EXAMPLE 22 Comminution

1
2
3
4
5
6
7
8
9
10
11

NO
SEC
SCR
CRJ
CVB
SCR
CRC
SCR
CRC
MLB
SMP
CYH

FLOWSHEET DATA
OPR UNIT PROCESS IS1 IS2 IS3 IS4 IS5 IS6 INV OS1 OS2 OS3 OS4 OS5 OS6
COMMINUTION
0
0
0
0
0
0
0
0
0
0
0
0
0
GRIZZLY
1
0
0
0
0
0
0
2
3
0
0
0
0
JAW
3
0
0
0
0
0
0
4
0
0
0
0
0
CONVEYOR
2
4
0
0
0
0
0
5
0
0
0
0
0
DOUBLE DECK
5
0
0
0
0
0
0
6
7
8
0
0
0
CONE
7
8
0
0
0
0
0
9
0
0
0
0
0
DOUBLE DECK
6
9 13
0
0
0
0 10 11 12
0
0
0
CONE
11 12
0
0
0
0
0 13
0
0
0
0
0
BALL MILL
10 14 18
0
0
0
0 15
0
0
0
0
0
15 16
0
0
0
0
0 17
0
0
0
0
0
CYCLONE
17
0
0
0
0
0
0 19 18
0
0
0
0

Cummulative Fraction Passing Data

17.00 IN
12.00 IN
8.48 IN
6.00 IN
4.24 IN
3.00 IN
2.12 IN
1.50 IN
1.05 IN
0.742 IN
0.525 IN
0.371 IN

1.0
0.98
0.85
0.68
0.48
0.37
0.26
0.20
0.14
0.11
0.08
0.06

3 TY
2000 TY

0.04
0.00001

91

COMMINUTION EXAMPLE
The design of the circuit is to achieve a product of 110 microns.
Process Data
The components required are SiO2 (Quartz) Solid and H2O aqueous.
Stream 1 - The Feed flowrate is 400 mt/hr and contains 95% solids.
Stream 14 - Ball mill make-up water. Initially estimated as 10 mt/hr. This flowrate will be adjusted by a percent solids
controller, PSC, on the ball mill unit operation, maintaining 68% solids.
Stream 16 - Cyclone make-up water. Initially estimated as 10 mt/hr. This flowrate will be adjusted by a percent solids
controller to maintain 55% solids.
Percent Solids Controls
CN
ID
1001
MLB 68% Solids
1002
CYH 55% Solids
User Created Objects
Scaler Name
ID
USMLBRATIO
MLB L-WR

OP
9
11

SN
14
16

PS
0.68
0.55

Value
1.25

Then click the Ball Mill unit operation with the Edit Object Data Tool & in the Controls CtA field enter
USMLBRATIO(IL+0)ID
IL is the Ball Mill Length Inside Liners

ID is the Ball Mill Diameter Inside Liners

Now add the following Stream Graphic Boxes, remembering there is already an EXAMPLE in the List
window of the Stream Graphics Boxes and this is Box number 1.
Stream Graphic Boxes - Add the following Stream Graphics Boxes.
Box No 2
Box No 3
BX Outputs
Cyclone
CW
6
L1 SN
SN
F1 S
S
L2 SI Mt/Hr
SI Mt/Hr
F2 SI VCWT S
SI VCWT S
L3 LI Mt/Hr
LI Mt/Hr
F3 LI VCWT S
LI VCWT S
L4 % Solids
% Solids
F4 100 VPCS S
100 VPCS S
L5 P80
P80
F5 VP80 S
VP80 S
L6
No CYH
F6
'NO' VFLS u11
L7
Dia CYH INCHES
F7
'DC' VFLS u11
L8
CYH PRESS
F8
'PR' VFLS u11
L9
% CIRC LOAD
F9
100(SI VCWT s18)SI VCWT s19
All Streams
Except 15 & 19

Stream 19

Box No 4
Ball Mill
6
SN
S
SI Mt/Hr
SI VCWT S
LI Mt/Hr
LI VCWT S
% Solids
100 VPCS S
P80
VP80 S
No. MLBs
'NO' VFLS u9
DIA INSIDE LINERS
'ID' VFLS u9
Length INSIDE LINERS
'IL' VFLS u9
MLB L TO W RATIO
USMLBRATIO
Stream 15

92

From the results it will be noticed the cyclone overflow did not meet the requirements of 80% passing 110
microns. A feedback controller will now be applied to adjust the cyclone feed stream percent solids to
achieve the required micron size.
Feedback Control
CN
1003

OP
11

NO
10

SN
0

OV
0.55

LV
0.5

HV
0.6

VF
VP80 s19 110

SP
1

SL
ID
Control % Solids so P80=110

The Feedback Controller above will adjust the Percent Solids Controller 1002 until a P80 of 110 microns is
achieved in stream 19.
Percent Solids Control
For the Feedback Control to adjust the Percent Solids Control the following changes must be made to the
Percent Solids Control 1002.
The PS variable in PSC controller 1002 should be change to;
VCTL 1003
The model may be calculated again. The feedback controller adjusts the percent solids of the cyclone feed
until the desired product size of 110 microns is achieved in stream 19.
Unit Operation Data
All of the Input Data for the Unit Operations can be found on the diagram.
How The Flowsheet Is Calculated.
1. Calculate the Current Section.
2. After Calculating select to Edit the Ball Mill and then select the Dimensions Window.
The Ball Mill is setup initially with Calculation Option 2 - P80.
The variable P8 is set at 110 microns
which is our target and the Diameter Of The Inside Liners, ID, is set at 15.5 feet. After Calculating
METSIM will predict the Inside Liners Length, IL. In this example 39.45928869 feet. 15.5 x 39.5 is too
long for a Ball Mill so we go to the to the Ball Mill Window of the Unit Operation data and change the
Number of Ball Mills, NO, to 2.
Now Calculate just the Ball Mill. Then go back to the Dimensions Window in the Ball Mill Unit Operation
Data and look at the value for IL. It should now be 19.72964435. The Mill Ratio for this is 1.375 = 15.5 x
19.75. So to set METSIM to use this size change the CO option to 1-Bond Inside Length so that METSIM
will now use the IL in the Calculation instead of the P8, P80, value.
Next Calculate the Flowsheet. Notice in the results that 10 Cyclones were predicted but the P80 value was
a little low at 104 microns.
A feedback controller will now be applied to adjust the cyclone feed stream percent solids to achieve the
required micron size.
Feedback Control
CN
1003

OP
11

NO
10

SN
0

OV
0.55

LV
0.5

HV
0.6

VF
VP80 s19

SP
110

SL
1

ID
Control % Solids so P80=110

The Feedback Controller above will adjust the Percent Solids Controller 1002 until a P80 of 110 microns is
achieved in stream 19.

93

Percent Solids Control

For the Feedback Control to adjust the Percent Solids Control the following changes must be made to the
Percent Solids Control 1002.
The PS variable in PSC controller 1002 should be change to;
VCTL 1003
The model may be calculated again. The feedback controller adjusts the percent solids of the cyclone feed
until the desired product size of 110 microns is achieved in stream 19.
The Cyclone achieves 110 microns in stream 19 but only 9 Cyclones have been predicted. As an equal
number of Cyclones are required for 2 Ball Mills it will be necessary to change the IL .
Set the IL variable in the Ball Mill to 19.5 and Calculate.
Still only 9 Cyclones predicted so set the IL variable in the Ball Mill to 19.25 and Calculate.
Now METSIM Predicts 10 Cyclones at a pressure inside our range for the Cyclone.
RESULTS
NO. STREAM MT/HR-SI MT/HR-LI MT/HR-TC
---+--+--------+--------+-------1 1
380.000
20.000 400.000
2 2
242.449
12.760 255.210
3 3
137.551
7.240 144.790
4 4
137.551
7.240 144.790
5 5
380.000
20.000 400.000
6 6
126.013
6.632 132.645
7 7
111.292
5.857 117.149
8 8
142.695
7.510 150.206
9 9
253.987
13.368 267.355
10 10
380.000
20.000 400.000
11 11
172.922
9.101 182.023
12 12
243.849
12.834 256.683
13 13
416.771
21.935 438.706
14 14
0.000 237.547 237.547
15 15
2253.630 1060.532 3314.162
16 16
0.000 708.939 708.939
17 17
2253.630 1769.471 4023.101
18 18
1875.364 803.725 2679.089
19 19
378.267 965.746 1344.013

94

Comminution Example
SCREEN SIZE ANALYSIS

---------------SCREENS MICRON
---------------12.0 IN 304800
8.48 IN 215392
6.00 IN 152400
4.24 IN 107696
3.00 IN 76200
2.12 IN 53848
1.50 IN 38100
1.05 IN 26670
.742 IN 18847
.525 IN 13335
.371 IN
9423
3 TY
6730
4 TY
4760
6 TY
3360
8 TY
2380
10 TY
1680
14 TY
1190
20 TY
841
28 TY
595
35 TY
420
48 TY
297
65 TY
210
100 TY
149
150 TY
105
200 TY
74
270 TY
53
400 TY
37
600 TY
26
800 TY
19
1200 TY
13
1600 TY
9
2000 TY
7

STREAM NO. 1
1
P80= 194554
-------------------MT/HR % RET % PAS
-------------------7.600 2.000 98.00
49.400 13.000 85.00
64.600 17.000 68.00
76.000 20.000 48.00
41.800 11.000 37.00
41.800 11.000 26.00
22.800 6.000 20.00
22.800 6.000 14.00
11.400 3.000 11.00
11.400 3.000
8.00
7.601 2.000
6.00
7.599 2.000
4.00
0.765 0.201
3.80
0.769 0.202
3.60
0.761 0.200
3.40
0.769 0.202
3.19
0.761 0.200
2.99
0.766 0.202
2.79
0.764 0.201
2.59
0.769 0.202
2.39
0.765 0.201
2.19
0.765 0.201
1.99
0.758 0.199
1.79
0.773 0.203
1.58
0.772 0.203
1.38
0.737 0.194
1.19
0.793 0.209
0.98
0.779 0.205
0.77
0.692 0.182
0.59
0.838 0.220
0.37
0.812 0.214
0.16
0.593 0.156
0.00

STREAM NO. 10
10
P80= 9941
-------------------MT/HR % RET % PAS
-------------------0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
89.86 23.647 76.35
103.46 27.226 49.13
58.59 15.419 33.71
29.65 7.803 25.91
15.30 4.027 21.88
11.84 3.115 18.76
10.60 2.790 15.97
9.45 2.487 13.49
8.36 2.201 11.29
7.36 1.936
9.35
6.41 1.688
7.66
5.55 1.460
6.20
4.74 1.248
4.96
4.04 1.062
3.89
3.39 0.891
3.00
2.77 0.729
2.27
2.32 0.611
1.66
1.87 0.493
1.17
1.43 0.376
0.79
1.28 0.338
0.46
1.04 0.274
0.18
0.69 0.181
0.00

STREAM NO. 15
15
P80= 795
-------------------MT/HR % RET % PAS
-------------------0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
0.00 0.000 100.00
10.13 0.449 99.55
24.05 1.067 98.48
39.46 1.751 96.73
56.95 2.527 94.21
76.42 3.391 90.81
97.06 4.307 86.51
122.33 5.428 81.08
150.57 6.681 74.40
185.24 8.220 66.18
223.51 9.918 56.26
261.41 11.600 44.66
243.15 10.789 33.87
177.24 7.864 26.01
131.00 5.813 20.19
99.19 4.402 15.79
85.27 3.784 12.01
66.12 2.934
9.07
46.66 2.071
7.00
43.65 1.937
5.07
31.85 1.413
3.65
82.35 3.654
0.00

---------------SCREENS MICRON
---------------3 TY
6730
4 TY
4760
6 TY
3360
8 TY
2380
10 TY
1680
14 TY
1190
20 TY
841
28 TY
595
35 TY
420
48 TY
297
65 TY
210
100 TY
149
150 TY
105
200 TY
74
270 TY
53
400 TY
37
600 TY
26
800 TY
19
1200 TY
13
1600 TY
9
2000 TY
7

STREAM NO. 17
17
P80= 795
-------------------MT/HR % RET % PAS
-------------------10.13 0.449 99.55
24.05 1.067 98.48
39.46 1.751 96.73
56.95 2.527 94.21
76.42 3.391 90.81
97.06 4.307 86.51
122.33 5.428 81.08
150.57 6.681 74.40
185.24 8.220 66.18
223.51 9.918 56.26
261.41 11.600 44.66
243.15 10.789 33.87
177.24 7.864 26.01
131.00 5.813 20.19
99.19 4.402 15.79
85.27 3.784 12.01
66.12 2.934
9.07
46.66 2.071
7.00
43.65 1.937
5.07
31.85 1.413
3.65
82.35 3.654
0.00

STREAM NO. 18
18
P80= 973
-------------------MT/HR % RET % PAS
-------------------10.13 0.540 99.46
24.05 1.282 98.18
39.46 2.104 96.07
56.95 3.037 93.04
76.42 4.075 88.96
97.06 5.175 83.79
122.33 6.523 77.26
150.57 8.029 69.23
185.24 9.877 59.36
223.37 11.911 47.45
257.76 13.744 33.70
217.14 11.579 22.12
124.36 6.631 15.49
74.08 3.950 11.54
50.31 2.683
8.86
41.09 2.191
6.67
31.06 1.656
5.01
21.65 1.154
3.86
20.10 1.072
2.78
14.59 0.778
2.01
37.64 2.007
0.00

STREAM NO. 19
19
P80= 110
-------------------MT/HR % RET % PAS
-------------------0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.000 0.000 100.00
0.001 0.000 100.00
0.136 0.036 99.96
3.655 0.966 99.00
26.011 6.876 92.12
52.878 13.979 78.14
56.919 15.047 63.09
48.886 12.924 50.17
44.182 11.680 38.49
35.055 9.267 29.22
25.015 6.613 22.61
23.552 6.226 16.38
17.257 4.562 11.82
44.719 11.822
0.00

95