Tutorial For Simple Flotation Example PDF

HSC Chemistry
6.1 1

Pertti Lamberg J une 25, 2007 06120-ORC-T
HSC Sim 6.1 Tutorials
Simple Flotation Example

Prepared by Pertti Lamberg
Date 25
th
J une 2007
For HSC Chemistry Version 6.1
For HSC Chemistry Modele Sim
Tutorial version Draft 2.0, J une 2007
Checked and approved -
Language checked -
Keywords Flotation

Table of Contents

Table of Contents...........................................................................................................................1
Introduction.................................................................................................................................... 1
Drawing the flowsheet ................................................................................................................... 4
Mineralogical set-up .................................................................................................................... 14
Defining the unit models.............................................................................................................. 21
Simulation..................................................................................................................................... 23

Introduction
Simple flotation example shows how to use mineral based models and Excel Wizards in the HSC
Chemistry. Table on page three is a useful checklist. Use it.

Before you start the drawing of the flowsheet and simulating a process with the HSC Chemistry, you
should do the following:
1. Decide the level of details you want to have in the drawing and simulation.
a. Is it necessary to draw all the existing units (e.g. pump sumps), or could the circuit be
simplified without losing any information?
b. It is a good idea to draw a draft of the flowsheet on a piece of paper. That helps you in
placing the units in a good way.
2. Decide the level in terms of particles. The possible levels from the lowest (least information) to
the highest are:
a. Sized model without composition. Typically grinding circuits are
modeled like this. The chemical and mineral composition of the
input (e.g. ROM) is identical to the output (e.g. flotation feed), and
the main interests are in flowrates and in required energy.
(Typically 5-25
particles)
b. Unsized mineral model. Each mineral is treated separately but all (Typically 3-8
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the size classes are treated together. Typically a simple flotation
models are like this.
particles)
c. Unsized floatability components model. Each mineral is divided
in 2-3 floatability classes, i.e. fast floating, slow floating and non-
floating.
(Typically 9-25
particles)
d. Size-by-mineral model. Each mineral by size is treated separately.
This approach enables the simulation of full mineral processing
circuit including crushing, grinding, classification and different
kind of separation techniques like flotation, gravity separation,
magnetic separation and dewatering.
(Typically 15-
50 particles)
e. True particles model. This is the highest level of the modeling
where particles treated in the process has been measured with e.g.
MLA and all of them or groups formed from them are treated in the
process.
(Typically 200-
1000 particles)

Remember that if you go to higher-level approach you need more data and better models.

3. List the minerals present in the circuit. Find their chemical composition. Decide the level in terms
of particles. The possible levels from the lowest (least information) to the highest are:

The steps are (use table on page 3):
1. Draw the units of the flowsheet and rename them
2. Draw the streams and rename them. Draw only the input streams with solids (water additions are
drawn later)
3. Check the connections.
4. Save the flowsheet
5. Do the mineralogical set-up
a. Define minerals
b. Define size fractions
c. Define the Feed stream(s) mineral grades, check the elemental grades
d. Save
6. If there are any water additions, draw them now. Save.
7. Load the Excel Wizards.
8. Run the Excel Wizards.
9. Modify the Models created with the wizards. Save.
10. Simulate.
11. Do required changes. Add controls if required.
12. Iterate steps 10 and 11 until ready. Save.
13. Report. Add labels, check the stream report.
14. Test different process options using the Remote Control
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Model: Drawn by: Date:
Flowsheet. Draw a sketch below. Think do you really need all the units.
Units / models

Model level Sized Unsized
mineral
Unsized floatablity
component
Size-by-
mineral
Particles
model
Minerals and their chemical compositions: Number of minerals: _______ and elements______
No 1 2 3 4 5 6 7 8 9
Mineral

Size classes: Number of size classes: ___________
Fraction 1 2 3 4 5 6 7 8 9
From
To
Progress in HSC Chemistry
1. Draw units Draw the units and rename them.
2. Draw streams Draw the streams and rename them
3. Check the connections Check that all streams are connected properly
4. Save the flowsheet Create a new folder for each new flowsheet
5. Run the mineral set-up Define minerals and size classes. Run variable list.
6. Add water additions Add the water additions after the mineral set-up. Save.
7. Load the Excel wizard models Unit by unit select Wizard Load Excel Wizard
8. Run the Exel wizard models Unit by unit select Wizard Run Excel Wizard.
9. Edit models and save Check and edit cells with blue text. Do not touch cells with red text.
10. Simulate Check that material is transported as you expect.
11. Continue. Continue by doing changes and simulating. Report results etc.
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Drawing the flowsheet
The basic information of the flowsheet created here is given in Figure 1. In this tutorial the flowsheet
includes units whose pictures are in the folder C:\HSC6\Sim\Units\Flotation. If you cant find the folder in
the combo box under the Process tab in the Properties panel on right follow Figures 2-3 to make it
available.

Figure 1. Basic information of the flowsheet.
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Figure 2. Changing the unit folder level, press first the -button.

Figure 3. Changing the unit folder level.

The draw the flotation cells select Flotation folder as shown in
Figure 4. Select the flotation cell (Figure 5), move the cursor on the right place in the flowsheet and draw
a unit by dragging the mouse (Figure 6). Draw the second and the third unit (Figure 8). Click the Persist
Tool on to keep the flotation cell picture active (Figure 9). Click the Snap to Grid tool on to make the
alignment of the units easier (Figure 9).

To make the roughers same size select them first using Shift+Left Mouse Button. Then select from the
menu Arrange Make Same Size Both (Figure 10). To align the roughers select Arrange Align
Bottom (Figure 11).

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Figure 4. Selecting unit folder.

Figure 5. Select a unit.

.
Figure 6. Drag a unit

Figure 7. Drawing the second cell.

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Figure 8. Preparing to draw the third cell.

Figure 9. Options for Snap to Grid and Persist Tool.

Figure 10. Make the roughers similar in size.
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Figure 11. Align the roughers.

To rename the units select each unit individually and in the right pane, in the Properties pane, select the
Process tab and write the name of the unit in the NameID field (Figure 12). After renaming the units the
flowsheet should look like the one shown in Figure 13.

Figure 12. Renaming units.
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Figure 13. Flowsheet after drawing the units and renaming them.

The next step is to draw all the streams (except the water addition streams). Select the stream tool from the
left button bar (Figure 14), click the stream starting point (and release the mouse button), move the cursor
to the next node point, click (and release the button), and continue until you are in the stream ending point.
Double click to end the stream drawing. To edit the stream node points, select a stream, press Space and
drag the node points or add them. Press space again to return to normal stream drawing mode (Figure 15).

Continue until all streams are drawn (Figure 16). Rename each stream individually (Figure 17): 1) Select
the stream, 2) In the Properties pane on right click to Process tab and 3) Write the proper stream name in
the NameID field.

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Figure 14. Selecting the stream tool.

Figure 15. Edit points toggle with
space bar.

Figure 16. All streams drawn.
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Figure 17. Renaming a stream.

After drawing the streams you need to check if the connections are correctly. To have a quick look which
streams are input streams for the whole flowsheet, which are output streams and which are intermediate
ones push the Overlay and Route Check button (Figure 18).

Figure 18. Check the stream connections by pressing the Overlay and Route Check button. Keep it
pushed down and color-coding tells which streams are input streams (blue), output streams (red) and
intermediate streams (black). In the figure 4RC is not connected correctly; red color indicates that it is not
going to any unit, i.e. is one of the output streams of the flowsheet.

To connect the stream properly select the stream, go to the Properties pane on right and in the Destination
field select from the list the proper unit; e.g. like in the Figure 19 the Destination is set to Pump sump.

After you have checked and made sure that stream connections are correct, save the flowsheet. Since each
unit will appear as a separate Excel file, create a new folder for each flowsheet. Follow steps shown in
Figure 20-Figure 23. Figure 24 shows the content of the folder after saving the flowsheet, i.e. an Excel file
for each unit.
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Figure 19. Redirecting the stream 4RC to the Pump sump.

Figure 20. To save the flowsheet select File Save Process As
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Figure 21. Create New Folder.

Figure 22. Rename the folder.

Figure 23. Give name for the flowsheet and press Save.
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Figure 24. Content of the folder.

Mineralogical set-up
After you have completed the drawing of the flowsheet, the next step is to do the mineralogical set-up. To
do that select Data Mineral set-up from the menu (Figure 25). The setup contains six steps (Figure 26
and Figure 27):

1. Minerals (define the minerals and their composition, global)
2. Size classes (define the size classes used globally)
3. Streams (give composition of the input streams)
4. Variables (HSC Sim creates the variables in the units)
5. Save the setup
6. Ready

Figure 25. Starting the mineral set-up.

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Figure 26. Mineral set-up window.

Figure 27. Mineral set-up contains six steps.

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Follow figures 28-30 to load the approapriate minerals, remove unnecessary ones and editing the chemical
composition of them.

Figure 28. Mineral setup. Selecting Au ore simple for the minerals.

Figure 29. Simle Au ore consists of five minerals. To remove one place cursor to any cell on that column
you want to remove, press right mouse button and select remove mineral.
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Figure 30. Edit the chemical composition of minerals, their names. Check and edit, if necessary, all fields
with blue text.

To define size classes press button 2. Size classess.. Follow Figures 31-32 to complete that.

Next, press button 3. Streams and edit the mineral grades in the feed stream, e.g. Flotation Feed in
this case (Figure 34). Check the elemental grades below. To ensure that chemical grades have been
updated press right mouse button and select Update chemical composition (Figure 35).

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Figure 31. Selecting size classes.

Figure 32. Edit upper and lower sizes.

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Figure 33. Step 3.

Figure 34. Edit the mineralogy of the feed stream, Flotation Feed.

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Figure 35. Update the calculation of the chemical composition (calculated from mineral grades, blue
values) using right mouse button.
Finish the mineral set-up by pressing the buttons 4. Variables, 5. Save, and 6. Ready (Figure 36).

Figure 36. Finishing the mineral setup; 4, 5 and 6.
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Defining the unit models

The next thing needed is to load the appropriate models in each unit. Here we will use Mineral
Distributor for the flotation units and Perfect Mixer for the pump sump. Follow figures 37-40 to
complete the task. In flotation use following recoveries in each of the units: Gold 90%, pyrite 80%,
chalcopyrite 92% and gangue 8%.

Figure 37. Double click the unit 1
st
Rougher and select in the Excel model window:Wizard Load Excel
Wizards

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Figure 38. Loading model for flotation units: Mineral Distributor.

Figure 39. When loading the model HSC Sim creates Wizard sheet. After checking that the model is the
correct one apply it by selecting Wizard Run Excel Wizard
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Figure 40. When running the wizard model HSC Sim creates a model in the Model sheet and creates
appropriate references to other sheets (Dist, Output, Input). Edit the split values of minerals (note that the
split to is indicated in the cell C17 and it can be either concentrate or tailing, depending on which order
did you draw them).

Simulation and reporting

To simulate press the Star Simulation button (Figure 41). In the simulation window press calculate
(Figure 42) and after Sim has completed the calculations check streams one-by-one and check in the right
pane that each variable has a value, i.e. that the particles are transported in the units as expected (Figure
43).

Figures 44-49 show how to add value and header labels and display values of any selected variable in the
flowsheet.

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Figure 41. Start simulation.

Figure 42. Run the simulation.
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Figure 43. Click streams one-by-one and check that material has been transported. Values are shown in
the right pane.

Figure 44. For adding value labels select all streams
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Figure 45. and select Tools Insert Value Label.

Figure 46. To edit the styles of value labels simultaneously select the first

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Figure 47. and edit the style in Properties pane, Drawing tab.

Figure 48. Insert the Header Label.

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Figure 49. Value labels and header label added. In simulation window selected variable appears as
numbers in each stream. By clicking a unit you can see the balance of the selected variable.

Tutorial For Simple Flotation Example PDF

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