grates. Note that the grate open
area includes grates and pebble ports. The recycle streams are selected from
the unit menu.
The measured recycle rate (-20 +4 mm) should also be entered as data. (When
this field is zero, the calculated recycle is used. This is appropriate for
simulation).
The new feed size (F80) should be noted and entered for both Sim(ulated) and
Org(inal) mills as should all of the other measured mill data.
If the xg, xm and PP (pebble port) size fit is plausible, adjust the scale factors
on Breakage Rate Constants to 0.1 and include them in the next fit.
The open area fractions (Grate OA) can be selected to fit. They are only suited
to matching wear conditions and should not be fitted together with grate or
pebble port sizes as the parameters are likely to interact quite severely.
Given good data and ore characterisation this model will often predict the
measured results quite well and model fitting is very simple.
Remember xg, xm and PP size are all square mesh equivalent sizes.
Therefore, aperture shape and particle shape will interact. A slabby particle
will appear much larger to a square mesh screen than to a slotted grate
aperture!
Fitting Multiple A comprehensive pilot test program will produce data over a range of
Data Sets operational conditions. For sophisticated users, the variable rates model
allows several sets of pilot data to be analysed simultaneously.
The first step is to analyse each set by using its own select list. This should
identify any data problems. Then add each data set onto a combined select
list for master slave fitting.
One of the pilot data sets is selected as a base case. For this set, simulated and
original inputs are the same. For the other sets, change the simulated mill
conditions as required (eg. Ball load) and use the base case original mill
conditions in all tests. Add all of the measured load and product streams to
the model fit data list. Use the master/slave capability to simultaneously fit,
xg, xm, PPort size and grinding rate intercepts to all data sets at once.
Notes:
a fast computer (Pentium 166 or better) is required for three or more SAG
data sets
Multi-fit capability is not available in Version 5. However, the number of
fittable sets of port data will be expanded in later releases.
This approach can also be used to simultaneously analyse several sets of
operating plant data, even between different sizes of mills treating similar
ores.
In either case, a good overall fit indicates a model which can be used for
prediction over a wide range of operating conditions.
A poor overall fit, particularly if the grinding rates are lower than typical
(negative intercepts) may indicate shortcomings in data collection. More
seriously, it may also indicate more significant problems such as poor liner

design or inadequate pulp transport capacity (i.e. pulp lifters).

Larger rates may indicate particularly good practice or at the coarse knots,
decreasing ore competence at coarser sizes.
8.2.6.7 Variable Rates for Simulation & Design
This model is quite complex and a good appreciation of both the model and
SAG mill operations are recommended before use for design.
Comprehensive industrial research work over the last decade has built up the
database for this model and exposed some conceptual weaknesses which are
being addressed with two new models. However, the variable rates model is
now a powerful tool for data analysis, circuit evaluation and AG/SAG mill
design.
The following points should be noted.
Recycle Streams Up to three recycle streams can be selected from the model menu. These
should be recycles which actually go into the mill, eg. Recycle crusher
product, not feed. The Fixed Recycle input should be set to zero for
simulation to allow the calculated flow of -20 +4mm to be used. (Input the
measured flow for model fitting).
Where the material has been recycle crushed, it is considered to have similar
properties to new feed and is not included as -20 +4 mm recycle.
NB: V5 handles recycle loads differently from V4. See pages 106-107 for
details of the differences.
Load Limits The feed trunnion diameter indicates the maximum volumetric load limit. If
the simulated mill limits at a lower level than the actual mill, reduce this
diameter.
Beyond a certain load, the power model is unlikely to be reliable and the
power estimates are set to zero.
Grate Flow The flow correlation detailed in A11.3 provides a maximum flow estimate at
Limits (Mass the simulated mill load. The user may enter a design maximum load level for
Transfer Law) which a maximum flowrate estimate is also calculated. These estimates relate
to flow through the grate. They assume that the pulp lifters can remove all of
the grate discharge. This is not always true for mills operating in closed
circuit with cyclone or fine screens.
If the simulated flow exceeds the maximum, the mill will likely fill up with
fines and go into overload as the slurry pool reduces impact breakage. This
effect is not simulated by the model.
Feed Size The F80 values for new feed for both simulated and original mills are entered
Considerations by the user.
For design, a reasonable estimate of F80 is often difficult. Power based
equations typically divide by the feed size so the assumption becomes
unimportant but real mills are sensitive to feed sizing as are accurate models.
The JK database shows reasonably systematic dependence of AG/SAG F80
(crusher P80) with all hardness measures. The harder an ore, the coarser the
resulting crusher product at the same crusher closed side setting. The best
correlation is with the JK abrasion parameter ta.

For a design case, the F80 of the feed can be estimated from the measured ta
with a standard deviation of about 10% of the primary crusher closed side
setting.
F80 (mm) = { css - 78.7 - 28.4 ln (ta) } (A11.7)
s.d. = 0.1 css
This is not a perfect answer, as the size distribution slope also varies as
shown below.
Typical AG/SAG mill feed sizings
The size converter model (see Appendix A10) can be used to adjust from a
similar ore to the target range for simulation.
(Note that it is also possible to conduct a test in a pilot adit to estimate the
likely run of mine size distribution. This distribution can be fed to the crusher
model to predict the mill feed distribution. Contact JKTech for assistance with
test blast design.)
The Variable Rates SAG mill model now warns if the simulated void fill
fraction is >=1 and if the simulated load volume is more than 0.3% different
from the measured value
This model does not take account of the variation in breakage energy at
different mill loads. Therefore pilot and industrial operation should be
measured at realistic operating loads (ie. >20%). As noted earlier, pulp lifter
capacity may limit before maximum grate capacity is reached.
The single number grate characterisation (Mean relative radial position) is a
useful approximation. However, it should be used with actual grate designs,
not hypothetical variations which may not be able to be manufactured. As the
database of very large mills expands, it is becoming apparent that the charge
in a large coarse feed mill restricts the maximum circulating load. Hence for

mills 11m in diameter (or larger) treating coarse feed, the simulated circulating
load should be restricted to 25% of new feed rate. This can be done by
reducing the grate open area parameter. This is an area of continuing research
at JKMRC.
With the large database of SAG mill test work, it is clear that maximum
throughput does not always correspond to maximum mill power draw or
maximum mill load.
For hard ores, maximum throughput requires sufficient impact energy at the
toe of the charge. Hence the maximum throughput (at maximum discharge
coarseness) will often occur between 20 and 30% volume mill load.
Research at JKMRC is developing models which will account for this effect
and others such as the difficulty of removing pebbles for crushing from very
large mills. For mills of larger diameter than 10m, a maximum recycle crusher
flow of less than 25% of new feed rate is recommended as a constraint on
simulations. (Mills with very fine feed and large grates may exceed this
estimate)
Manipulating the SAG mill feed size distribution by pre-crushing is another
way of shifting the throughput/product relationship for hard ores.
A limitation has been found on the accuracy of the response of the rate
equations to changes in F80, particularly if the new feed F80 is outside the
range of the data base. The recommended F80 for use in the model is
calculated from the equation:
F80 = 71.3 28.4 * ln (ta)
This F80 value should be used as the Reference F80 value on the Recycles tab
in the Variable Rates SAG Model equipment window.
It has also been found that if the aperture of a grate is above 36 mm, then the
grate needs to be modelled as a series of pebble ports because modelling it as a
grate can lead to optimistic throughput predictions by JKSimMet.
As with model 430 there is not an explicit maximum for the mill load.
However, a warning will be flagged if the total load (ie. balls and pulp)
exceeds 40% by volume. If the total load exceeds 60% by volume an error will
be flagged and the model calculations will be stopped.

8.2.6.9 Variable Rates SAG Model Printout

8.2.6.10 References
Ahlberg J H, Nilson, E N & Walsh, J L, 1967. The Theory of Splines and Their
Applications. Mathematics in Science and Engineering, 38, Academic
Press, New York and London
Andersen J S, 1989. Development of a Cone Crusher Model. M.Eng.Sc Thesis,
University of Queensland.
Leung. K, Morrison R D & Whiten W J, 1987. 1987. An Energy Based Ore
Specific Model for Autogenous and Semi-autogenous Grinding Mills.
Copper 87, Santiago Chile.
Morrell, S. 1996. Power Draw of Wet Tumbling Mills and its Relationship to
Charge Dynamics. Part I: A Continuum Approach to Mathematical
Modelling of Mill Power Draw. Trans. Instn. Min.Metall, 105, C43-53.
Morrell S & Stephenson I, 1996. Slurry Discharge Capacity of Autogenous and
Semi-autogenous Mills and the Effect of Grate Design. Int. J. Miner.
Process. (In press).
Morrell S & Morrison R D, 1989. Ore Charge, Ball Load and Material Flow
Effects on an Energy Based SAG Mill Model. Presented SAG 1989,
University of British Columbia. Editors. Mular & Agar.

Morrell S & Morrison R D, 1996. AG and SAG Mill Circuit Selection and
Design by Simulation. SAG 96, edited Mular, Barrett and Knight,
Vancouver 769-790.
Mutambo. J, 1993. Further Development of an Autogenous and Semi-
autogenous Mill Model. M. Eng Sci. Thesis. University of Queensland
(unpublished).
Needham T M & Folland G.V. 1994. Grinding Circuit Expansion at Kidston
Gold Mine. Presented at SME Annual Meeting, Albuquerque, New
Mexico. February 14 -17.
8.2.7 High Pressure Grinding Rolls (Model 402)
HPGR Model This chapter contains a description of the HPGR model.
The high pressure grinding rolls crusher (HPGR) - also known as the roller
press or roller mill - was invented by Klaus Schnert in Germany as an
outcome of his fundamental research on rock fracture (Schnert 1988). The
device has been most widely used in cement clinker grinding in Europe, but is
beginning to find application also in mineral processing. One of the first such
applications was in diamond ore processing in Southern Africa and latterly
in Australia, where it was shown that the device offered some degree of
selective liberation of the diamond from the host rock. However the claimed
advantage for most mineral processing operations is the very high reduction
ratio achieved, and the favourable specific energy consumption, compared to
conventional technologies. Some evidence has also been reported for
downstream benefits such as reduced grinding strength and improved
leachability due to microcracking (Knecht 1994).
Potential applications therefore include preparation of material for fine
grinding, replacement of tertiary crushing, rod milling and primary ball
milling in primary grinding, and the attainment of enhanced leaching
performance. The general principle is illustrated in the figure below.
Figure A12.1 - The High Pressure Grinding Rolls (Roller Mill)
Schnerts research has shown that the most efficient way to fracture a rock
mechanically is to load it between two opposing platens until it fails. One

way to do this at a high throughput is to compress a bed of such particles

between two contra-rotating driven rolls. In industrial practice these rolls can
be very large, up to 2.8 m in diameter. One roll is mounted on fixed bearings,
and the other can move linearly against a hydraulic ram or (in small
machines) a spring.
The hydraulics are set to deliver a particular pressure to the bed of particles
passing through the machine, compressing it to a density greater than 70% by
volume. This pressure, which usually exceeds 50 MPa, controls the size
reduction in the machine.
The material leaves as a compressed cake (flake), which may have to be de-
agglomerated prior to further processing. Particular care must be taken to do
this correctly when determining a product size distribution.
The preferred method is to break-up the cake using a 2 or 3 mm screen, take
representative samples and then to use an ultrasonic bath to de-agglomerate
the particles. De-agglomeration can be completed in either water or acetone
but preferably the latter. The objective is to produce a repeatable size
distribution without additional comminution.
8.2.7.2 Model Structure
Underlying the structure of the size reduction model are three assumptions
about the inherent breakage mechanisms that occur in HPGRs, as illustrated
in the Figure below.
Pre-crusher If particles are bigger than a certain critical size they will be broken directly by
the roll faces as would occur in a conventional rolls crusher. The breakage in
this zone can be considered as analogous to a pre-crusher, the products from
which may subsequently pass to a region where a bed under compression has
formed. The boundary between the pre-crusher and bed compression regions
is defined by a critical gap (xc).
Edge Effect Breakage at the edge of the rolls is different to that at the centre and conforms
Crusher more to that experienced in a conventional rolls crusher. This is the so-called
edge effect which defines the proportion of relatively coarse particles usually
seen in HPGR products. Its existence has been explained by the pressure
gradient across the width of the roll and the static confinement of the ore at
the edges of the rolls which the cheek-plates provide.
Compressive At some point away from the edges of the rolls, and extending upwards from
Bed Crusher the area of minimum gap (xg) to an area bounded by the critical gap (xc), is a
compression zone where breakage conditions are similar to those experienced
in a compressed packed bed.
From a modelling viewpoint these assumptions can be accommodated in the
conceptual structure shown in the figure below. Feed firstly passes to the
pre-crusher. Particles with diameters that exceed the critical gap (xc) are
crushed below this size in a single particle breakage mode. The products from
this breakage then combine with feed particles that are smaller than xc. A
proportion is then diverted to another single particle crusher stage where all
particles greater than the minimum gap (xg) are crushed to below this size.
The remainder are diverted to a compression stage where all particles greater
than xg are crushed below this size but in a compressed bed mode.

All products then combine to produce the final HPGR product.
Figure A12.2 - Schematic Structure of the HPGR Model
8.2.7.3 Breakage Processes
HPGR Model The model contains three breakage processes and one splitting process
between the edge and compressed bed zones. For the breakage processes the
JKSimMet crusher model is used to describe the size reduction. Four model
parameters are required for each breakage process: K1 , K2 and K3 and t10 . The
first three are used to describe the probability that a particle will be broken
whilst the t10 is used to describe the product size distribution that results. For
a detailed model description, refer to the Crusher Models section 343 of this
Appendix.
t10 Definition The t10 is defined as the percentage passing one tenth of the original particle
size in the product after breakage. Other tn parameters can be similarly
obtained from a product size distribution, eg. t2 is the percentage passing one
half of the original particle size. From breakage tests the t10 and a number of
other tn values are determined from the breakage products. These values are
stored in tabular form in the model which, given a value of t10 , uses spline
interpolation to determine the associated tn values and hence reconstructs the
entire product size distribution.
Pre-crushing For the pre-crushing process, breakage of particles is assumed to be in single
particle mode in which rocks are nipped directly by the faces of the rolls,
similar to a conventional rolls crusher. The parameters used to describe
crushing in this zone are determined from tests conducted in a conventional
(non-HPGR) laboratory rolls crusher and single particle breakage tests, and
remain constant in the model fitting and scale-up. The parameter K2 is set as
the critical gap xc, which is defined by Morrell et al (1997) by the expression

0.5
2
4 g Dx g
xc 0.5 (D + x g ) (D + x g ) - (A12.1)
c
where xg is the working gap, D is roll diameter, c

is bulk density of feed and
g
is flake density.
Figure A12.3 - HPGR Schematic Showing Compression or Nip Angle
In the edge zones, rock breakage is also assumed to take place in single
particle mode. The parameters used to describe crushing in this zone are the
same as those used in the pre-crushing zone, except for K2 , which now takes
the value of the working gap xg.
Compressed Bed In the compressed bed crushing zone on the other hand, size reduction is
Breakage assumed to be similar to that experienced by a bed of particles in a piston
press. The parameters used to describe size reduction are determined from
tests in a laboratory or pilot scale HPGR machine combined with breakage
tests in a piston press. The piston press tests provide information on the
relationship between size reduction and energy input in a compressed bed.
They also provide a description of the characteristic shape of the product size
distribution. If the piston press tests are not available, then the results from
the single particle Drop Weight test may be used to determine the Compressed
Bed Breakage Function (see next topic 407 )
The parameter K2 for the compressed bed crushing is the working gap xg,
whilst K1 is set as zero.
The parameters K3 and t10 are fitted to the laboratory scale HPGR test data.
These are the only two breakage parameters required to be fitted to laboratory
data.
Edge Crushing The last sub-process in the model is the split to the edge and compressed bed
Bypass zones. The edge zones are associated with the drop in pressure that is
experienced towards the edge of the rolls. Their extent is assumed to be a
function of the working gap. The fraction of feed that is crushed in the edge
zones (f) can therefore be expressed as:
f = g (xg/L) (A12.2)
where g is split factor and L is the roll length. Using pilot scale HPGR test
results where sizing data of both pure flake and total product were available,
the split factor g was found to be approximately constant with a value of 3.4.

In physical terms this means that the edge effect zone extended from the edge
of the roll a distance equivalent to 1.7 times that of the working gap. By sizing
the pure flake and total products from lab/pilot test results, f can be
determined experimentally. Recent work suggests that the fraction of material
being subjected to edge crushing is usually about 10%. Thus, the model may
be simplified by manipulating g (split factor) to ensure that 10% of the feed
reports to the edge crushing zone.
8.2.7.4 Compressed Bed Breakage Function
The product size distributions produced at different energy inputs (or

reduction ratios) can be characterised by a family of t curves. Measurement
and analysis for impact breakage is described in the Crusher Models section
346 .
This approach can be extended to predict required breakage power and scaled
to net crushing power using an efficiency factor., typically - 1.25 (see the
Crusher Model topics Breakage Parameters 348 and Crusher Power
Predictions 348 ).
Single Particle t10 t75 t50 t25 t4 t2
Impact Breakage 10.0 6.05 7.94 12.60 46.70 74.60
Data
20.0 8.33 10.90 17.30 62.60 90.30
30.0 10.0 13.10 20.70 74.50 99.20
This approach can be extended to compressive breakage by using a piston
4
2
press to compress closely sized fractions in a controlled manner. The
resulting products are sized and fitted to a spline surface. This surface can be
regenerated by the model from a matrix of spline function values. These
values are input to the model as
Compressed Bed t10 t75 t50 t25 t4 t2
Breakage Test 10.0 4.04 6.48 7.51 17.65 35.44
30.0 13.53 19.71 22.24 41.35 58.36
50.0 23.02 31.91 38.00 52.37 69.01
It can be clearly seen that these breakage models are different. The power
requirements can also be characterised with particle size dependence if
required and also related to motor power (see the section on Power Draw 410 ).
8.2.7.5 Throughput
Throughput is controlled principally by roll dimensions, speed and profile,

and material characteristics such as size hardness and particle-roll friction
(and thus nip-angle). The profile and material of the roll surface is important
in controlling both wear and machine performance, and various options are
offered by the different manufacturers.
The rolls throughput can be theoretically expressed as
Q = 3600 U L xgf g
(A12.3)
where

Q mass throughput (tph)

U circumferential velocity of the rolls (m/s)
L length of rolls (m)
xgf working gap (m) from the flake thickness measurements
g flake density (t/m3 )

Note that equation A12.3 does not take into account the slip between feed
material and the rolls surface, which can be influenced by the feed
characteristics (particle size and size distribution, moisture, etc). The figure
below shows the deviation between measured throughput and throughput
calculated using Equation A12.1 for primary diamondiferous ore treated
through a 100 mm Polysius laboratory scale HPGR. It is obvious that
Equation A12.3 over-predicts the HPGR throughput at high rolls speed,
which may indicate that slip exists in the HPGR operation at these speeds.
Figure A12.4 - Deviation of the Throughput Calculated from Equation

A12.4 for Diamondiferous Ore Treated through a Laboratory HPGR at
Various Speeds
To correct for the slip effect it is considered that for a specific feed the slip is a
function of the rolls speed and the relative working gap (dimensionless)
which is defined as xg /D, where D is the rolls diameter.
The figure below plots the correction factor c, (c = Qm/Qc, where Qm is the
measured throughput and Qc is the throughput calculated by Equation A12.3)
versus the product of the speed and the dimensionless gap (U * xg/D) for the
Diamondiferous ore using the laboratory HPGR data. A linear regression on
the plot was obtained and Equation A12.3 was accordingly modified as:
Q = 3600 U L xg g
c (A12.4)

where c is the correction factor determined from Figure A12.5 below.

Recent work by Schonert (2000) suggests that under normal operating
conditions, slip does not occur in the compression zone. If normal operating
conditions are assured, then the correction factor should be set to 1.0.
Figure A12.5 - Throughput Correction Factor for Diamondiferous Ore

Treated through a Laboratory Scale HPGR

Figure A12.6 - Prediction of Throughput for Two Pilot Scale HPGRs from
Equation A12.4 with Model Parameter c Calibrated Using Laboratory
Scale HPGR data
Using Equation A12.4 with c determined from Figure A12.5 the throughput's
for a laboratory scale HPGR (D = 0.25 m) and two pilot scale HPGRs (KHD, D
= 0.8 m; Krupp Polysius, D = 0.71 m) were predicted. A comparison between
the calculated and the measured throughput's is given in Figure A12.6. The
rolls speeds varied from 0.29 m/s to 3.1 m/s, rolls length from 0.1 m to 0.21 m,
rolls diameters from 0.25 m to 0.80 m, and working gaps from 3 mm to 23 mm.
Figure A12.6 shows that good prediction of throughput has been achieved by
the model over the wide range of conditions tested.
8.2.7.6 Power Draw
Conventional The impact size reduction model contains an energy balance equation
Crusher Power (Andersen and Napier-Munn, 1988) which ensures that the energy for size
reduction is compatible with that provided by the motor. The t10 parameter is
related to the specific energy used by the machine and will follow a curve
described by the equation:
t10 = A (1 - e-bEcs) (A12.5)
where A and b are parameters and Ecs is the specific energy.

HPGR Crusher In the size reduction model the two parameters K3 and t10 were fitted to the
Power laboratory scale HPGR power data. It was found that the fitted t10 's for 24 sets
of Diamondiferous ore tests under various rolls speeds and feed size
conditions fell on a t10 v Ecs master curve, as shown in Figure A12.7
Equation A12.5 was hence fitted to these data to generate the A, b parameters,
which are used for the scale-up as will be demonstrated in the next section. In

JKSimMet, the points for t10 = 10, 30 and 50 are placed in the Compressive
Breakage Specific Community Energy Matrix.
Figure A12.7 - The Fitted t10 vs Specific Energy Ecs for Diamondiferous
Ore Treated through a Laboratory HPGR
A power coefficient kp is required which relates the measured power to that

predicted by the model for size reduction. This model uses the specific energy
(kWh/t) and associated t10 values from the piston press breakage
experiments. From these it calculates the overall specific energy in a piston
press. The difference between this value and that observed from the motor is
accommodated by kp, ie. kp is the ratio of the observed to the theoretical piston
press specific energy. This coefficient has been found to be reasonably
constant over a range of specific energies but increases rapidly beyond a
certain limiting value. This is shown in Figure A12.8 for the 24 sets of data.

Figure A12.8 - Relationship between Power Coefficient (kp) and Specific

Energy for Diamondiferous Ore Treated Through a Laboratory Machine .
(Where kp = Observed power/Piston Power)
Power Draw vs The prediction of the working gap xg is also required for simulation. The
Working Gap working gap depends on pressure and power draw.
Working Gap/ This relationship is developed from the laboratory/pilot scale test. The
Specific Energy specific motor energy is plotted against the working gap.
Relationship The parameters rc and rg in Equation A12.2 405 are functions of feed type,
operating conditions (eg working pressure) and the roll surface (eg smooth,
chevroned, studded). Therefore, provided the pilot scale or the full scale
machines are operating under similar conditions to the laboratory unit, then
xg will be proportional to the diameter of the rolls. The principal dependence
of the working gap will be on the working pressure, with the gap reducing as
the pressure increases. As working pressure is directly related to specific
energy, then it will be found that as the specific energy increases the gap will
decrease. An example of this is shown in Figure A12.9 for Diamondiferous
ore treated through a laboratory machine.

Figure A12.9 - Relationship between Working Gap and Specific Energy

for Diamondiferous Ore Treated Through a Laboratory Machine
8.2.7.7 HPGR Model Printout

8.2.7.8 Fitting the HPGR Model
SpFact
K1H
T10H
Power Coeff. H
Split Factor (g) This factor determines the proportion of material that is crushed in bypass
mode. This is usually 1.7 times the effective gap at each end, the default total
(SpFact)
value being 3.4. (See Breakage Processes 405 )
Setting the split factor to zero and running a simulation generates the size
distribution expected from pure compression crushing, ie. pure flake and
may be compared with (or fitted to) an actual sample taken from the centre of
the roll discharge.
Pre and Edge Using the same feed material as for the pilot/lab HPGR test, laboratory roll
Crusher Model crusher is operated at close to the nipping gap and the working gap of the
Parameters HPGR.
(K1H & T10H) The Whiten/Awachie/Anderson crusher model 343 is used to derive K1 and
t10 where K2 is the crusher gap and K3 is set at 2.3.
The ratio K1 /K2 is the input to the pre crush and edge effect models along
with the fitted t10 values. It is unlikely that power can be measured with
sufficient accuracy in this test to justify using other than the default power
factor of 1.25.
Throughput As noted previously 407 , throughput is strongly controlled by geometry at low
Relationship throughput's and by slippage at high throughput's. Pilot or laboratory scale
tests can be used to derive the slope and intercept for the slip correction factor
Cp.
The model defaults are for smooth rolls. It is highly likely that different roll
surfaces will generate different correction factors.

Compressed Bed Breakage within the compressed bed is assumed to be uniform and able to be
Breakage described by a single parameter t10 . The t10 parameter will increase as the
reduction ratio increases. In compression, all particles are assumed to be able
(t10 HPGR)
to be selected for breakage ie. K1 = 0 and every particle larger than the working
gap will always be broken, ie. K2 = calculated Working Gap.
Power Model The HPGR model takes a somewhat circuitous approach to power modelling.
Fitting As noted previously, the combination of piston press tests and laboratory/
pilot scale HPGR produces a relationship between the compressive bed t10
and net motor power (Figure A12.7 410 ).
Developing this relationship requires some modelling using the Andersen/
Whiten model 343 . The objective is to find a t10 for each data set with K2 set to
the working gap and K3 a constant value over all sets. To do this, enter all sets
of data into one test, master slave K3 , set K2 to working gap and fit each of the
t10 values. This provides a set of t10 values which can be plotted against the
motor power per tonne (Ecs) corrected for no load and the power drawn by
pre-crush and edge crushing (as in Figure A12.7 410 ). Equation A12.5 is fitted
to this data with A=100 and Ecs values calculated at t10 =10, 30 and 50 for
input into the Compressed Bed Breakage Matrix.
This relationship allows compressive power draw to be calculated 348 for any
set of K1 , K2 , K3 and t10 values. Figure A12.7 shows the power coefficient
(observed motor power divided by calculated piston power) for a range of
specific energy inputs, expressed as kWh/t.
If this model was ideal, the coefficient would be constant. Between zero and 5
kWh/t it is approximately constant at say 2.5 and increases rapidly at high
powers (ie. the crusher becomes less energy efficient). More energy is
converted into heat and does not result in further comminution.
8.2.7.9 Scaling the HPGR Model
To predict the performance of pilot scale and full scale HPGRs the model is
firstly calibrated using the results from the laboratory, conventional rolls,
single particle breakage and piston bed breakage test. Figure A12.10
illustrates the scale-up procedures. Also shown in Figure A12.10 are the
values of the parameters obtained from the calibration, which have been used
to predict the two pilot scale units and one full size machines treating a
Diamondiferous ore (Morrell, Shi and Tondo, 1997).

Figure A12.10 - Schematic of the Model Algorithm and Scale-up Procedure
The full scale-up procedure is implemented in JKSimMet. When running the

simulations of pilot scale or of full scale machines, the parameter K3 for the
compressed bed crushing zone is automatically adjusted until the model
predicts the same power draw as was originally chosen for the simulation.
As a result, the calculated power draw is identical to that observed, and the
product size distribution is predicted based on this power consumption.
In the simulation the maximum throughput of a scale-up HPGR is calculated
using the throughput model (Equation A12.4 407 ) with the correction factor c

determined in the laboratory unit with similar rolls surface on the same type
of ore. The required power is then calculated from the maximum throughput
and the specific energy selected. The model is iterated until the breakage
power, which is the sum of the power used in the three sub-processes of pre-
crushing, compressed bed crushing and edge effect crushing, matches the
required power. The overall product size is then predicted based on the
breakage power.
Roll Surface Tests using a Krupp Polysius pilot roll (rolls diameter 0.71 m), with 4 mm
profiles (on the rolls) resulted in a considerably larger working gap than was
observed for the KHD pilot tests using smooth rolls. Therefore, laboratory
tests must be conducted with a rolls surface similar to that proposed on the
full scale machine.
Limited Data As only limited production scale data were available, the models need to be
Base further tested and validated against more real data in the future, and their
capabilities explored in case studies.
Power Ideally, this coefficient should be constant. A better understanding and
Coefficient (kp ) (possibly) a better representation need to be developed.
8.2.7.11 Nomenclature
Symbol Meaning
nip angle (degree)
c
split factor
bulk density of feed (t/m3)

c
flake density (t/m3)
g
c correction factor for rolls throughput
D rolls diameter (m)
Ecs specific energy (kWh/t)
f fraction of feed which is crushed in the edge zones
g split factor
K1, K2, size reduction model parameters

K3
kp power coefficient
L rolls length (m)
Qm measured mass throughput (tph)
Qc calculated mass throughput without correction tph)
t10 size distribution parameter

U rolls circumferential speed (m/s)
xc critical gap (m)
xgf working gap (m).
8.2.7.12 Acknowledgements
This model was developed with the financial support of the sponsors of the
AMIRA P428 project (Application of High Pressure Grinding Rolls in Mineral
processing) including the Centre for Mining Technology and Equipment
(CMTE). Considerable assistance was also provided by the staff at KHD and
Krupp Polysius, as well as the staff and students at the JKMRC and CSIRO,
Division of Mineral products.
8.2.7.13 References
Andersen J S and. Napier-Munn T J, 1988. Power prediction for cone crushers.

Proc. 3rd Mill Ops Conf, Cobar, Aus. Inst. Min. Met.
Andersen J S, 1988. Development of a cone crusher model. M. Eng. Sc. Thesis,
University of Queensland (JKMRC).
Fuerstenau D W, Shukla A and. Kapur P C. 1991. Energy consumption and
product size distributions in choke-fed, high compression roll mills.
Int. J. Miner. Process., 32: 59-79.
Kapur P C, 1972. Self - preserving size spectra of comminuted particles. Chem.
Engng. Science, 27: 425-431.
Knecht, J, 1994. High pressure grinding rolls, a tool to optimise treatment of
refractory and oxide gold ores. Fifth Mill Operators Conf. Roxby
Downs, Oct, 51-59 (AusIMM, Melbourne)
Morrell, S, Shi F & Tondo, L. 1997. Modelling and scale-up of High Pressure
grinding rolls. IMPC Aachen.
Morrell S, Lim, W, Shi F and Tondo L. 1997. Modelling of the HPGR crusher.
SME Annual Conference, Denver, Colorado. Comminution Practices
Symposium, Ed Kawatra, 117-126.
Schnert K. 1988. A first survey of grinding with high compression roller
mills. Int J of Min Proc, 22, 401-412.
Schnert K.and Sander, U., 2000. Pressure and shear on the roller surfaces of
high pressure roller mills, Proc. XXI IMPC, Rome, Italy, Sect A4, 97 -
103.
Tondo L, 1996. Modelling of HPGR crushers. M. Eng Science Thesis,
University of Queensland (unpublished).
Whiten W J, 1972. The simulation of crushing plants with models developed
using multiple spline regression. J. South Afr. Inst. Min. Metall. 72:
257-264.

8.2.8 Size Degradation (Model 480)
Size Degradation This chapter contains a description of the Size Degradation model.
Model
The concept of a degradation model has its origins in iron ore and coal
operations where particles may undergo significant size reduction during
mechanical handling such as dropping on to a stock pile from a conveyor or
perhaps at a conveyor transfer point.
8.2.8.2 Model Structure
The model structure is a simple representation of a single drop which results

in the particles being broken to a specified t10 value. The breakage
distribution parameter, t10 , characterises the size distribution of the broken
product. More details of this parameter and the concepts behind it are given
under the heading Crusher Models 346 . The appearance function data
discussed in this section are required for the degradation model and these are
produced as part of the standard JKMRC Drop Weight Test.
Breakage The breakage distribution parameter, t10 , is entered as a model parameter. It
Distribution must be calculated by the user and is generally based on the Energy v Size
Parameter (t10) Reduction relationship for the particular ore derived from the JKMRC Drop
Weight test.
Specific The Specific Comminution Energy in a drop is a function of the height of the
Comminution drop and can be calculated using the following equation:
Energy Ecs = 0.00272 * h (A13.1)
where:
Ecs specific comminution energy (kWh/t)
h height of the drop (m)

Energy Size The relationship between Specific Comminution Energy and size reduction
Reduction represented by t10 is also one of the results of the JKMRC Drop Weight test.
Relationship The relationship is of the form:
t10 = A * ( 1 exp( - b * Ecs )) (A13.2)
where:
t10 breakage distribution parameter
Ecs specific comminution energy (kWh/t)
A & b are ore characteristic parameters

Conditioning In most cases, the damage inflicted by a second drop is less than that inflicted
by the first drop. This effect is known as conditioning. Of course, the height
of each drop is important as well as the number of drops.
Effectively, the particles become a little more resistant to impact after each
successive drop. The amount of this effective increase in resistance depends
on the ore type and on the drop heights.

This effect can be included in the simulation by an appropriate reduction in

the b value used in equation A13.2. For an ore that is only a little affected by
conditioning, a reduction of b to 75% of its starting value is typical. For an ore
which is significantly affected by conditioning, b is typically reduced to 40%
of its starting value.
Example The A and b values from the JKMRC Drop Weight test for the example ore are
50 and 0.5 respectively.
For a drop height of 20 m, from equation A13.1:
Ec = 0.00272 * h
s
= 0.00272 * 20
= 0.054 kWh/t
and from equation A13.2
t1 = A * ( 1 exp( - b * Ecs ))
0
= 50 * ( 1 exp( - 0.5* 0.054))

= 1.33
this value of t10 is then entered into the model.
For a second 20 m drop of an ore which is strongly affected by conditioning, b

is reduced to 0.2 (40% of 0.5) and
from equation A13.2
t10 = A * ( 1 exp( - b * Ecs ))
= 50 * ( 1 exp( - 0.2* 0.054))

= 0.54
this value of t10 is then entered into the model for the second drop.
Use for the The degradation model can be used to represent a lightly loaded Vertical Shaft
Vertical Shaft Impactor. In this case, the energy of an impact is calculated from the velocity
Impactor of the particle imparted by the rotor. This energy must be converted to units of
kWh/t before equation A13.2 can be applied.
For example, for a VSI with a rotor diameter of 0.6 m spinning at 2000 rpm, the
energy imparted to a particle leaving the rotor at its peripheral speed is:
Ec = 0.5 * m * v2 / ( 3600 * m )
s
= 0.5 * v2/ 3600

= 0.5 * ( p * 0.6 * 2000 / 60 )2/ 3600
= 0.55 kWh/t
where:
m = particle mass (which cancels out)

E = specific comminution energy (kWh/t)

cs
v = peripheral velocity of rotor (m/s)
3600 is the conversion factor for kWh/t

The Ecs value is substituted into equation A13.2 to calculate t10 for use in the
model.
8.2.8.3 Degredation Model Printout
Degradation Model Printout
8.2.8.4 Fitting the Degredation Model
This is a very simple model to fit, the only fittable parameter being t10 .
A typical range of starting estimates for degradation by drop is 0.2 to 0.8

depending on amenability to degradation and drop height.
A typical range of starting estimates for the VSI is 5 to 20 depending on rotor
diameter and speed and ore type.
It is recommended that the ore specific appearance function is measured by a

Drop Weight test rather than using the default values. Although the variation
of the crusher appearance function data in the JKTech data base (of ores
subjected to Drop Weight testing) is not particularly large, ore specific values
will provide better results.
If several drops actually occur, it may be better to simulate these as separate
drops than as a single drop of the total accumulated drop height, particularly
if conditioning is likely.
It should also be noted that ores which are particularly susceptible to
degradation are also likely to be degraded during the process of screening to
determine the size distribution, thus making the size distributions somewhat
doubtful.

Index -F-
flowsheet name 61
-A-
adding streams 72
-H-
AG model 370 hardware key 19
hardware requirements 17
-B- high pressure grinding rolls model 403
backing up work
backup copy 18
18
-I-
ball mill inflexion points 72
perfect mixing model 361 Installation procedure 47
-C- -L-
changing circuit 99 loading a project 100
circuit performance 99
computer requirements 17
configurable stream overview 97 -M-
courses 19
crusher 343 maintenance agreements 19
crusher models 343 mass balance 17
cursor 57 mass balancing 230
infinite division problem 268
middlings problem 267
-D- metallurgical accounting 268
model building 56
data collection 230 model fitting 17
data entry conventions 81 graphing results 287
data structure 51 printing results 287
direction change for streams 72 problems 291
display 58 references 292
dongle 19 models 18, 343
drawing streams 72 AG 370
ball mill - perfect mixing 361
-E- double deck screen 325

efficiency curve - variable d50c 330
efficiency curve high pressure grinding rolls 403
simple 325, 326 rod mill 355
splined 328 SAG 370
variable d50c 330 simple efficiency - fitting 326
water & fine 326, 327 simple efficiency - water & fine 326
elemental assay labels 78 simple efficiency - water & fine - fitting 327
ending a session 99 simple efficiency curve 325
equipment icons 52 single deck screen 317
equipment items 52 size converter 385
equipment labels 63 size degradation 419
example project 18 splined efficiency - fitting 328
2014 JKTech Pty Ltd

Index 423
models 18, 343 streams 51

splined efficiency curve 328 structure 18
variable rates SAG 386 structured example 18
modules 18
mouse 57
-T-
-N- terminating a session 99
naming streams
nudging 72
72
-U-
units - changing 78
-O- updates 19
operatiing systems
operating systems
17
17 -V-
values from simulation 56
-P- variable rates SAG model
viewing stream data 94, 97
386
parameters
types 273
preferences 57 -W-
project name 61
window size 60
windows 58
-R-
redrawing flowsheet 72
restrictions 322, 330, 331, 332
Efficiency Curve Variable D50c 331
Single Deck Screen Model 322
rod mill model 355
routing of streams 72
-S-
SAG model 370
sample degradation model 419
screen model
double deck 325
single deck 317
selecting a flowsheet 100
Sieve Series 175
simulation 59
results display options 15
simulation window 87
size classes 78
size converter model 385
Standard deviation 231
start up 60
stream data 94
stream data overview 97
2014 JKTech Pty Ltd

Endnotes 2... (after index)
2014 JKTech Pty Ltd

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Jksimmet v6 Manual

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Version 6.

Steady State Mineral Processing Simulator

by JKTech Pty Ltd

JKTech Pty Ltd

telephone: +61 7 3365 5842

2014 JKTech Pty Ltd

Printed: March 2014 in Brisbane, Qld, Australia.

Special thanks to:

Part II Changes from Version 5 21

Part III Installing JKSimMet 47

Part IV Learning JKSimMet 51

2014 JKTech Pty Ltd

Part V Using JKSimMet 131

2014 JKTech Pty Ltd

Part VI Mass Balancing 230

2014 JKTech Pty Ltd

Part VII Model Fitting 272

Part VIII Model Descriptions 294

2014 JKTech Pty Ltd

2014 JKTech Pty Ltd

2014 JKTech Pty Ltd

2014 JKTech Pty Ltd

Steady State Simulation Software for Comminution and

2014 JKTech Pty Ltd

1.1 About JKSimMet V6

1.1.1 General Capabilities

Version 6.0.1 - March 2014

1.1.2 How the Program Works

About JKSimMet V6 Version 6.0.1 - March 2014

DOS versions of JKSimMet.

Streams A stream is a description of any flow of material. The description is usually in

Version 6.0.1 - March 2014 About JKSimMet V6

view the size distribution data plotted as graphs on the screen,

1.1.3 JKSimMet Simulation

Available JKSimMet performs steady state simulation of comminution and related

About JKSimMet V6 Version 6.0.1 - March 2014

emphasis on the process experience and knowledge of the operator.

1.1.4 JKSimMet Mass Balancing

JKSimMet enables users to mass balance comminution circuits on both a size

1.1.5 JKSimMet Model Fitting & Analysis

1.2 Hardware & Operating System Requirements

Version 6.0.1 - March 2014 About JKSimMet V6

Operating MS Windows 7, Vista or XP

1.3 Cautionary Tales

1.4 JKSimMet Structure

Program JKSimMet consists of the following software modules:

1.5 Available Models

Hardware & Operating System Requirements Version 6.0.1 - March 2014

Pump sump Semi-autogenous mill

1.6 JKSimMet Support

Documentation Three levels of documentation are supplied:

Version 6.0.1 - March 2014 Available Models

2 Changes from Version 5

JKSimMet V6 is based on the JKSimFloat architecture and so presents a new

2.1 Summary of Main Changes

Flexible flowsheet drawer 31

Configurable Stream Overview 36 including data entry

Size x Assay mass balancing 44

2.2 Precautionary Notes on Main Changes

Version 6.0.1 - March 2014

2.3 Toolbar Changes

Precautionary Notes on Main Changes Version 6.0.1 - March 2014

2.4 Creating Projects

Version 6.0.1 - March 2014 Toolbar Changes