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ABSTRACT
Hodouin, D. and Everell, M.D., 1980. A hierarchical procedure for adjustment and
material balancing of mineral processes data. Int. J. Miner. Process., 7: 91--116.
In order to evaluate and model mineral processes, it is very useful to obtain consistent
data in order to satisfy mass conservation. Since collected data are often redundant and
erroneous due to natural disturbances, sampling errors, unreliable instrument readouts
and laboratory analyses inaccuracies, they must be adjusted. The proposed procedure to
minimize the weighted sum of squared residuals consists in a supervisory program
working on a set of independent variables necessary to define overall ore flow rates.
Within this algorithm, the variables are separated into two sets: the microscopic ones
(particle size distributions, chemical assays... ) and the macroscopic ones (flow rates,
mass fraction of solids in p u l p . . . ) , each set corresponding to a part of the sum of squares
criterion to be minimized. The minimum of the microscopic part of this function can be
found directly since the constraints are linear and the function quadratic. The macroscopic
part is minimized using the standard Powell algorithm which is also used as supervisory
algorithm. The material balance constraints are written using matrix formalism and flow-
network description of the circuit. Three industrial application examples are given: a flota-
tion circuit for which ten chemical elements were analyzed, a grinding circuit closed by
DSM screens and a three-stages grinding circuit with rod, ball mills and hydrocyclones.
INTRODUCTION
T o p r o p e r l y o p e r a t e a m i n e r a l b e n e f i c i a t i o n p l a n t o r p r o c e s s , it is e x t r e m e -
ly useful, in a basic step, t o h a v e s y s t e m a t i c e v a l u a t i o n s o f t h e p e r f o r m a n c e
o f t h e m a c h i n e r y , t h e p r o c e s s or t h e w h o l e p l a n t . W h a t e v e r t h e p u r p o s e o f
t h e s e e v a l u a t i o n s , w h i c h can s i m p l y be t h e k n o w l e d g e o f t h e i n p u t s / o u t p u t s
o f a p r o c e s s or, a t t h e o t h e r e n d , t h e i m p l e m e n t a t i o n o f an o p t i m a l c o n t r o l
s t r a t e g y in t h e c o n c e n t r a t o r , t h e s t u d i e s b e g i n i n v a r i a b l y b y a c o l l e c t i o n o f
m e a s u r e m e n t s . T h e m i n e r a l p r o c e s s i n g p l a n t s are g e n e r a l l y p o o r l y i n s t r u m e n t e d
a n d t h e r e is a c o n s i d e r a b l e l a c k o f i n f o r m a t i o n a b o u t t h e s t a t e o f t h e p r o c e s s .
F r e q u e n t l y , d a t a m u s t be c o l l e c t e d t h r o u g h h a n d s a m p l i n g a n d a n a l y s i s , since
t h e c o n t r o l - r o o m r e a d o u t s are o f t e n i n e f f i c i e n t t o o b t a i n a s h a r p i m a g e o f t h e
p r o c e s s . G e n e r a l l y , m a i n v a r i a b l e s such as t h e f l o w r a t e s o f v a r i o u s s l u r r y
NOMENCLATURE
_ L
In order to test and demonstrate the use of the procedure developed here,
three practical examples have been selected, one for the flotation process and
two for the comminution process.
Flotation circuit
FEED
-O- ROUGHER I - - g ' - z - ~ I S C A V E N G E R
I
3
CONC.
THICKENER
In the circuit represented on Fig. 2, the ore is firstly ground in a rod mill
and then preclassified in a two-stages unit of DSM screens. The oversize of
the screens is thickened by a screw classifier before being fed to a grate dis-
charge ball mill. Pulp samples have been collected at locations indicated on
Fig. 2 and analyzed for particle size distribution and for mass fraction of
solids in the pulp. The only flow rate measured was that of the wet ore fed
to the rod mill. The objective was here to obtain a complete and consistent
image of the circuit in order to elaborate a simulator of the c o m m i n u t i o n
circuit.
In the circuit represented on Fig. 3, the ore is ground in a rod mill and then
fed to two closed ball milling systems in series. In each stage, the ore is pre-
classified in a cyclopack before feeding the mill. The pulp was sampled in
various streams for sieving analysis and mass fraction of solids measurement.
For the secondary circuit, the particle size distributions were analyzed with
95
r • JDSM I
13 5 ,i 4 i~~ 6 ~ D S M 2
HzOIL2 H20
£¢:~w , -'~ T O % M I N G
- ~ i ROD MILL ~.7"L'~.:.', . . . . H CIRCUITAND
~L~bblr"I#..~J FLOTATION
_3j
Wet ore
14 0 • 0 tl2
H20
HzO H20
SAMPLED FOR { SIZE DISTRIBUTION
PULP PERCENT SOLIDS
Macroscopic network
F o r the overall material (pulp, water or ore), one can define a flow
diagram with m nodes and p branches. Within these p branches, there are Pw
and Ps branches in which respectively only water or only solids is flowing.
F u r th er mo r e, there are mw " w a t e r n o d e s " and ms " o r e nodes". A water node
is defined as a node at which only water branches c o n n e c t and similarly for
an ore node. As a consequence, there are p - P w - P s "pul p branches" and
m - r o w - m s " p u l p nodes".
Two sub-networks can be defined, one for the ore and one for the water.
The ore n e t w o r k contains p - p w branches and m - m w nodes and the water
n e t w o r k contains p - P s branches and m - m s nodes. For c o m p u t a t i o n purpose,
it is useful to a d o p t a matrix representation of these flow diagrams. The
matrix entries take the form 0, 1 or -1 depending upon the existence and
direction of flow of a process stream at a particular node (+1 for incoming
stream and - 1 for o u t c o m i n g stream). Dimensions of the n e t w o r k matrix of
the ore sub-diagram are ( m - m w , P-Pw) and those of the n e t w o r k matrix of
the water sub-diagram are ( m - m s , P-Ps).
F o r each o f these sub-systems, it is necessary, for c o m p u t a t i o n purposes,
to determine the i n d e p e n d e n t branches. A set of i ndependent branches is
such th at all the flow rates of the n e t w o r k can be calculated if the values for
the i n d e p e n d e n t branches are known. Such a set can be found by techniques
used for solving linear systems by gaussian elimination (Anton, 1977).
Elemen tar y operations on rows transform the initial n e t w o r k matrix into a
" r o w - e c h e l o n " f o r m in which the i n d e p e n d e n t branches becom e obvious. In
the present study, we use the following row-echelon form:
branches
X X X X X X ~ 0
nodes
X X X X X X ]8
X X X X X X X
where a cross stands for -1, 1 or 0, and ~ for -1 or +1, and 0 for null values.
Due to the simple structure of the flow diagram matrices which contain
only 1, - 1 or 0 terms, and a m a x i m u m n u m b e r of t w o elements differing from
zero in each column, one of the various row-echelon forms can be obtained
simply by m o d i f y i n g the initial ordering sequence of nodes and branches. By
this procedure, one obtains a new matrix which represents the same initial
97
flow diagram and consists in the juxtaposition of two block matrices, one
which is rectangular and one which is lower triangular. The branches of the
first matrix block constitute a set of independent branches. Using this trans-
formation, the t w o n e t w o r k matrices for ore and water can be written as:
M = (M~, M=) (la)
Mw (M w,M w)
= (15)
where indices 1 and 2 stand, respectively, for rectangular and triangular blocks
and where dimensions are:
(m-row, p-pw-m+mw) forM1
(m-mw, rn-mw) forM2
(m-ms , p-ps-m+ms) form w
(m-ms , m-ms) for M w
Figures 4a, 5a, b and 6a, b give the networks of ore and water for the three
industrial examples considered. For illustration of the method, in example 2,
ROUGHER SCAVENGER I
FEED ~ ~ TAILINGS
/ N
o-M0crosco w0rk
CLEANER I I I~ I SCAVENGER2
CONCENTRATE ~ . . I ,,.~__L_%........~ ] . I " ' "
CLEANER
TAILINGS
FEED ~ i I
b-~cp~CemN~ ~ /Pulp in stream 6
analysis) 51 [ ,arrives from stream J
CONCENTRATE ~.L 12 \ 13 and other circuit./
q =5
SUMP I CI SUMP 2 C 2 ~
I P =1 I
ROD .-J .-"" I"" ~-'~
MIL~_ "" 5 " 6 " 7 ~10 [ ;, =91
I I
DIS % "T5 3Fo T9
CARGE'h ;5 t8 ;9 I"' :'61
(Sieve onolysis)
b- MGcroscqpi_£ (O_£e)
CI ~ I 0 ~
OVER-X.J V
FLOW 18 ;9
(Cyclosizer analysis )
2 ~ 5 ~ 7TODESLIMING
D ~'~ ~ ) ( Z--:~CIRCUITAND
C2 7 _ ~ IO b
FEEDy
(Chemicol ossay)
c- Microscopic Networks
U~O~,n~R~E "T / BALL MILL
c-Microscopic (Size distributions) ~11 FEED
Fig. 5. Macroscopic and microscopic networks for grinding Fig. 6. Macroscopic and microscopic networks for grinding
circuit of Fig. 2. circuit of Fig. 3.
99
1 3 4 8 12 13 14 15 9 11 2 10 5 16 6 7
0 -1 0 0 0 0 1 0 1 0 0 0 0 0 0 O'
0 0 0 0 0 0 0 1 -1 1 0 0 0 0 0 0
1 0 0 0 1 0 0 0 0 0 -1 0 0 0 0 0
0 0 -1 0 0 0 0 0 0 -1 0 1 0 0 0 0
nodes
0 1 1 0 0 1 0 0 0 0 1 0 -1 0 0 0
0 0 0 1 0 0 0 0 0 0 0 -1 0 1 0 0
0 0 0 -1 0 0 0 0 0 0 0 0 1 0 -1 0
0 0 0 0 0 0 0 0 0 0 0 0 0 -1 1 -1
MD = O, and (3a)
MWD w = 0 (3b)
Microscopic n e t w o r k
Md = 0 (6)
mk dk = 0 (7)
Figures 4b, 5c and 6c give the microscopic networks for the three industrial
examples considered. For the flotation circuit and for the grinding circuit
with DSM screens, there is only one sub-network, while there are three dif-
ferent ones for the grinding circuit with cyclones: one for screen analysis,
one for cyclosizer analysis and one for concentrations. The only difference
between microscopic and macroscopic flow-networks for flotation circuit
consists in the elimination of node VIII accounting for the possible differ-
ences between assays of the secondary scavenger tailings of the two flotation
circuits. Furthermore, for this circuit, it is assumed that D~6 is neglectible and
that D~7 is equal to Dis.
Mathematical formulation
water mass flow rates. Thus, by adding this function to the two material
balance equations (eqs. 3), we can globally formulate the macroscopic
material balance equations by the system:
Hmac (O1, d, D w) = 0 (9a)
y = y (Dl, d, D w) (95)
If the measured values of y and Xm are substituted in the system, eqs. 8 and 9,
one obtains the following system of equations:
The purpose of the present work is to solve the system (eqs. 10) in the cases
3 or 4 (redundant or partially redundant cases). Since the material conserva-
tion equations are n o t verified due to errors on measurements, one possible
way to solve exactly the system (eqs. 10) is to correct the measurements.
These corrections must be as small as possible and in agreement
with the reliability o f the measurements. The weighted least-
squares procedure is generally used to meet these requirements when the
errors are assumed to be normal and unbiased (Draper and Smith, 1966).
The weights are selected as the elements of the inverse of the measurements
covariance matrix V. Since it is not always certain that the errors are of a
normal type and unbiased (Klimpel, 1979 and Ragot and Aubrun, 1979), and
since the variances can only be estimated in general, we cannot prove that in
the present case this procedure leads to least-variance estimates; it seems to
be still reasonable, however, to adopt it (Wiegel, 1972).
102
Solving techniques
To solve the problem as stated by eqs. 11 and 12 in the case where errors
are uncorrelated (V diagonal), two procedures have been followed. Some
authors such as White et al. (1977, 1979) and Mular et al. (1976) use direct
minimization techniques which work on independent variables, i.e. on a set
of variables from which all other ones can be calculated using mass balance
constraints. Other authors such as Cutting (1976, 1979), Wiegel (1972, 1978,
1979) and users of the Wiegel method (Laguitton and Wilson, 1979a, b;
Tippin, 1979) assemble a new function named the Lagrangian which in-
corporates the constraints in the function to be optimized by defining new
variables named Lagrange's multipliers.
If the relative flow rates d are known, the microscopic material balance
equations (eq. 4) become linear with respect to the variable x. Some authors
such as Smith and Ichiyen (1973) and Hockings and Callen (1977) have used
this property to solve the system (eqs. 11 and 12) for the x values. Ragot et
al. (1978) extend this method of hierarchical minimization to the case where
macroscopic measurements are available, for data adjustment around a
cyclone and apply this m e t h o d to more complex flow-sheets where only
microscopic data are available (J. Ragot, pers. commun., 1980).
Another procedure, which can be called " m e t h o d of nodes imbalance", is
used by Lynch (1977), Tipman et al. (1978), Finch and Matwijenko (1977),
Klimpel (1979), when only microscopic measurements are available. It con-
sists in finding in a first stage the relative flow rates d and then to calculate
the x values. But this procedure is not iterated and leads only to an approxi-
mation of the solution, which is, however, in some cases quite sufficient. Their
m e t h o d of d calculation consists in finding the d values which minimize the
sum of squared deviations to zero of the mass balance equations (eq. 4) written
for the experimental values a.
The procedure developed in this paper uses some of the ideas found in
literature, extends their applications to the general solution of the problem
(eqs. 11 and 12) and formulates it in a systematic way.
It is established that the complexity of large dimension optimization
problems can be reduced by performing partition of the criterion to be op-
103
Jmac = (Y - b) r Y ~ a e (Y - b) (16)
w th Md = 0
t
x~ d• d~ y~
COMPUTATION PROCEDURES
Supervisory program
I dr+l 1
d2
= -M21M1 (19)
dp-pw 5r
So the supervisory algorithm works on the r - 1 search variables 0T =
(d2.... , dr) and the relative ore flow rates on all the branches are given by:
A d j u s t m e n t o f microscopic variables
mk 5k
Bk = 0 (24)
mk 5k
I ........ I ...... I
() I (nk-1)_mk
bk = 1 (25)
i I pk
and:
= (x l, . . . x r ki, . . . x Tknk ) (26)
q (27)
Jmic = ~ Jk
k=l
where:
Jk = ( x k - ak) r Vk I ( x k - ak) (28)
(It has been admitted that the sub-networks have been reduced to branches
where microscopic values are measured; this does not reduce the generality
of the method but simplifies the presentation since X m k becomes identical
to xk).
C h e m i c a l assays a d j u s t m e n t s
Since there is generally no constraint equation between the analyses of two
different elements and because it is assumed that there is no correlation of the
errors inside a sub-network, the J k criterion can be further partitioned in
terms related to each element:
nk (29)
Jk ; EJk/
i--1
Finally, the optimization to be performed is:
Minimize Jlei = (xki - aki) T V ~ (xki - aki) (30a)
under the constraint:
mk Xki dk = 0 (30b)
The solution to this problem can be found by forming the Lagrangian:
L k i = Jki + ~ m k X k i dk (31)
and writing the stationarity conditions with respect to Lagrange multipliers
and unknown x k i , which gives:
(32a)
x k / + 8k - aki = 0
(32b)
m k X k i dk = 0
whose x k i solution is:
(33)
x k i = aki - Vki ~rk turk (ink 6k Vki 5k turk) -~ m k 8k aki
Jmic (x)
with Hmi C (d*, X) = 0
A d j u s t m e n t o f m a c r o s c o p i c variables
Flow-sheet
The a l g o r i t h m n a m e d B I L M A T has been i m p l e m e n t e d in A P L language.
T h e p r o g r a m is fully c o n v e r s a t i o n a l and can be used b y individuals n o t
familiar with the m a t h e m a t i c s o f the p r o b l e m . T h e p r o g r a m m i n g is general,
such t h a t a n y kind o f circuit can be treated. The s t r u c t u r e is o f a m o d u l a r
f o r m which allows fast m o d i f i c a t i o n s or additions t o the program.
The p r o g r a m begins, if r e q u e s t e d , b y a series o f e x p l a n a t i o n s on the m a n n e r
t o use it (see Fig. 9). T h e n , the p r o g r a m asks for the kind o f m e a s u r e m e n t s
which have been p e r f o r m e d (chemical assays, pulp density m e a s u r e m e n t s ,
size a n a l y s e s . . . ) . T h e circuit n e t w o r k is built up b y a series o f q u e s t i o n s /
answers a b o u t the branches t h a t converge o r diverge at each node. T h e n , the
109
BILMAT
Explanations ~ I
l
Kind of measurements performed ?I
l
I i
1
Construction of micro networks ~] i
I
Data input : measurements and
associated variances
Initial values and controE
parameters of algorithm
I COmputatiOn I
t
I Print out I
t
jSpecial items J
IErr°r analysis I
IE ° ]
Fig. 9. Flow-sheet of BILMAT program.
where A k i is defined for aki as X k i was defined for Xki. This system has
generally no solution unless the data are self-consistent. In general, the
problem is defined such as there exists a particular sub-network which is the
most informative and allows the computation of the whole set of 8 values.
The mass balance equations for this particular micro network can be written
as (the index k is omitted in order to simplify the equations):
mAid = 0 i = 1,...n (40)
which, using eq. 21 is equivalent to:
M A r (LO + l ) = 0 (41)
where M is the partitioned block diagonal matrice constituted of n block
matrices m, and where A is the row block matrix o f A i for the n analyzed
elements. The 0 solution of eq. 41 which minimizes the sum of square
residuals of each equation is obtained using the pseudo-inverse of_MArL:
0 = - ( L r ~ L ) -1 L r a l (42)
with: a = A M r M A (43)
For computation convenience, a can be expressed as:
tl
a = ~ A i m r m A i (44)
i=l
111
The ore flow rate to the circuit is generally measured, so this value can be
used as an initial estimate. Crude approximations of the independent water
flow rates can be obtained using pulp percent solids or water flow rates
measurements. The estimates of macroscopic search variables are used only
the first time the macroscopic algorithm is used. Then, initial estimates of the
macro search variables are taken as the solution values of the previous macro-
scopic calculation, so the convergence of the macroscopic algorithm is faster
and faster and the initial values of macro search variables can be only crudely
estimated.
TABLE I
Chemical component 1 2 3 4 5 6 7 8 9 10
A s s u m e d s t a n d a r d d e v i a t i o n (%) 6 3 4 2 2 4 26 11 6 70
112
TABLE II
TABLE III
T h e r e s u l t s f o r t h e g r i n d i n g c i r c u i t o f Fig. 2 a p p e a r i n T a b l e II; c a l c u l a t e d
ore flow rates, observed a n d c a l c u l a t e d p e r c e n t a g e of solids in p u l p a n d corre-
s p o n d i n g r e l a t i v e a d j u s t m e n t s are p r e s e n t e d . F o r t h e m i c r o s c o p i c r e s u l t s , o n l y
t h e m e a n a d j u s t m e n t s o f t h e p a r t i c l e size f r a c t i o n s r e t a i n e d are g i v e n s i n c e
t h e d e t a i l e d r e s u l t s will b e d i s c u s s e d e l s e w h e r e .
M a c r o s c o p i c r e s u l t s f o r t h e g r i n d i n g c i r c u i t o f Fig. 3 a p p e a r i n T a b l e I I I :
113
ore and water feed rates, pulp percent solids are presented. Furthermore, this
example has been treated with a coupling of fine particles and water recycled
b y classifiers (Hodouin et al., 1978) and also with a simultaneous search of
cyclone efficiencies model parameters (Hodouin et al., 1980).
CONCLUSION
Raw data collected around a mineral processing unit can be treated by the
method presented here. The algorithm allows:
(a) the determination of flow rates in various locations of the circuit;
(b) the correction of the raw data in order to make them consistent in a
material balance view-point.
The method used is a weighted least-squares procedure and the minimiza-
tion is performed hierarchically. The variables are splitted into microscopic
ones (particle size distributions, chemical assays . . . ) and macroscopic ones
(flow rates, mass fractions of solids in p u l p . . . ) and the corresponding parts
of the function to be minimized are independently minimized. This indepen-
dence is obtained using a supervisory algorithm which works on a set of
independent relative flow rates. The constraints of the minimization prob-
lem are the material balance equations. They are written in a general form
using flow-networks and matrix calculations. The main advantages of the
method are:
(1) Very large numbers of micro variables can be handled. Due to the
existence of a partitioned analytical solution for the minimization of the
microscopic part, an increase of the microscopic data does not increase rapid-
ly the computation cost: in one of the examples given, the number of micro
data on one branch is as large as 23.
(2) The program is easy to use because of its conversational structure, even
for individuals n o t familiar with the technique.
(3) The program is general in the sense that very different processes and
measurement types can be accepted.
(4) The program is versatile. Due to the decomposition adopted and due to
the modular structure of the program, it is easy to implement special items
with minor programming. For example, the third industrial example has been
treated with incorporation of cyclone models.
ACKNOWLEDGMENTS
This work has been performed through t w o research contracts: one with
"Centre de Recherches min6rales, minist~re des Richesses naturelles du
Qu6bec", and one with CANMET (Minist6re de l'Energie, des Mines et des
Ressources du Canada). The authors are indebted to D. Laguitton and
I.B. K l y m o w s k y (CANMET) for participation to the sampling campaign, for
sample analysis and for many fruitful discussions. The authors are grateful to
W. Petruk (CANMET) for having provided flotation raw data. The grinding
data have been obtained through sampling campaigns performed in the Heath
Steele Mines concentrator and in the TMG services concentrator; the mill
superintendents G. Johnston (HSM) and M. R o b e r t (TMG) are here acknowl-
edged.
z =
(z)
Z can be partitioned as follows:
Zn-1 (A5)
Zn !
115
Vi 6 rnr Z i + ~ Vi Z n = 0
i=l i=l
w h i c h is e q u i v a l e n t t o :
[ vi,
n-1
i m 5Vi -
i=1
Vi Zn =
n-1
i=1
Vi m r S 7 ( 1 m S a i (A7b)
7i = m S V i ~ m r ; i=l,...,n-1 (ATc)
Finally, one can obtain the x solution by:
Xi = ai-VigmrZi-ViZn; i=l,...,n-1
(A8)
xn= an- VnZn
where Zn is obtained by resolving the linear system (eq. A7b) and Zi are ob-
rained by eq. A7a.
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