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makes possible the on-line computation of metallurgical balances. Finally, the application of steady-state
process modelsu21 for flotation circuit analysis and
optimization requires, as a first step, the computation
of complete and accurate internal metallurgical balances from experimental data.
This paper describes a numerical procedure for
computing mass balances which minimizes specialpurpose programming effort and computer storage
requirements, and which is suitable for both laboratory and plant (including on-line) use. An error
analysis is included.
INTRODUCTION
THE COMPUTATION of metallurgical balances from imprecise analytical data is a frequently occurring problem in flotation plants. In mill practice, very approximate methods have normally been used, due to the
computational difficulty of more accurate statistical
methods. With the steadily growing availability to
mill staff of computer facilities, more accurate methods are now feasible. In addition, the growing use
of on-line X-ray analysis and control computers now
PROBLEM, STATEMENT
Consider a flotation circuit in which streams 1, .. . ,
n have metallurgical compositions given by the composition vectors
=
C*
l
~fl]
ctn
w*
H. W. SMITH
wT J
~;
N. M. JCBIYEN
w*) = 0,
i = 1, .. , m.
However, the data available are not the true composition vectors c:, but rather the measured composition
vectors
Ci =
cf
+ e;
w,
f;
<2. w) = o
97
00
(Ci -
i=l
C; )
'M"j 1 (Ci -
where
M,
w.
E (e;d )
(i.e. the covariance matrix of sampling and measurement error ) and the prime denotes the transpose of a
vector or matrix.
'Briefly stated, therefore, the problem is: minimize
the objective function
(c, -
i=l .. . -
C;)
METHOD OF SOLUTION
COMPUTATIONAL EXAMPLES
Ci)
0.
w,
First consider a flotation circuit having the configuration 8hown in Figure 1. Grab samples were
taken from the eight process streams indicated, and
analyzed to yield the data shown in the first column in
Table 1. The three mass flows indicated in Figure 1
are to be estimated, together with the corrected values
of the twentycfour analyses.
@ ___!!1:.
mi~
R
S
w~
3
FIGURE 1 -
w,c
Zinc Circu it .
3 . Form
c, =
C;
+ OCi
:and evaluate J (w ) .
Adjusted Analysis
Stream
Cu
Zn
Fe
Cu
Zn
Fe
1
2
3
4
5
6
7
8
0.163
0.447
0.466
0.140
0.960
0.657
1.020
0.440
3.93
11.63
8.11
0.49
34.64
52.07
42.73
U.86
11.57
12.79
14.35
13.09
14.37
14.67
14.66
13.75
0.170
0.462
0.406
0.136
0.964
0.649
1.009
0.472
3.85
11.73
8.72
0.49
38.85
51.70
37.01
10.75
12.34
13.56
13.45
12.18
14.48
14.56
14.47
13.77
Cu
4.17
3.29
-12.83
- 2.76
0.43
- 1.20
- 1.06
7.38
Zn
- 1.87
0.83
7.48
0.12
12.16
- 0.71
- 13.39
- 9.39
Fe
6.59
6.02
-6.22
- 6.94
0.77
-0.73
- 1.30
0.11
w1=
98
CD
UNIT
CELLS
l. Circuit:
COPPER
FLOTATION
ZINC
FLOTATION
@)
\J)
WI
w3
2. Scavenger:
FIGURE 2 -
3. Cleaner :
W3C5 -
W1C6 -
W1 +
W2 +~w3) C2 -
(1 -
W1 +
W2)C3 -
W3C5 =
B (w) =
Flotation Circuit.
W1)C1 =
(w a -
4. Rougher:
(1 -
W2
- (1-wi)
-(1-wi)
Cu
Adjusted
Analysis
Zn
Cu
Per Cent
Adjustment
Zn
Cu
Zn
---1
2
3
4
5
6
7
1.93
0.45
0.13
0.09
19.86
21.44
0.51
3.81
4.92
5.36
0.41
7.09
4.95
52.10
1.91
0.45
0.13
0.09
20.04
21.45
0.52
4.61
4.58
4.38
0.41
6.91
4.92
51.59
-1.02
0.01
-3.78
2.45
0.91
0.03
l.17
20.94
6.82
18.26
0.09
2.55
0.51
0.98
0
Mass flows (with 503 probable error):
wI =
0
-(wa-W1)
-W3
0
0
.067,
w2
= .459,
wa =
-.058.
iv,
o.06563
w2=
3.781
wa
= o.5238
and to the corrected analyses given in the second colume of Table 1. The third column gives the per cent
change in the original analysis. The r.m.s. sampling
and analytical error may be approximated by the
standard deviation of the corrections, which is
a =
6.56% .
.06954 .00232;
.07066 .00668.
W2 =
.08964 .00261;
As a second example, consider a metallurgical balance over an entire plant, based on X-ray data. The
plant is shown in Figure 2 and the data in Table 2.
The mass balance equations are:
1. Unit cells
C1 -
(1 -
W1 ) C2 -
W1C5 =
2. Copper section
C1 -
(1 -
W2 ) C3 -
W2C6
= 0
3. Zinc section
(1 -
,v,
wa=
W2)C3 -
(l
- W2 -
W3) C4 -
W3C7
= 0
from which the B(w) matrix is found. In this particular case, the precision of the different X-ray measurements was approximately known from calibration experiments, and the M matrices were based on
these data. A starting value of
was found from
standard two-product formulas:
w,
= o.70, w2 = 0.091,
w3= o.096.
iv,
= o.06954,
w2 = o.08964, wa
= o.07066,
9S
ERROR ANALYS IS
SENSITIVITY OF SOLUTIONS
w,
Ai(c,) ow
+ B (w) oci
i = l, ... , m.
1, . ,m.
where
[(~*-~ ) ~*-~)'] =
.000644 - .000027
.000644 1.197
.1039
-.000027
.1039
.0398
w 1 =
0.01161,
aW2 =
1.094,
wa
= 0.1995,
wa,
At = (A:Ai)- 1A:
CONCLUSIONS
To use all the experimental data, the m sets of equations must be combined. It is easily verified that this
is done by forming
A' = [A; M ... A,:.]
B=
B 0
0 B
0 0
M1
M
=I
ACKNOWLEDGMENTS
. 0
M2
REFERENCES
(1) King, R. P., Model for the Design and Control of
Mrn
(2)
and finding
(3)
100
[c ..... C; n].
2
(4)
(5)
(6)