Home

Mass Balance User Manual

1. Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 22 29 Tommiska Pertti Lamberg 51 6 Error check messages 1 10 11 12 13 14 15 16 17 18 Dataset No Active dataset found Please contact the developers Units No selected units found At least one unit should be selected Streams No selected streams found Some of the streams should be selected Units No input stream Found a unit with no input streams Units No output stream Found a unit with no output streams otreams Source and destination missing Found a stream with no source and destination Fractions Bulk not found Please contact the developers Data No data found Add data in the measurement data view Variables Total solids measurement missing There should be exactly one selected variable of the Total Solids type Variables Too many variables of the type total solids There should be exactly one selected variable of the Total Solids type Variables No selected assays found There should be at least one selected variable of the Mineral Assay or Solids Component Assay type otreams All stream types unknown Go to Streams and press Detect Stream Types button or set the stream types manually User Values UserValues missing ValueStatus of some data is set to Fixed or Questimated but the UserValue is not given St
2. Datasetl stream n Variable z Fraction z Value Balanced Value Diff RelDiff Min Max R CCl Ou Bulk 11 11 0 0 0 00 74 106 um 12 41 13 59 92 0 09 37 74 um 11 57 11 65 0 0 0 00 20 37 um 10 15 10 21 0 1 0 01 106 250 um 14 49 16 35 GS ot 0 20 um 11 10 10 97 0 1 0 01 Fe Bulk 41 25 41 25 0 0 0 00 74 106 um 40 57 39 95 0 6 0 02 37 74 um 40 22 40 94 0 0 0 00 20 37 um 41 66 41 62 0 0 0 00 AAE ED c 5n 34 25 a4 nn n aa a i jp c g y c m Datasetl Indicative WSSQ Hound Meas Fig 15 Balancing Calculate Mass balance problems are solved in two stages firstly the total mass flow rates are solved and then the assays are reconciled In solving the assays the least squares solution finds the best solution by minimizing the weighted sum of squares i e WSSQ ie by F 1 Sij where j refers to the stream k is the number of streams i refers to the components analyses n is the number of components a is the measured value b is the balanced value and s is the standard deviation In non negative least squares all a s are subject to being non negative In constrained least squares all a s are subject to being between the min and max By clicking dataset you can see the solution parameters Balance tolerance Max iter and Estimate of null SD in the properties window Balance tolerance is the condition that defines when the iterations stop and Max iter is the maximum number of iterations If you don t get rea
3. Fiow subtiow 100 F tow M fraction m measurements l the flow enters the unit em 7 L the flow exits the unit 0 otherwise Unsized bulk mass balance In the unsized bulk mass balance solution solids and water flow rates are solved first After that the bulk analyses are solved During the calculation 1 the solids flow rates are solved first and after that 2 the water flow rates are solved 1 Bulk flow rates The equations for solving the bulk solids flow rate are mass balance Equations 2 Nei E Frow tot 0 unit 1 Ny 2 flow 1 analyses Equation 3 Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 24 29 Tommiska Pertti Lamberg Nri unit x cM uo gt Chow Chew tok ehamis _ element Frow tot Q unit T N U flow 1 3 chemical element 1 Nc solids flow rate measurements 4 F x FM flow tot flow tot flow 1 Ng 4 The equations for solving the bulk water flow rate are mass balance Equations 5 Np unit x EL Wow tot 0 unit i N 5 flow 1 water flow rate measurements Equation 6 M Wrow tot Wrow tot flow 1 Ney 6 solids measurements 7 Pc 1100 Wa tor Fow tor PC 1100 Fi flow 21 Ng 7 Mass balance Equations 2 and 5 are the equality constraints for the solutions The solution method used is element wise weighted total least
4. 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 29 29 Tommiska Pertti Lamberg 51 8 References 1 Golub van Loan Matrix Computations Third edition 1996 Markovsky Rastello Premoli Kuhush van Huffel The element wise weighted total least squares problem Computational Statistic amp Data Analysis 50 2006 pp 181 209 3 Lawson Hanson Solving Least Squares Problems 1974 4 Haskell Hanson An Algorithm for Linear Least Squares Problems with Equality and Nonnegativity Constraints Mathematical Programming 21 1981 pp 98 118 5 Barrodale Phillips Algorithm 495 Solution of an Overdetermined System of Linear Equations in the Chebyshev Norm ACM Transactions on Mathematical Software Vol 1 No 3 September 1975 pp 264 270 Copyright Outotec Oyj 2015
5. Find amp CES E Cell Styles Es Format Filter Select Alignment Number Styles Cells Editing fe Units C D E G H K L SAG Discharge Cyclone UF Cyclone OF RC CC1 Final Concentrate RT Final Tail CT2 1 Cyclone Rougher 1st Cleaner 2nd Cleaner Scavenger Process Waters 14 T Mo 4p M lt Survey 1 lt Survey 2 lt 3 Grinding Survey lt 4 Unszed Components lt 4 1D Fully Balanced 6 2D Full Balance lt 51D m Ready E H3 100 eS ee O Fig 19 An Excel sheet containing flowsheet data The measurement data is read from a different sheet of the same Excel file The first column must be named Streams Cell A1 the second Source Cell A2 and the third Destination cell A3 if the data are horizontal Fig 21 If the data are vertical the first row must be named Streams A1 the second row must be named Source A2 and the third Destination A3 Fig 20 Imported vertical data can only be unsized or sized without analyses Copyright Outotec Oyj 2015 Qutotec Research Center Pori Antti Remes Jaana Tommiska Pertti Lamberg xl a Home E Clipboard Insert Page Layout Arial mt WE M ui T SAG Cyclone Source Destination Mass Solids Flowrate t h Water t h ocolids Cu 96 o d 0 53um 53 7T5um f5 150um 150 300um 300 600um 600 850um 850 1180um 1180 2360um 2360 4750um 4750 3500um 9500 13200um 1
6. amp lt 2 Filter Select Editing Cell les H7 Source SAG Cyclone Cyclone Rougher 1st Cleaner 2nd Cleaner Rougher Scavenger Scavenger 2nd Cleaner 1st Cleaner Stream ROM SAG Discharge Cyclone UF Cyclone OF SAG Cyclone SAG Rougher 1st Cleaner 2nd Cleaner Scavenger 1st Cleaner Final Concentrat RT 10 SC 11 Final Tail 12 CT2 13 CT1 44 ap bl 1st Cleaner Scavenger Survey 1_ Survey 2 lt 3 Grinding Survey 4 Unsized Components 250 225 G ooocococcocococcocococcjeae 4 1D Fully Balanced e D E F Destination Solids Recovery Total Solids t t FractionNc Fraction nam Fraction m Note 225 Bulk Bulk Bulk Bulk Bulk Bulk Bulk Bulk Bulk Bulk Bulk Bulk 6 2D Full Balance C K Cu 1 040122 0 989001 1 040242 0 989115 12 4814 10 9394 15 753983 0 193961 4 303134 0 051718 3 009419 1 427522 L Fe 6 786279 6 836096 7 127088 7 379699 41 66124 48 75182 48 01802 4 137773 43 78948 4 474968 51 93595 40 93256 51D with ERROR Ma m Ready Fig 21 Horizontal unsized data me a 100 The program automatically detects a sheet named Streams as the sheet where the measurement data can be found If the name of the sheet containing the measurement data is not Streams the user should tell the program where the measurement data can be found Fig 23 Analyses The following screenshots
7. show how an HSC7 file is imported Importing an HSC7 file is started by clicking Tools Mass Balancing and then clicking the Import HSC7 Data button Fig 22 After that a dialog will open Fig 23 Copyright Outotec Oyj 2015 HSC 8 Mass Balance utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J Tommiska Pertti Lamberg ix HSC Sim 8 Mass Balance EDEA amp mHHM o y amp Open Save SaveAs Help Import HSC7 Data Import ReX Data Tools Balancing Navigator q x Selected Unit Name Properties q X E T bg Experimental Data Units Streams Variables Size Fractions Data Sets Measurement Data Data Status Stream View Variable View JA Standard Deviations SD Stream View SD Variable View 20 Balancing Calculate Compare Reporting Results 2014 Outotec Oyj Fig 22 Import HSC7 Data Import HSC Mass Balance Import Options HSC Data General Analyses Dimension Select Analyses Sheets 1D Unsized Data a PN 1 5D Size Fraction Data MT Streams a C Units L1 2D Size Fraction With A A EA A E ES C MineralMatrix Direction Flowsheet 3 Vertical Data Select Flowsheet 9 Horizontal Data A Nothing CJ Units Flowsheet 3 MineralMatrix O Streams 3 Balanced Flowsheet Direction Q Units Horizontal gt Streams Horizontal Fig 23 Import HSC7 Data
8. 15 8 2 0 3 8 pata Status 37 74 um a b c MIN a b c 2 79 8 6 0 2 20 37 um a b c MIN a b c 2 43 9 1 0 2 CN 106 250 um a b c MIN a tb c 4 31 7 3 0 3 Variable View 0 20 um a b c MIN a b c 3 23 8 1 0 3 JA Standard Deviations Cyclone OF Bulk a b c MIN a b c 1 00 15 0 0 2 s t hec MIN fa Ot the LAN isn na 51 4 5 Fig 14 Standard Deviations SD Variable View Mass balancing In the mass balancing upper bar the following can be selected The balancing results can be viewed graphically with see Fig 15 e Balance Convergence e Parity Chart To solve a mass balance problem the following mathematical methods are available in the Balance Report Options on the right hand side e Least Squares Solution LS e Non negative Least Squares Solution NNLS e Constrained Least Squares Solution CLS Copyright Outotec Oyj 2015 Sum 100 if the mineral component sum is required to be 100 Method LS NNLS CLS Data to Balance Assays only Solids and assays Solids and water PSD Balance Unsized Sized Sized by Assay Calculate runs the data reconciliation HSC 8 Mass Balance utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 14 29 Tommiska Pertti Lamberg amp A e IB 9 Le Uu x ou Import Check for Help X 100 Method Sizing Size Balance Solids Calculate Clear iC Data Errors hi LS by Assays and Assays T Balanced Dataset 4
9. 3200 20000um 20 96 6 1 2 124 3T 1 8 4 65 5 6 5 8 33 4 5 9 4 13 5 30 5 3 4 0 9 wo cso on B 0M p 11 12 13 14 15 16 T 18 19 20 Analyses Compatibility Mode Home Insert Formulas Data ns Paste Page Layout Arial Clipboard M mem ET Alignment 13 2 18 5 42 3 2 17 1 19 7 7 8 5 3 6 6 5 8 47 0 9 0 2 Review W HSC 8 Mass Balance January 27 2 14023 ORC J Data Review F General g ag ye lt 0 0 00 3 0 3 Number 3 D Cyclone SAG Cyclone 1290 520 11 2 13 14 3 11 1 2 5 5 5 15 5 232 10 3 7 2 9 6 fi 5 1 4 0 5 View Add Ins Team General A 00 0 Number 015 Ss SS Analyses Compatibility Mode Microsoft Excel View A Styles SAG Discharge Cyclone UF Cyclone OF Mill Water Rougher 1f 5 600 446 1 96 12 5 35 9 6 9 18 3 212 135 2 2 1 2 0 7 0 icrosoft Excel E ed 0g Conditional Format Formatting as Table Styles Sty i F 17 29 ap lame e Q oum LAT d Sort amp Find amp C Filter Select Editing secas Add Ins Team g Insert T q Delete E Format Cells F Mill Sump Water Process Waters Process Waters SAG Cyclone 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 D S amp S c3 SS Se ODODO GOG ODO co O O amp 41D DEE g Insert g Delete He Format Cells Fr d z Sot amp Find
10. 4 6 096 7 000 10 SAG Discharge 20 37 um 9 654 1 004 6 096 7 000 8 Data Status 11 SAG Discharge 37 74 um 16 405 1 004 6 096 7 000 12 SAG Discharge 74 106 um 10 780 1 004 6 096 7 000 Stream View 13 SAG Discharge 106 250 um 48 112 1 004 6 096 7 000 Variable View 14 Cyclone UF Bulk 258 612 1 004 6 096 7 000 E a A rmm PT a Ps A gt mA aa Fig 9 Experimental Data Measurement Data 51 4 3 Reviewing and complementing the data In this part the idea is to inspect the data and get an understanding of what values will be available after balancing Also the data status before balancing is reviewed here and can be changed Thus changes are reflected in the status after balancing Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 10 29 Tommiska Pertti Lamberg The status indications are Stream e Missing no data e Complete all variables have data e Partial some variables have data Variable e Missing no data e Measured data existing e Guesstimated data are a user given guesstimation high uncertainty is set automatically for this The guesstimation is given in the property User value e Fixed the user sets including the value that you do not wish to change during the balancing However the fixed value may change during balancing because the fixing is done by setting the uncertainty to small The fixed
11. 51 7 Mathematics and algorithms cccccccecccsseccseeeeseeeeseeeeeeeeseeeseeeesseeeseeeeseeeeseeeesaees 23 51 7 1 WNSIZEO bulk MASS Dalali6e uci inopi o oen paa rash beau oa or epe x pero a 23 51 7 2 Sized mass balance without sized analyses eeeseeeesseesss 25 51 7 3 Sized by assay mass balance ccc cece cecccseeecseeeeeeeeeseeeeseeeeseeeeseueesaeeeseeeesaeeesees 26 cm abo i i ae M ERR 29 Copyright Outotec Oyj 2015 HSC 8 Mass Balance utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 2 29 Tommiska Pertti Lamberg 51 1 Where do we need mass balancing Mass balancing is a common practice in metallurgy The mass balance of a circuit is needed for several reasons To estimate the metallurgical performance of the circuit To locate process bottlenecks and for circuit diagnosis To create models of the processing stages To simulate the process rw lw ccm The following steps are often required to simulate a process 1 Collecting experimental data experimental work sampling sample preparation assaying 2 Mass balancing and data reconciliation of the experimental data 3 Model building 4 Simulation In HSC Chemistry 8 you can do all the steps in one program HSC Sim with the Mass Balance tool The work flow in the HSC Sim and Mass Balance tool starts from a flowsheet drawing followed by importing experimental data perfo
12. Dialog Copyright Outotec Oyj 2015 18 29 HSC 8 Mass Balance O utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 19 29 Tommiska Pertti Lamberg 51 5 Mass balance buttons and dropdowns 9 Update and save changes to HSC Sim flowsheet and close and Close Discard and Close Discard changes and close HSC mass balance Open Save backup HSCMas file of the mass balance Backup Import 1SCY Data Check for Errors Import existing HSC7 mass balance data analyses xls Error check Help and examples Help Detects stream types automatically for Solid slurry and Liquid based on the data If there are streams with no data the stream type is set as ie Unknown The user should either uncheck these Unknown streams or Stream Types set the types manually 3 Select elements from periodic table Add Elements E jo On oe Select minerals from HSC database Add Mineral from DB a Add new variable Add Variable um Copyright Outotec Oyj 2015 Outotec HSC 8 Mass Balance January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 20 29 Tommiska Pertti Lamberg Remove Variable e Add Size Fraction Add Data Set X Remove Data Set E Flip Table Paste Experimental Data Element to Mineral HEA E 2 2 51 Ez 2 2 21 mja View Mineral Matrix 96 30 Sol to Water Back Calculat
13. HSC 8 Mass Balance Outotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 1 29 Tommiska Pertti Lamberg 51 Mass Balance Module TOC 51 1 Where do we need mass DalancinG cccccccsscccseeeseeeeceeeeseeeeseeeeseueesseeesseeesseeesaeeeeas 2 51 2 Mass balancing capabilities in HSC Chemistry 8 eeeeeeeeeeseeeeeeeeee 3 51 3 Overview of the HSC Sim 8 Mass Balancing tool eeeeeseeeeeeeeeeeese 5 51 4 Step by step example data reconciliation and mass balancing in HSC 8 6 O14 te Drawing ie BOWSDOGL sessamisuttsuid exte Pris iqE Ute tEpaeUPU PS UE E EEA coun shaper TORT eae cares 6 51 4 2 Importing the experimental data cc cecccccccseeeeseeeeeeeeeseeeeseeeeseeeeseeeeseeeeseeeeseeeeas 6 01 4 3 Reviewing and complementing the data cccccccseeceseeeeeeeeeseeeeseeeeeeeeeneeeeeeeeeas 9 51 4 4 Setting the measurement accuracies ccceecccceeeeeseeeeeseeeeseeeeeeceueeeseeeesaeeeeseaes 11 91 42 5 IWaSSOal ANGING EE vus Fete sube Ure NE Uca iE Satu eate neuer 13 51 4 6 Reporting and reviewing the results ccccccseccseeeceeeeeeeeseeesseeeseeeeeeeneeeseeenaees 15 51 4 7 Importing HSC7 Excel files seeeesseeessesesseeeeeeeeenn nennen 16 51 5 Mass balance buttons and dropdowns ccecccsescesesceseeseseseeseeeeeseeenseeeneeensueeneases 19 91 6 E dioe nie Silio mE 22
14. Unit Type Abbreviath M Tatalsolids th Total Solids SF be Experimental Data e v Cu E Solids Component Assay tiris Fj Fe 2b Solids Component Assay Streams i 5 Dn Solids Component Assay Variables Size Fractons Data Sets Measurement Data Fig 6 Experimental Data Variables Table 2 Data types of the variables p Size Fraction wt 96 0 20um 95 20 45um 96 IER oolids percentage 3596 Not included NA Column with comments extra data temperature etc 4 Add size fractions By default one size fraction exists Bulk which cannot be removed More size fractions can be added to removed from the list by clicking the buttons on the upper bar Fraction names can be given Mas 9o000B o 8 x Update Discard Backup Import l Check for Help Add Size Remove Size and Close and Close HSC Data iex Dat Errors Fraction Fraction Fig 7 Experimental Data Size Fractions Copyright Outotec Oyj 2015 HSC 8 Mass Balance utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 9 29 Tommiska Pertti Lamberg 5 Add dataset s By default one dataset exists which can be renamed here In addition more datasets can be added and selected one ata time to carry out data reconciliation Fig 8 Experimental Data Datasets 6 Import measurement data In this view a stream variable template is automatically generated and displayed The data can be entered by a Ty
15. ary 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 11 29 Tommiska Pertti Lamberg 51 4 4 1 View by streams The data are presented in a pivot table where the stream is the major column The data status is shown in pie charts T x Dataset 4 RO x Experimental Data Circuit Sampling on January Stream RUNS Stream Variable a Fraction Value Value Status Balanced Value ni greveeneeeeeenunsseeeenniii eese I Conditioned Cu Bulk i i Missing Non Available Streams TREE a ar a E Variables v Ni Bulk Missing Non Available Size Fractions 5 Bulk Missing Non Available Stream Status Data Sets v Total solids fl Bulk Missing Non Available Measurement Data Feed Cu Bulk 0 45 Measured Balanced Ni 96 Bulk 0 29 Measured Balanced Stream Variable Statu Missing Data Status S59 Bulk 1 84 Mer ed Palanesd Stream Flow by Equation Reference Stream Stream View Totalsolids fl Bulk 800 00 Measured Balanced Multiplier NaN Variable View Final Tails Cu Bulk 0 08 Measured Balanced v Ni Bulk 0 14 Measured Balanced Standard Deviations S956 Bulk 1 42 Measured Balanced v i Missi SD Stream View Total solids f Bulk Issing Calculated SD Variable View RiConc Cu Bulk 20 75 Measured Balanced c 9 x E 0c Balancing Calculated o9 Calculate z 5 Issin Compare 9 Available Reporting Results Fig 11 Data Status Stream View 2 View by variables The data is presented in a pivot table
16. e Missing Values ose Clear Back Calculated Values Remove the selected variable Add a new sieve size Add a new data set Remove the selected data set Transpose streams and variables Copy the whole table Paste data to correct places based on the stream and variable names Element to mineral conversion using HSC Geo View minerals and their compositions Converts solids percentage measurements to water flow rates Back calculate missing data if possible Clear back calculated missing data Copyright Outotec Oyj 2015 Outotec Research Center Pori Antti Remes Jaana HSC 8 Mass Balance January 27 2015 14023 ORC J 21 29 Tommiska Pertti Lamberg f x Balance Equations Unselect Streams with no Data i Exclude Elements MI j ra I c e _s in amp 4 o CL S Sizing Unsized HHE A Balance Solids and Assays ra Calculate Clear Balanced im Stream Tables View the mass balance equations Unselect the streams without data Exclude all elements A and do balancing with minerals M oet component sum 100 when balancing minerals Select calculation method The available methods are LS NNLS and CLS PSD balance Possible selections are Unsized Sized and Sized by Assays Select the data to be balanced Calculates mass balance Clears the mass balancing results Create or update HSC Sim stream tables Copyright
17. ections have been checked you can import your experimental data The following subsections will concentrate on how to import the data for mass balancing and data reconciliation 1 Select units The units are listed based on the flowsheet drawing figure but they cannot be edited here In this view you can e Select or deselect the units to be included in the balancing calculation e oet whether the unit will change the particle size distribution of the solids e g grinding mills This selection is needed in sized balancing to indicate that the fraction balance will not be held over those units Copyright Outotec Oyj 2015 HSC 8 Mass Balance UTOTeC January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 7 29 Tommiska Pertti Lamberg C e Check for Help Errors Selected Unit Name 4 PSD Changing ist Cleaner 2nd Cleaner Cycdone Process Waters Rougher SAG v Scavenger ME KE SS S Fig 4 Experimental Data Units 2 Select streams The streams are listed based on the flowsheet drawing figure but they cannot be edited here Here you can e Select and deselect the streams to be included in the balancing calculation e Change the stream type o Unknown o Solids Slurry o Liquid Water By default it is unknown since the data has not yet been imported When importing the data the type is detected by pressing Detect stream types but it can be changed here Selected Type S
18. ed by assay fraction analyses Let Gand G be News x Ne matrices The operator vec stacks the matrix columns into a vector The equations for the analyses solution are vec G x ved G 24 mass balance equations 25 for the analyses vec B G 0 25 where the Ns 1 Nu Nsnu X Ne2 Ns 1 matrix B is defined B diag B5 Pflow sublow 1 Na 1 26 Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 28 29 Tommiska Pertti Lamberg Sub flows are indexed up to Ns 1 to avoid linear dependency of equality constraints Where the operator diag adds matrices B9 9 at the diagonal of the matrix B and sublow unit x B nit flow flow E ow eub 27 the sum of sub flows is the total flow 28 NS UN a aT Gisow chemical element subflow Friow tot Giiow tot chemical element subflow 1 28 If the option minerals sum 100 is selected the following Equations 29 are included Ne gt Crew Bienes element subflow 100 flow 1 Ney chemicalelement 1 29 subflow 1 Ns If Equations 29 are included B is Ns 1 Nu Nsnu 1 x Ne2 Ns 1 to avoid linear dependencies The solution method used is weighted least squares The equations can be solved without any constraints LS subject to non negativity constraints NNLS and subject to simple bounds CLS Copyright Outotec Oyj
19. k a b c MIN a96 b c 0 0 0 0 af iram Variables S96 Bulk ajb c MIN a b c 0 0 0 0 Measurement Metho a b c MIN a9 o b c Size Fractions Totalsolids t h Bulk a b c MIN a b c 0 0 0 0 x 0 Data Sets c5 v Gr E eS SBS DENNER T e Measurement Data a PEE aa os be a 5 Data Status 5 Bulk a b c MIN b c 00 00 2 Total solids t h Bulk a b c MIN a96 b c 0 0 0 0 Stream View CT2 Cu Bulk a b c MIN a b c 0 0 0 0 Variable View 3 ENS Fig 13 Standard Deviations SD Stream View 2 Standard deviations by variables The data are presented in a pivot table where the variable is the major column Standard deviation settings of all streams for that variable can be easily set at once Copyright Outotec Oyj 2015 Outotec HSC 8 Mass Balance January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 13 29 Tommiska Pertti Lamberg iix HSC Sim 8 Mass Balance E z Update Discard Backup Import Check for Help and Close and Close v HSC7 Data Errors x q Dataset 4 bg E Dataset1 xperimental Da ae Variable lt Stream e Fraction Measurement Method Value RSD SD Units Cu CT1 37 74 um a b c MIN a96 b c 1 27 12 9 0 2 Streams 20 37 um a b c MIN a b c 1 20 13 3 0 2 Variables 106 250 um a b c MIN a96 b c 2 00 10 0 0 2 GEH 0 20 um a b c MIN a b c 1 77 107 0 2 CT2 Bulk a b c MIN a b c 2 91 8 4 0 2 Measurement Data 74 106 um a b c MIN a b c 3
20. l Concentrate 0 002 0 026 0 033 0 019 15 RT 0 000 0 000 16 sc 0 000 0 000 17 Final Tail 2 781 0 882 6 354 0 070 18 cT2 0 000 0 000 19 cri 0 000 0 000 20 Mill Water 0 000 0 000 Mill Sump Water 0 000 0 000 Fig 17 Reporting Results Goodness Copyright Outotec Oyj 2015 HSC 8 Mass Balance Outotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 16 29 Tommiska Pertti Lamberg A 8 C D E F G 1 huc _Equations Stream Total Solids Cu 2 SAG Cycla ROM Final Concentrate Final Tail 3 Inputs ROM 215 000 1 874 14 142 17 653 4 Outputs Final Conce 6 076 1 586 0 679 2 418 5 Final Tail 208 924 0 288 13 463 15 235 6 Balance O DO EHQ0U amp 3bE 13 3 57E 11 5 13E 12 7 Fig 18 Reporting Unit Balance 51 4 7 Importing HSC7 Excel files The Excel files to be imported may contain a sheet with flowsheet information Fig 19 If this sheet is named Flowsheet the program automatically detects the sheet where the flowsheet information is located If the name is something else or there is no sheet containing flowsheet information the name must be specified Fig 23 Select Flowsheet F Analyses Compatibility Mode Microsoft Excel F w Home Insert Page Layout Formulas Data Review View Add Ins Team P db Arial z P General ES Conditional Formatting g Insert iaa E i Format as Table 3 5 Delete 0 00 itt Sort amp
21. mes Jaana 14023 ORC J 5 29 Tommiska Pertti Lamberg 51 3 Overview of the HSC Sim 8 Mass Balancing tool The HSC Mass Balance tool is started from the HSC 8 Main Menu dialog or from HSC Sim Menu Tools Mass Balance The window layout consists of Balancing Navigator Working Area Property Panel and Upper Buttons Upper Buttons Mas HSC Sim 8 Mass Balance Balancing Navigator d Q 9 fi v Update Discard Backup Import Check for Help q and Close and Close Y HSC7 Data Errors X bg Experimental Data Units Y mum Mas HSC Sim 8 Mass Balance Variables epmea xe Update Discard Back Import Check for Hel xui add Sores pace eee HSC Data ius d Property Panel Measurement Data 4 Selected UnitN Name PSD Changing q q bee ta v E amp Data Status M n Units v cyd as M B hea 5 Mee M Stream View varia bles Ee PSD Changing Variable View sica i Zi Selected A Mea v A Standard Deviations SD Stream View Ste gt Vari SD Variable View H standard Deviations Working Area Lg Balancing Stream View Variable Vi Calculate Balandi Calcula Em R i exo pe Results Resul ts 2014 Outote Fig 2 Main components of the Mass Balance window Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 6 29 Tommiska Pertti Lamberg 501 4 51 4 1 51 4 2 Step by step example data reconciliati
22. on and mass balancing in HSC 8 This step by step example shows how to do mass balancing for unsized data consisting of the solids flow rates and assayed element Cu Ni S for a rougher scavenger flotation bank The work starts from HSC Sim 8 by drawing the process flowsheet The Mass Balance tool is started from the HSC Sim Tools menu The steps to import the data and to balance it follow the left side Balancing Navigator panel Fig 2 from top to bottom More examples are found in Chapter 52 Drawing the flowsheet First the flowsheet is prepared in HSC Sim 8 In this rougher scavenger flotation example it looks as shown in Fig 3 You can draw all the streams and units HSC will create the mass balance equations according to the available data therefore there is no need to draw a flowsheet for mass balancing only or a new flowsheet every time for different kinds of mass balance problems When naming the streams use identical names to those in your analysis lists Before proceeding please check the stream connections and check the flowsheet for possible errors File Edit View Tools Drawing Tools Window Help ei a Proce ss Information balize im db dd ag ud E Gum ogg o amp E E 3 E eB ool b dus LCA Evaluation Main Process Fig 3 HSC Sim flowsheet drawing of a flotation process with rougher and scavenger cells Importing the experimental data When the flowsheet is ready i e all streams are named properly and conn
23. ons of error model functions Fixed Fixed standard deviation as a plain number or fixed 0 1 relative standard deviation as a negative number or in parentheses 5 5 X X X 0 X The integer is the relative standard deviation the 10 1 decimal is the detection limit X 0 1 Given parameter is the relative standard deviation 0 1 is the detection limit 10 X Parameter is the detection limit relative standard 0 05 deviation is fixed at 10 a b c MIN a b c a is the relative standard deviation b is the detection 10 0 01 0 5 limit and c is the maximum standard deviation sb a b c MAX a b c a is the relative standard deviation b is the detection 10 0 02 0 2 limit and c is the minimum standard deviation a b cz9e MIN MAX a is the relative standard deviation MIN is the 10 minimum standard deviation and MAX is the maximum standard deviation Manual Standard deviation is given in the data individually for each stream 1 Standard deviations by streams The data are presented in a pivot table where the stream is the major column Standard deviation settings of all variables for that stream can be easily set at once iix HSC Sim 8 Mass Balance LA oooGma se Update Discard Backup Import Check for Help and Close and Close v HSC7 Da Errors v Dataset Dataset_1 Experimental Data SO z bg Stream Variable Fraction Y Measurement Method Value RSD SD Units CCl Cu Bulk a b c MIN a b c 0 0 0 0 Streams Fe Bul
24. ping manually in the table b Copying an empty data template gt organizing the data e g in Excel gt select Paste Experimental Data This will automatically place the data in the correct rows and columns based on the clipboard table content Note if the data is horizontal stream names in rows there must exist a column labelled Fraction that contains fraction names If the data is vertical stream names in columns there must exist a row labelled Fraction containing the fraction names c Importing the old HSC7 Analyses xls mass balance file Each dataset is presented in a separate table tab Mas HSC Sim B Mass Balance o o 3G Update Discard Backup Import and Close and Close T HSC Data EE 0000 9L iz 0000 Ho amp A oN EE amp Check for Help Flip Table Copy Paste Element to View Mineral Sol to Back C Errors T Tm Experimental Data Mineral Matrix Water Missing Balancing Navigator a a A B C D E F amp H I Fraction Fraction m TotalSolidst h Cu Fe S E Ex Experimental Data 2 ROM Bulk 112 000 1 004 6 096 7 000 3 ROM 0 20 um 1 000 1 004 6 096 7 000 Units 4 ROM 20 37 um 2 000 1 004 6 096 7 000 E Streams 5 ROM 37 74 um 5 000 1 004 6 096 7 000 Variables 6 ROM 74 106 um 12 000 1 004 6 096 7 000 Size Fractions 7 ROM 106 250 um 80 000 1 004 6 096 7 000 Data Sets 8 SAG Discharge Bulk 370 612 1 004 6 096 7 000 Measurement Data g 5AG Discharge 0 20 um 15 049 1 00
25. quares The weights are standard deviations of the solids flow rate measurements F the analyses G and fraction m M As before the flow rates can be solved without any constraints LS subject to non negativity constraints NNLS and subject to simple bounds CLS If there are no constraints the minimal maximum norm solution can be calculated LS MinMax 2 Size fraction flow mass balance Then the m values of the sub flows are solved The equations are fraction m measurements 16 M M flow subflow Ir owisubf w 1 6 mass balance equations 17 Ney gt Chow Mrowsubtiow Frowtt 9 unit 1 Ny unit not size reducing 17 flow 1 subflow 1 Ns sum fraction m is a hundred 18 Nsp XM flow subflow i 1 100 18 Equations 17 and 18 are equality constraints The solution method used is element wise total least squares and m values can be solved without any constraints LS subject to non negativity constraints NNLS and subject to simple bounds CLS 3 Bulk analyses If the unsized bulk analyses are given the balanced analyses are calculated as described above see unsized mass balance Sized by assay mass balance Before a sized by assay mass balance solution the unsized or sized mass balance must be solved first The results Frowto of the unsized or sized solution are used in the sized by assay solution In a sized by assay solution the size fraction sub flows are calcula
26. ream Types Unknown found Go to Streams and press Detect Stream Types button or set the stream types manually Variables Size Fraction wt 96 variable missing There should be exactly one variable of the type Size Fraction wt 96 Variables Too many variables of the type Size Fraction wt There should be exactly one variable of the type Size Fraction wt 96 Units No combined units found There can be several reasons why combined units cannot be formed There may be too many missing measurements or there may be errors in the flowsheet Notification Min or Max values detected It is recommended to use the CLS method Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 23 29 Tommiska Pertti Lamberg 91 7 51 7 1 Mathematics and algorithms In this section the main algorithms and methods for data reconciliation in HSC Chemistry 8 are briefly summarized Definitions Ne number of flows unsized Ne number of flows sized sized by assay Nu number of units Nsgu number of size reducing units PSD changing unit Ns number of sub flows Ne number of chemical elements G grade of chemical element G measured grade of chemical element F solids flow rate F 2 measured solids flow rate W water flow rate W measured water flow rate F6 solids F 100 F W Pc measured solids M fraction m
27. rming mass balancing model fitting amp building model fitting will be available later on and simulation Fig 1 ES Sim HSC HSC HSC Experimental WEER Fig 1 From flowsheet with data through mass balancing to modeling and simulation Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 3 29 Tommiska Pertti Lamberg 51 2 Mass balancing capabilities in HSC Chemistry 8 HSC 8 allows the user to solve the following mass balance problems Table 1 There are three different possibilities for the solution Solids Assays only Solids and water independently Liquid flow rates and 9esolids are solved only if Solve solids and water independently is chosen If Assays only is chosen there must be a Total solids measurements for all the flows to be balanced 1 Unsized Balance Total Solids flow rates At least one total solids flow rate measurement must be given Balance Total Water liquid flow rate This is done by first balancing the Total solids flow rates and after that the Total Water liquid flow rate independently Balance solids Balance Solids component assays Mineral assay At least one solids component assay or mineral assay must exist Sized Balance Total Solids flow rates for bulk and all the size fractions At least one total solids flow rate measurement for bulk must be given Balance size fraction wt 96 for si
28. sonable balance you can try to change Estimate of null SD greater Copyright Outotec Oyj 2015 Outotec Research Center Pori Antti Remes Jaana Tommiska Pertti Lamberg 51 4 6 Mas HSC Sim 8 Mass Balance xS HSC 8 Mass Balance January 27 2015 14023 ORC J 15 29 Reporting and reviewing the results 1 i e EE f Update Discard Backup Import Import Check for Help Copy Stream and Close and Close T HSC7 Data Rex Data Errors T m Tables Main Menu Reporting Balancing Navigator A C E F A tr _Fraction name Total Solids t h Meas Total Solids t h Bal Cu Meas Cu Bal F Units ROM Bulk 215 000 215 000 0 890 0 872 Streams SAG Discha Bulk Variables Cyclone UF Bulk Size Fractions Cyclone OF Bulk Data Sets RC Bulk Measurement Data CCl Bulk Final Conce Bulk 6 076 26 100 26 101 Data Status RT Bulk Bulk stream View FinalTail Bulk 208 924 0 120 0 138 Variable View CT2 Bulk CTi Bulk Pa Standard Deviations SD Stream View Fig 16 Stream Summary SENE 5 c D j E i p i variable WssQ DiffTot RelDif AVG 5D AVG RSD Total Solids t h 0 000 0 000 0 000 0 500 0 002 Cu 0 045 0 037 0 136 0 250 0 028 Fe 6 681 1 556 6 429 0 450 0 056 S 96 0 102 0 222 0 401 0 490 0 027 7 Str Sum W550 Diffsum RelDiffsum RelDiffAvg 8 ROM 4 044 0 907 0 393 0 007 SA 0 000 0 000 Cyclone UF 0 000 0 000 Cyclone OF 0 000 0 000 12 BE 0 000 0 000 13 cci 0 000 0 000 14 Fina
29. squares The weights are standard deviations of the solids flow rate measurements F the analyses G the water flow rate measurements Ww and the solids measurements Pc The flow rates can be solved without any constraints LS subject to non negativity constraints NNLS and subject to simple bounds Ibi F lt ubi Ib2 x W x ub2 CLS 2 Bulk analyses Let Gand Gy be Ne x Ne matrices The operator vec stacks the matrix columns into a vector The equations for the analyses solution are measurements 8 vec G ved G 8 mass balance Equations 9 for the analyses vec B G 0 9 where the Ny x Ne matrix B is defined Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 25 29 Tommiska Pertti Lamberg _ Allow x unit flow unit Fsow tot B 10 If the option minerals sum 100 is selected the following Equations 11 are included Ne gt Grow tot chemical _ element 100 flow 1 Ng 11 chemicalelement 1 Equations 9 and 11 are the equality constraints for the solution The solution method used is weighted least squares 1 If Equations 11 are included in Equations 9 the matrix B is Ny 1 x Ne to avoid linear dependency of equality constraints As before the analyses can be solved without any constraints LS subject to non negativity constraints NNLS and subject to simple bo
30. ted first and after that the analyses are solved 1 Sized by assay fraction sub flows The equations for size by assay sub flow solutions are mass balance Equations 19 for each unit that is not size reducing Nr unit x u 7 s gt efon Faow subtow O unit2n nyy4 unit not size reducing flow flow 1 1 9 subflow 1 Ns Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 27 29 Tommiska Pertti Lamberg Above n is the index of the ith unit that is not size reducing Units are indexed up to Ny 1 to avoid linear dependency of equality constraints oum of sub flows is the total flow 20 NS gt Fu Euo Fyow tot flow 1 Nez 20 subflow 1 Analyses for each unit that are not size reducing 21 Ne unit x gt C flow E peroneal element sublow IrenbtoN 0 flow 1 unit 2n ny unit not size reducing chemical element 1 N Subflow 1 Ns Fraction 6m measurements 22 MM F sow s bliow flow subflow i F ioui 100 flow 1 Ne 22 subflow 1 Ns or alternatively flow measurements 23 P few s0biow P r flow 1 Ne 23 Subflow 1 Ns The solution method used is element wise weighted least squares The equations can be solved without any constraints LS subject to non negativity constraints NNLS and subject to simple bounds CLS 2 Siz
31. tream Name a Source Destination gt 4 Unknown Conditioned Conditioner Rougher 1 4 Unknown Feed Conditioner 4 Unknown Final Tails Scavenger 4 4 Unknown RiConc Rougher 1 Rgh Conc Sump M Unknown R 1Tails Rougher 1 Rougher 2 i Unknown R2Conc Rougher 2 Rgh Conc Sump 4 Unknown R2Tails Rougher 2 Scavenger 1 v Unknown Rgh Concentrate Rgh Conc Sump FA Unknown RS1Conc Scavenger 1 Scav Conc Sump vi Unknown RS1Tails Scavenger 1 Scavenger 2 4 Unknown RS2Conc Scavenger 2 Scav Conc Sump A Unknown RS2Tails Scavenger 2 Scavenger 3 v Unknown RS3Conc Scavenger 3 Scav Conc Sump 4 Unknown RS3Tails Scavenger 3 Scavenger 4 M Unknown RS4Conc Scavenger 4 Scav Conc Sump v Unknown Scav Concentrate Scav Conc Sump Fig 5 Experimental Data Streams 3 Add variables Next the measured variables are added removed from the upper bar buttons The variable name and unit on the list can be edited and the variable can also be unselected from balancing if desired The variable types are listed in Table 2 Copyright Outotec Oyj 2015 HSC 8 Mass Balance Outotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 8 29 Tommiska Pertti Lamberg acis HSC Sim B Mass Balance o Oo Update Discard Backup Import and Close and Close T H5C7 Data amp e o x E Check for Help Add Elements Add Mineral Add Variable Remove Errors from DB Variable Balancing Navigator IR Selected Variable Name Meas
32. unds CLS If there are no constraints the minimal maximum norm solution can be calculated LS MinMax 51 7 2 Sized mass balance without sized analyses Sized mass balance differs from unsized bulk solution in that the fraction m is solved and the fraction m measurement is used in the solution of total flows Sized differs from Size by Assay in that the analyses are not given and the number of flows is the same as in the unsized case T Total flow mass balances of the streams Firstly the total flows are solved The Equations are mass balance Equations 12 Nei gt eios Frow tot 0 unit 1 Ny 12 flow 1 fraction m measurements 13 Ne 2 Crow Meow subtiow Frow tot O unit 1 Ny Ngpy 1 flow 1 1 3 subflow 1 Nor Units are indexed up to Ny Nsau 1 to avoid linear dependency of equality constraints Flow measurements 14 Fui 8 FM flow 1 Ng 14 flow tot flow tot If 1D analyses are given the following Equations are included analyses 15 Ne j 7 unit x gt Crow Grew tererencsl element Foowdoi m 0 unit lesus Ny flow 1 1 5 chemical _ element 1 N Copyright Outotec Oyj 2015 HSC 8 Mass Balance Q utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 26 29 Tommiska Pertti Lamberg 51 7 3 Equations 12 are equality constraints for the solution The solution method used is element wise weighted total least s
33. value is given in the property User value e By Equation stream total solids can be set to be a multiple of another stream e Excluded data will not be included in the calculation After Balancing e Balanced solved using data reconciliation e Calculated calculated based on unit material balance Non Available data are also missing after balancing The status indications can be changed by clicking the data table cell dropdown menu or from the property panel on the right The balance equations for the units can be reviewed by clicking the upper bar button shown f x Balance Equations Mass Balance Equations Equation BRARRARRARARRRRRRRRRARARARARARARRARARARARARARARARARARARARARARARERARARARARARARARARARARARARARARARRRARARRARARARARARHARARARARARARARARARARARARARARARRARHARARARARHARARARARHARARARARERRARARARHARARARARHARRARARARARRARARARHARRARARRARARRARARRARHARRARARRARHRRARRHRRRHRRRRNM RRRRRERRHSRHEEHHEREREAREREEAERERHSRSRERERESERERREHAERERHERHSESREHREAZRREHAERERHSRSRERESREHEARZERERHAERERHERHRESREHEREARZRAEEAERERHSRSRERESAESARERERHAERERHSERESREHAREARERAHARERERHSRSRERESAEARREAERHSERERHHESRESREHERERERAEEHRERESERHSEREREHREREEAHRERERHHESREREHARERERAERERSERHSESRERESAERREASSSERSSRHSEHREREHAE Cydone OF RC RT RC 50 TUCIZ UCUCI FCTi CC1 Final Concentrate CT2 RT CT1 5C Final Tail Copy to Clipboard Close Fig 10 Opening and reviewing the balance equations Copyright Outotec Oyj 2015 HSC 8 Mass Balance O utotec Janu
34. where the variable is the major column The data status is shown in pie charts Dataset Circuit_Sampling_on_January Variable Stream Fraction Value Value Status Balanced Value v Cu Conditioned Bulk Missing Non Available Feed Bulk 0 45 Measured Balanced Final Tails Bulk 0 08 Measured Balanced RiConc Bulk 20 75 Measured Balanced RiTails Bulk 0 24 X Balanced R2Conc Bulk 17 12 Missing N Balanced RZTails Bulk 0 15 a l Balanced Fixed Rgh Concent Bulk Exduded Non Available RSiConc Bulk 14 00 Measured Balanced RSi1Tails Bulk 0 12 Measured Balanced RS2Conc Bulk 12 35 Measured Balanced Fig 12 Data Status Stream View Setting the measurement accuracies Each assay and piece of raw data is subject to errors Mass balancing and data reconciliation is meant for adjusting unreliable values whereas reliable values should be adjusted only a little if at all Therefore the user has to give a value of how reliable each item of raw data is This is done by defining the error model to give a standard deviation value for the measurement data In the HSC Sim 8 Mass Balance tool the standard deviation can be given using user friendly pre settings for the error models Copyright Outotec Oyj 2015 HSC 8 Mass Balance utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J 12 29 Tommiska Pertti Lamberg To define the standard deviations vou need to select Table 3 Descripti
35. ze fractions Balance Total Water liquid flow rate for bulk This is done by first balancing the Total solids flow rates and after that Total Water liquid flow rate independently Balance solids for bulk Balance Solids component assays Mineral assay for bulk If no solids component assays mineral assays exist the solids component assays mineral assays for bulk are not balanced oized by assay Balance Total Solids Slurry flow rates for bulk and all the size fractions At least one total solids slurry flow rate measurement must be given Balance size fraction wt 96 for size fractions Balance Total Water liquid flow rate for bulk This is done by first balancing the Total solids flow rates and after that Total Water liquid flow rate independently Balance solids for bulk Balance Solids component assays Mineral assay for bulk and the size fractions Copyright Outotec Oyj 2015 HSC 8 Mass Balance utotec January 27 2015 Research Center Pori Antti Remes Jaana 14023 ORC J Tommiska Pertti Lamberg Table 1 Mass balance cases that can be solved with HSC Sim Measured or Unsized Sized Sized by Assays estimated values Components Solids component Assay Mineral X X X Assay bulk Solid Component Assays Mineral X X assays Size Fractions fem oo a o mo Total Solids Flow rate size X X fractions Copyright Outotec Oyj 2015 4 29 HSC 8 Mass Balance O utotec January 27 2015 Research Center Pori Antti Re

Mass Balance User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents