SIMULATION

&

MODELING

of
Mineral Processing Systems

LABORATORY MANUAL
for

M.Tech. (Mineral processing)

V Semester
S.M.SHASHIDHAR

GULBARGA UNIVERSITY POST-GRADUATE,CENTRE,

KRISHNADEVARAYANAGAR, NANDIHALLI, SANDUR.

CONTENTS
SL. NO.

DATE

EXPERIMENT

About MODSIM

II

Drawing Icons on the flowsheet

III

Unit Models available in MODSIM

IV

Procedure for Simulation

Simulation of Jaw Crusher

Simulation of Gyratory Crusher

Simulation of Screen

Simulation of Hydrocyclone

Simulation of Ball Mill Circuit

Simulation of Flotation Cell

Simulation of Stream Splitter

Simulation of Mixer Unit

Simulation of Sump

10

Simulation of Conveyer

PAGE

About MODSIM
MODSIM is a simulator that will calculate the detailed mass balance for any ore
dressing plant. The mass balance will include total flowrates of water and solids, the particle
size distribution of the solid phase, the distribution of particle composition and the average
assay of the solid phase. The assay can include mineralogical composition, metal content
and element content. Other special particle properties that are specific to particular systems
can also be accounted for. Some are calorific value, volatile matter, pyritic sulfur, organic
sulfur and ash content for coal, and magnetic susceptibility and electrical conductivity for
mineral systems that are processed by magnetic or electrostatic separators. Other,
sometimes very subtle, particle properties such as particle shape, mineralogical texture and
surface characteristics have important influences on the behavior of some of the unit
operations of mineral processing. MODSIM can accommodate all of these particulate
properties. The main unit operations of ore dressing include the sizereduction operations,
crushing and grinding, classification operations for separation of particles on the basis of
size, concentration operations that separate particles according to their mineralogical
composition and solid-liquid separations. MODSIM provides a repertoire of standard models
for these operations.
MODSIM has a completely modular structure which allows models for the unit
operations to be added into the simulator. Thus the models that are used to simulate the
operation of the various unit operations can be developed and modified to suit the plant
under any operating conditions and can be tuned to meet the needs of any application. This
characteristic of MODSIM also allows the user to develop and incorporate the results of
ongoing research in the mathematical modeling of the unit operations of mineral processing.
The repertoire of models available to the system increases continuously as more are added
by users. The user can call on any available model.
MODSIM calculates the composition and completely characterizes the particulate
material in each stream of the plant. The output includes the total flowrates of water and
solid, the particle-size distribution and the distribution of particle composition over the particle
population as well as the detailed assay of each stream. In addition a comprehensive report
is produced for the performance of each unit in the plant. The report will vary according to the
duty that the unit must handle in its position in the flowsheet. The data in the report can be
used for detailed unit design and sizing, for unit costing, for equipment selection and for
equipment and process evaluation.
MODSIM is unique among currently available simulators in that it can simulate the
liberation of minerals during comminution operations. This aspect of mineral processing plant
operation is becoming increasingly relevant as plant managers seek greater operating and
plant efficiency.
MODSIM is a steady-state simulator and is not designed to simulate dynamic
operations. It is not suitable for the design and simulation of process control systems.

DRAWING ICONS ON THE FLOWSHEET

PROCEDURE FOR SIMULATION EXERCISES

1 Drawing the Flowsheet
i. Go to File menu and click Start a new job .
ii. Go to Edit menu and click location cursor. The cursor appears on the screen
and it should be placed in a convenient position on the screen.
iii. Go to Select menu and Click the equipment and the type
(Example: Crusher> Jaw crusher)
iv. Go to Edit menu and click Rubber band cursor. Now draw the streams, one
for the feed and another for the product and others as required.
2 Accept the flowsheet
Go to file menu click accept flowsheet then dialog box appears and specify a
job name.
3 Editing System data
Go to Edit menu and click Edit syatem data. A box appears to specify Ore
characteristics, Stream data. Click accept.
4. Choosing Model and Model Parameters
i. Click edit and Unit Model parameters
ii. Choose the Model
iii. Select model parameters.
iv. Click accept
v. Go to file menu and save this job
5. Simulation Stage
Go to Edit menu and click Run simulation, then a box appears Simulation
completed successfully. Another box appears data output file completed
successfully. Click OK
6. Result stage
i. Go to view menu and click flowsheet, it appears with flyouts displaying the
stream data.
ii. Go to view menu and click report file, it appears on the screen.
iii. Go to view menu and click stream data, it appears on the screen.
iv. Go to view menu and click size distribution graphs, it appears on the screen.
v. Go to view menu and click Liberation distribution graphs, it appears on the screen.

SIMULATION OF JAW CRUSHER

Flowsheet

Data Output File

ja
Stream
number
1
2

Solid
flow
kg/s
1.00
1.00

MODSIM UNIT DESIGN REPORT

UNIT EQUIPMENT DATA SHEET - JAW CRUSHER
***************************************
Unit number 1
Job name: ja

MODSIM model name JAW1

Tonnage to be processed 3.600

Open-side setting 2.540

tons per hour

cms

Size distribution in feed

Size
% passing
cms
.421
99.86
.297
98.63
.210
94.09
.149
84.52
.105
70.80
.743E-01 55.61
.526E-01 42.22
.371E-01 32.26
.263E-01 24.65
.186E-01 18.84
.131E-01 14.40
.929E-02 11.00
.657E-02
8.41
.465E-02
6.42
.328E-02
4.91
.232E-02
3.75
.164E-02
2.87
.116E-02
2.19
.821E-03
1.67
.581E-03
1.28
.411E-03
.98
.290E-03
.75
.205E-03
.57
.145E-03
.44
.000
.00
Top size in feed is approximately .32 cms
Specify crusher size to accommodate this......
"Fall through" material in feed 100.00 percent.
Scalping of the feed is recommended.

Size distribution in product

Size
% passing
cms
.421
19.14
.297
14.06
.210
10.24
.149
7.41
.105
5.35
.743E-01
3.84
.526E-01
2.75
.371E-01
1.97
.263E-01
1.41
.186E-01
1.01
.131E-01
.72
.929E-02
.51
.657E-02
.37
.465E-02
.26
.328E-02
.19
.232E-02
.13
.164E-02
.09
.116E-02
.07

.821E-03
.05
.581E-03
.03
.411E-03
.02
.290E-03
.02
.205E-03
.01
.145E-03
.01
.000
.00

Crusher capacity from manufacturer's tables.....tons per hour.

Number of crushers required......
Impact work index of the material is 10.00 kWhr/ton
80% passing size in feed is 1.31 mms.
80% passing size in product is 34.11 mms.
Estimated power requirements -7.98 kW

NOTES:

STREAM PROPERTIES
Stream number:
1
ja
Solid flowrate:
1.00 kg/s
Water flowrate:
.00 kg/s
Slurry flowrate:
1.00 kg/s
Slurry volumetric flowrate: .3704E-03 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume:
100.00 %
Simulated size distribution
Number of size classes:
25
80% passing size:
.131E-02 m
50% passing size:
.646E-03 m
20% passing size:
.200E-03 m
Size
% passing
meters
.421E-02 99.86
.297E-02 98.63
.210E-02 94.09
.149E-02 84.52
.105E-02 70.80
.743E-03 55.61
.526E-03 42.22
.371E-03 32.26
.263E-03 24.65
.186E-03 18.84
.131E-03 14.40
.929E-04 11.00
.657E-04
8.41
.465E-04
6.42
.328E-04
4.91
.232E-04
3.75
.164E-04
2.87
.116E-04
2.19
.821E-05
1.67

.581E-05
1.28
.411E-05
.98
.290E-05
.75
.205E-05
.57
.145E-05
.44
.000
.00
Stream number:
2
ja
Solid flowrate:
1.00 kg/s
Water flowrate:
.00 kg/s
Slurry flowrate:
1.00 kg/s
Slurry volumetric flowrate: .3704E-03 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume:
100.00 %
Simulated size distribution
Number of size classes:
25
80% passing size:
.341E-01 m
50% passing size:
.143E-01 m
20% passing size:
.443E-02 m
Size
% passing
meters
.421E-02 19.14
.297E-02 14.06
.210E-02 10.24
.149E-02
7.41
.105E-02
5.35
.743E-03
3.84
.526E-03
2.75
.371E-03
1.97
.263E-03
1.41
.186E-03
1.01
.131E-03
.72
.929E-04
.51
.657E-04
.37
.465E-04
.26
.328E-04
.19
.232E-04
.13
.164E-04
.09
.116E-04
.07
.821E-05
.05
.581E-05
.03
.411E-05
.02
.290E-05
.02
.205E-05
.01
.145E-05
.01
.000
.00

JAW CRUSHER

SIMULATION OF GYRATORY CRUSHER

* MODSIM UNIT DESIGN REPORT *

UNIT EQUIPMENT DATA SHEET - GYRATORY CRUSHER
Unit number 1
Job name: fg

MODSIM model name GYRA

Tonnage to be processed 90.72

Open side discharge setting 15.00

tons per hour

cms

Size distribution in feed

Size
% passing
cms
.421
99.86
.297
98.63
.210
94.09
.149
84.52
.105
70.80
.743E-01 55.61
.526E-01 41.49
.371E-01 29.78
.263E-01 20.81
.186E-01 14.26
.131E-01
9.65
.929E-02
6.48
.657E-02
4.33
.465E-02
2.88
.328E-02
1.90
.232E-02
1.26
.164E-02
.84
.116E-02
.55
1

.821E-03
.37
.581E-03
.24
.411E-03
.16
.290E-03
.11
.205E-03
.07
.145E-03
.05
.000
.00
Top size in feed is approximately .31 cms
Dimension A of crusher must be at least .39 cms
Minimum head diameter required to handle the tonnage.....
"Fall through" material in feed 100.00 percent.
Scalping of the feed is recommended.
Size distribution in product
Size
% passing
cms
.421
5.63
.297
4.22
.210
3.16
.149
2.37
.105
1.77
.743E-01
1.32
.526E-01
.98
.371E-01
.73
.263E-01
.55
.186E-01
.41
.131E-01
.30
.929E-02
.23
.657E-02
.17
.465E-02
.13
.328E-02
.09
.232E-02
.07
.164E-02
.05
.116E-02
.04
.821E-03
.03
.581E-03
.02
.411E-03
.02
.290E-03
.01
.205E-03
.01
.145E-03
.01
.000
.00
Impact work index of the material is 10.88 kWhr/ton
80% passing size in feed is 1.31 mms.
80% passing size in product is 216.88 mms.
Estimated power requirements -251. kW
2

Power requirement to allow for 35% surge capacity-339.0

Crusher selected.....
Crusher capacity from manufacturer's tables.....tons per hour.
Number of crushers required......
NOTES:

Stream Properties

Stream number:
1
fg
Solid flowrate:
25.20 kg/s
Water flowrate:
.00 kg/s
Slurry flowrate:
25.20 kg/s
Slurry volumetric flowrate: .9333E-02 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume:
100.00 %
Simulated size distribution
Number of size classes:
25
80% passing size:
.131E-02 m
50% passing size:
.651E-03 m
20% passing size:
.253E-03 m
Size
% passing
meters
.421E-02 99.86
.297E-02 98.63
.210E-02 94.09
.149E-02 84.52
.105E-02 70.80
.743E-03 55.61
.526E-03 41.49
.371E-03 29.78
.263E-03 20.81
.186E-03 14.26
.131E-03
9.65
.929E-04
6.48
.657E-04
4.33
.465E-04
2.88
.328E-04
1.90
.232E-04
1.26
.164E-04
.84
.116E-04
.55
.821E-05
.37
.581E-05
.24
.411E-05
.16
.290E-05
.11
3

KW.

.205E-05
.07
.145E-05
.05
.000
.00
Stream number:
2
fg
Solid flowrate:
25.20 kg/s
Water flowrate:
.00 kg/s
Slurry flowrate:
25.20 kg/s
Slurry volumetric flowrate: .9333E-02 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume:
100.00 %
Simulated size distribution
Number of size classes:
25
80% passing size:
.217 m
50% passing size:
.799E-01 m
20% passing size:
.208E-01 m

Size
% passing
meters
.421E-02
5.63
.297E-02
4.22
.210E-02
3.16
.149E-02
2.37
.105E-02
1.77
.743E-03
1.32
.526E-03
.98
.371E-03
.73
.263E-03
.55
.186E-03
.41
.131E-03
.30
.929E-04
.23
.657E-04
.17
.465E-04
.13
.328E-04
.09
.232E-04
.07
.164E-04
.05
.116E-04
.04
.821E-05
.03
.581E-05
.02
.411E-05
.02
.290E-05
.01
.205E-05
.01
.145E-05
.01
.000
.00

SIMULATION OF SCREEN

* MODSIM UNIT DESIGN REPORT *

UNIT EQUIPMENT DATA SHEET - SINGLE DECK SCREEN
Unit number 1
MODSIM model name SCR2
Job name: Ex 10-1 Screen
Tonnage to be processed
: 3.60 tons/hour.
Screen length is
: 4.88 m
Screen width is
: .24 m
Mesh aperture is
: 3.18 cms
Wire diameter is
: 1.27 cms
Screen is inclined at 20.00 degrees to the horizontal
PARTICLE SIZE DISTRIBUTION IN THE FEED.
Size
% passing
cms
6.39
98.40
4.52
93.17
3.19
82.13
2.26
68.01
1.60
53.70
1.13
41.17

.799
.565
.399
.282
.200
.000

31.23
22.90
16.85
12.40
9.13
.00

Calculated throughfall aperture

: 2.92 cms
Percent oversize in feed
: 21.267 %
Percent half size in feed
: 50.322 %
Near size in feed
: 20.335 %
D50 for separation
: 3.82 cms
Percent moisture in feed
: .00 %
Bulk density of material in feed : 1762.00 kgs/m**3
Basic capacity factor A
Oversize factor B
Half-size factor C
Deck location factor D
Wet screening factor E
Material weight factor F
Near-size factor Gc

: 18.375 tph/m*m
: 1.345
: 1.393
: 1.000
: 1.000
: 1.100
: .868

Tonnage in underflow
: 3.09 tph
Total capacity factor (B*C*D*E*F*Gc) : 178.84 %
Simulated efficiency
: 109.14 %
Area utilisation factor
: .08
WARNING: This screen is underloaded. A smaller screen could be considered.
Calculated rate of travel
Bed depth at feed end
Bed depth at discharge end

.77 m/s
.30 cms
: .04 cms

PARTICLE SIZE DISTRIBUTION IN THE OVERFLOW.

Size
% passing
cms
6.39
88.61
4.52
51.61
3.19
10.74
2.26
1.46
1.60
.17
1.13
.02
.799
.00
.565
.00
.399
.00

.282
.200
.000

.00
.00
.00

PARTICLE SIZE DISTRIBUTION IN THE UNDERFLOW

Size
% passing
cms
6.39
100.00
4.52
99.98
3.19
93.82
2.26
78.91
1.60
62.47
1.13
47.91
.799
36.35
.565
26.65
.399
19.61
.282
14.43
.200
10.62
.000
.00
NOTES:
The screen was shown as operating without water sprays
Using water sprays could increase the capacity of the screen.
Surface water retained on the oversize .00 %

STREAM PROPERTIES

Stream number:
1
Ex10-1Screen
Solid flowrate:
3.97 s ton/hr
Water flowrate:
.00 gal/min
Slurry flowrate:
1.00 kg/s
Slurry volumetric flowrate: .3704E-03 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume:
100.00 %
Yield of solids:
100.00 %
Simulated size distribution
Number of size classes:
80% passing size:
50% passing size:
20% passing size:
Size
% passing
meters
.639E-01 98.40
.452E-01 93.17
.319E-01 82.13

12
.302E-01 m
.145E-01 m
.484E-02 m

.226E-01 68.01
.160E-01 53.70
.113E-01 41.17
.799E-02 31.23
.565E-02 22.90
.399E-02 16.85
.282E-02 12.40
.200E-02
9.13
.000
.00
Stream number:
2
Ex10-1Screen
Solid flowrate:
.56 s ton/hr
Water flowrate:
.00 gal/min
Slurry flowrate:
.14 kg/s
Slurry volumetric flowrate: .5211E-04 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume:
100.00 %
Yield of solids:
14.07 %
Simulated size distribution
Number of size classes:
80% passing size:
50% passing size:
20% passing size:
Size
% passing
meters
.639E-01 88.61
.452E-01 51.61
.319E-01 10.74
.226E-01
1.46
.160E-01
.17
.113E-01
.02
.799E-02
.00
.565E-02
.00
.399E-02
.00
.282E-02
.00
.200E-02
.00
.000
.00

12
.581E-01 m
.448E-01 m
.362E-01 m

Stream number:
3
Ex10-1Screen
Solid flowrate:
3.41 s ton/hr
Water flowrate:
.00 gal/min
Slurry flowrate:
.86 kg/s
Slurry volumetric flowrate: .3183E-03 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume:
100.00 %
Yield of solids:
85.93 %

Simulated size distribution

Number of size classes:
80% passing size:
50% passing size:
20% passing size:
Size
% passing
meters
.639E-01 100.00
.452E-01 99.98
.319E-01 93.82
.226E-01 78.91
.160E-01 62.47
.113E-01 47.91
.799E-02 36.35
.565E-02 26.65
.399E-02 19.61
.282E-02 14.43
.200E-02 10.62
.000
.00

12
.231E-01 m
.119E-01 m
.408E-02 m

SIMULATION OF HYDROCYCLONE

* MODSIM

UNIT DESIGN REPORT *

UNIT EQUIPMENT DATA SHEET - HYDROCYCLONE

****************************************
Unit number 1
MODSIM model name CYCL
Job name: Ex10-2Cyclone
PARAMETERS:
Cyclone diameter
.380 meters
Vortex-spigot distance 1.281 meters
Inlet diameter
.100 meters
Vortex finder diameter .152 meters
Spigot diameter
.076 meters
Feed head
3.81 meters
Cyclones in cluster
3
Flowrate through each cyclone .309E-01 m**3 per sec.
Volumetric fraction of solids in the feed
.380
Viscosity of slurry .0010 kg/ms
Specific gravity of slurry in separation zone 1.09
Index for variation of d50 with density .64
Pressure drop across the hydrocyclone 68.6 kPa
Plitt's calibration parameters:
For D50 1.00
For the sharpness factor .36
For the flow split 2.00
1

Size distribution in feed

Size
% passing
mms
4.21
99.91
2.97
99.53
2.11
98.59
1.48
96.48
1.05
92.57
.742
86.54
.526
78.49
.371
68.17
.263
55.54
.186
43.66
.131
33.48
.929E-01 25.53
.657E-01 19.72
.464E-01 15.68
.328E-01 12.47
.232E-01
9.92
.164E-01
7.90
.000
.00
Volumetric flow split to underflow .636
Sharpness index = .126
D50 for particle type 1 is 249.3 microns
Size distribution in underflow.
Size
% passing
mms
4.21
99.86
2.97
99.24
2.11
97.70
1.48
94.37
1.05
88.42
.742
79.73
.526
68.98
.371
56.37
.263
42.46
.186
30.70
.131
21.66
.929E-01 15.32
.657E-01 11.13
.464E-01
8.47
.328E-01
6.52
.232E-01
5.08
.164E-01
4.00
2

.000

.00

Size distribution in overflow.

Size
% passing
mms
4.21
100.00
2.97
100.00
2.11
99.96
1.48
99.77
1.05
99.06
.742
97.17
.526
93.35
.371
86.57
.263
75.97
.186
63.90
.131
51.92
.929E-01 41.46
.657E-01 33.12
.464E-01 26.93
.328E-01 21.76
.232E-01 17.48
.164E-01 13.98
.000
.00
Water split to underflow = .253
Ratio of air core to underflow diameter by Concha's formula is 1.47
***WARNING!***
This cyclone will rope under these operating conditions
according to the Concha criterion.
The underflow diameter should be increased to alleviate this condition.

STREAM PROPERTIES

Stream number:
1
Ex10-2Cyclone
Solid flowrate:
417.96 tonne/hr
Water flowrate:
206.82 tonne/h
Slurry flowrate:
173.55 kg/s
Slurry volumetric flowrate: .9263E-01 m^3/s
Percent solids by mass:
66.90 %
Percent solids by volume:
37.98 %
Yield of solids:
100.00 %
Simulated size distribution
Number of size classes:
80% passing size:
50% passing size:
20% passing size:

18
.559E-03 m
.225E-03 m
.669E-04 m
3

Size
% passing
meters
.421E-02 99.91
.297E-02 99.53
.211E-02 98.59
.148E-02 96.48
.105E-02 92.57
.742E-03 86.54
.526E-03 78.49
.371E-03 68.17
.263E-03 55.54
.186E-03 43.66
.131E-03 33.48
.929E-04 25.53
.657E-04 19.72
.464E-04 15.68
.328E-04 12.47
.232E-04
9.92
.164E-04
7.90
.000
.00
Stream number:
2
Ex10-2Cyclone
Solid flowrate:
163.19 tonne/hr
Water flowrate:
154.44 tonne/h
Slurry flowrate:
88.23 kg/s
Slurry volumetric flowrate: .5664E-01 m^3/s
Percent solids by mass:
51.38 %
Percent solids by volume:
24.25 %
Yield of solids:
39.04 %
Simulated size distribution
Number of size classes:
80% passing size:
50% passing size:
20% passing size:
Size
% passing
meters
.421E-02 100.00
.297E-02 100.00
.211E-02 99.96
.148E-02 99.77
.105E-02 99.06
.742E-03 97.17
.526E-03 93.35
.371E-03 86.57
.263E-03 75.97
.186E-03 63.90

18
.297E-03 m
.124E-03 m
.287E-04 m

.131E-03 51.92
.929E-04 41.46
.657E-04 33.12
.464E-04 26.93
.328E-04 21.76
.232E-04 17.48
.164E-04 13.98
.000
.00
Stream number:
3
Ex10-2Cyclone
Solid flowrate:
254.77 tonne/hr
Water flowrate:
52.38 tonne/h
Slurry flowrate:
85.32 kg/s
Slurry volumetric flowrate: .3600E-01 m^3/s
Percent solids by mass:
82.95 %
Percent solids by volume:
59.58 %
Yield of solids:
60.96 %
Simulated size distribution
Number of size classes:
80% passing size:
50% passing size:
20% passing size:
Size
% passing
meters
.421E-02 99.86
.297E-02 99.24
.211E-02 97.70
.148E-02 94.37
.105E-02 88.42
.742E-03 79.73
.526E-03 68.98
.371E-03 56.37
.263E-03 42.46
.186E-03 30.70
.131E-03 21.66
.929E-04 15.32
.657E-04 11.13
.464E-04
8.47
.328E-04
6.52
.232E-04
5.08
.164E-04
4.00
.000
.00

18
.750E-03 m
.319E-03 m
.121E-03 m

SIMULATION OF A BALL MILL

* MODSIM UNIT DESIGN REPORT *

UNIT EQUIPMENT DATA SHEET - BALL MILL
*************************************
Unit number 1
MODSIM model name HFMI
Job name: Ex10-3BallMill

PARAMETERS:

Parameters for selection function

Energy-specific selection function at 1 mm:
Zeta 1:
.800
Zeta 2:
-.312
Parameters for breakage function
Beta:
3.700
Gamma:
.748
Delta:
.000
Phi at 5mm:
.720
Specified power draw for the mill:

.600 tonnes/kWhr

616. kW

Size distribution in FEED

Size
% passing
mms
4.21
99.82
2.97
99.25
2.11
97.84
1.48
94.65
1.05
89.36
.742
81.59
.526
71.58
.371
59.02
.263
44.59
.186
32.02
1

.131
22.23
.929E-01 15.72
.657E-01 11.57
.464E-01
8.86
.328E-01
6.78
.232E-01
5.20
.164E-01
3.98
.000
.00
Size distribution in PRODUCT
Size
% passing
mms
4.21
99.94
2.97
99.76
2.11
99.28
1.48
98.07
1.05
95.67
.742
91.36
.526
84.48
.371
74.12
.263
60.21
.186
46.02
.131
33.69
.929E-01 24.67
.657E-01 18.45
.464E-01 14.14
.328E-01 10.85
.232E-01
8.33
.164E-01
6.40
.000
.00
80% passing size in feed
700. microns
80% passing size in product
449. microns
Calculated specific power input
2.39 kWhr/tonne
Calculated operating work index for this mill 25.4 kWhr/tonne

STREAM PROPERTIES
Stream number:
1
Ex10-3BallMill
Solid flowrate:
71.58 kg/s
Water flowrate:
20.78 kg/s
Slurry flowrate:
92.36 kg/s
Slurry volumetric flowrate: .4247E-01 m^3/s
Percent solids by mass:
77.50 %
Percent solids by volume:
51.07 %
2

Simulated size distribution

Number of size classes:
18
80% passing size:
.700E-03 m
50% passing size:
.301E-03 m
20% passing size:
.118E-03 m
Size
% passing
meters
.421E-02 99.82
.297E-02 99.25
.211E-02 97.84
.148E-02 94.65
.105E-02 89.36
.742E-03 81.59
.526E-03 71.58
.371E-03 59.02
.263E-03 44.59
.186E-03 32.02
.131E-03 22.23
.929E-04 15.72
.657E-04 11.57
.464E-04
8.86
.328E-04
6.78
.232E-04
5.20
.164E-04
3.98
.000
.00
Stream number:
2
Ex10-3BallMill
Solid flowrate:
71.58 kg/s
Water flowrate:
20.78 kg/s
Slurry flowrate:
92.36 kg/s
Slurry volumetric flowrate: .4247E-01 m^3/s
Percent solids by mass:
77.50 %
Percent solids by volume:
51.07 %
Simulated size distribution
Number of size classes:
18
80% passing size:
.449E-03 m
50% passing size:
.205E-03 m
20% passing size:
.722E-04 m
Size
% passing
meters
3

.421E-02 99.94
.297E-02 99.76
.211E-02 99.28
.148E-02 98.07
.105E-02 95.67
.742E-03 91.36
.526E-03 84.48
.371E-03 74.12
.263E-03 60.21
.186E-03 46.02
.131E-03 33.69
.929E-04 24.67
.657E-04 18.45
.464E-04 14.14
.328E-04 10.85
.232E-04
8.33
.164E-04
6.40
.000
.00

1.000

100.0

0.

1.000

100.0

2 0.

kg/s
kg/s

% Sol

SIMULATION EXERCISE NO.__________

Date_______

SIMULATION OF STREAM SPLITTER

Stream
number
1
2
3

Solid flow
kg/s
0.20
0.06
0.14

* MODSIM UNIT DESIGN REPORT *

*****************************
UNIT EQUIPMENT DATA SHEET - SPLITTER
************************************
Unit number 1
Job name: ew

MODSIM model name SPL1

SIMULATION EXERCISE NO._____________

Date___________________

SIMULATION OF BELT CONVEYER

Stream
number
1
2

Solid
flow
kg/s
1.00
1.00
* MODSIM UNIT DESIGN REPORT *

UNIT EQUIPMENT DATA SHEET - CONVEYOR

Unit number 1
Job name: ff
Parameters:
Belt width
Freeboard
Idler trough angle
Belt speed
Angle of repose
Bulk density

MODSIM model name CONV

1.00 m
20.0 cm
20.0 degrees
2.00 m/s
35.0 degrees
1600.0 kg/m^3

Belt capacity required: 3.600 tonnes/hr

Calculated belt capacity: 1009. tonnes/hr
Stream number:
1
ff
Solid flowrate:
1.00 kg/s
Water flowrate:
.00 kg/s
Slurry flowrate:
1.00 kg/s
Slurry volumetric flowrate: .2000E-03 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume: 100.00 %
Simulated size distribution
Number of size classes:
25
80% passing size:
.131E-02 m
50% passing size:
.651E-03 m
20% passing size:
.254E-03 m
Size % passing
meters
.421E-02 99.86
.297E-02 98.63
.210E-02 94.09
.149E-02 84.52
.105E-02 70.80
.743E-03 55.61
.526E-03 41.48
.371E-03 29.78
.263E-03 20.80
.186E-03 14.26
.131E-03 9.65
.929E-04 6.48
.657E-04 4.33
.465E-04 2.88
.328E-04 1.90
.232E-04 1.26
.164E-04
.84
.116E-04
.55
.821E-05
.37
.581E-05
.24
.411E-05
.16
.290E-05
.11
.205E-05
.07
.145E-05
.05
.000
.00
Stream number:
2
ff
Solid flowrate:
1.00 kg/s
Water flowrate:
.00 kg/s
Slurry flowrate:
1.00 kg/s
Slurry volumetric flowrate: .2000E-03 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume: 100.00 %

Simulated size distribution

Number of size classes:
25
80% passing size:
.131E-02 m
50% passing size:
.651E-03 m
20% passing size:
.254E-03 m
Size % passing
meters
.421E-02 99.86
.297E-02 98.63
.210E-02 94.09
.149E-02 84.52
.105E-02 70.80
.743E-03 55.61
.526E-03 41.48
.371E-03 29.78
.263E-03 20.80
.186E-03 14.26
.131E-03 9.65
.929E-04 6.48
.657E-04 4.33
.465E-04 2.88
.328E-04 1.90
.232E-04 1.26
.164E-04
.84
.116E-04
.55
.821E-05
.37
.581E-05
.24
.411E-05
.16
.290E-05
.11
.205E-05
.07
.145E-05
.05
.000
.00

This unit splits 2 ways

Fractional splits requested were .300 .700 .000
Splits used were
.300 .700 .000
Stream number:
1
Solid flowrate:
.20 kg/s
Water flowrate:
.00 kg/s
Slurry flowrate:
.20 kg/s
Slurry volumetric flowrate: .4000E-04 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume: 100.00 %
Simulated size distribution
Number of size classes:
25
80% passing size:
.131E-02 m
50% passing size:
.651E-03 m
20% passing size:
.254E-03 m
Size % passing
meters
.421E-02 99.86
.297E-02 98.63
.210E-02 94.09
.149E-02 84.52
.105E-02 70.80
.743E-03 55.61
.526E-03 41.49
.371E-03 29.78
.263E-03 20.80
.186E-03 14.26
.131E-03 9.65
.929E-04 6.48
.657E-04 4.33
.465E-04 2.87
.328E-04 1.90
.232E-04 1.26
.164E-04
.84
.116E-04
.55
.821E-05
.37
.581E-05
.24
.411E-05
.16
.290E-05
.11
.205E-05
.07
.145E-05
.05
.000
.00

Stream number:
2
ew
Solid flowrate:
.06 kg/s
Water flowrate:
.00 kg/s
Slurry flowrate:
.06 kg/s
Slurry volumetric flowrate: .1200E-04 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume: 100.00 %
Simulated size distribution
Number of size classes:
25
80% passing size:
.131E-02 m
50% passing size:
.651E-03 m
20% passing size:
.254E-03 m
Size % passing
meters
.421E-02 99.86
.297E-02 98.63
.210E-02 94.09
.149E-02 84.52
.105E-02 70.80
.743E-03 55.61
.526E-03 41.49
.371E-03 29.78
.263E-03 20.80
.186E-03 14.26
.131E-03 9.65
.929E-04 6.48
.657E-04 4.33
.465E-04 2.87
.328E-04 1.90
.232E-04 1.26
.164E-04
.84
.116E-04
.55
.821E-05
.37
.581E-05
.24
.411E-05
.16
.290E-05
.11
.205E-05
.07
.145E-05
.05
.000
.00
Stream number:
ew
Solid flowrate:
Water flowrate:

3
.14 kg/s
.00 kg/s

Slurry flowrate:
.14 kg/s
Slurry volumetric flowrate: .2800E-04 m^3/s
Percent solids by mass:
100.00 %
Percent solids by volume: 100.00 %
Simulated size distribution
Number of size classes:
25
80% passing size:
.131E-02 m
50% passing size:
.651E-03 m
20% passing size:
.254E-03 m
Size % passing
meters
.421E-02 99.86
.297E-02 98.63
.210E-02 94.09
.149E-02 84.52
.105E-02 70.80
.743E-03 55.61
.526E-03 41.49
.371E-03 29.78
.263E-03 20.80
.186E-03 14.26
.131E-03 9.65
.929E-04 6.48
.657E-04 4.33
.465E-04 2.87
.328E-04 1.90
.232E-04 1.26
.164E-04
.84
.116E-04
.55
.821E-05
.37
.581E-05
.24
.411E-05
.16
.290E-05
.11
.205E-05
.07
.145E-05
.05
.000
.00