Jksimmet 20v6 Intro 2bsim1 140403001229 Phpapp02 Gs

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JKSimMet

OVERVIEW


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JKSimMet Overview

• JKSimMet is a package developed by the JKMRC/JKTech

for the modelling and simulation of comminution circuits.

• It includes models for crushers, autogenous mills, ballmills, rod mills, screens, and hydrocyclones.

• It is a closed package: you can not add your own

process models.

• There is detailed information on the models included

with JKSimMet in the user manual.


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JKSimMet Overview

Mass Balance

Model Fit

Simulate

Flowsheet Design

Data Input

Model Fitting

Simulation

Mass Balancing

Results Analysis


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JKSimMet References

JKSimMet V6 Help Files

(HELP FILE)

JKSimMet V6 User Manual

(PDF)

Mineral Comminution Circuits: Their Operation and Optimisation

(Published by JKTech)


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JKSimMet User Manual

• Part I – Overview

• Part II – Changes from Version 5

• Part III – Installing JKSimMet

• Part IV – Learning JKSimMet

• Part V – Using JKSimMet

• Part VI – Mass Balancing

• Part VII – Model Fitting

• Part VIII – Model Descriptions

Read Once

JKSimMet 101

MODELS REFERENCE

JKSimMet Reference


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JKSimMet Help File


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JK Blue Book

CONTENTS

Ch 1 Introduction

Ch 2 Models of Comminution Processes

Ch 3 Mineral LiberationCh 4 Rock Testing

Ch 5 Surveying Comminution Circuits

Ch 6 Crushers

Ch 7 AG and SAG Mills

Ch 8 Rod MillsCh 9 Ball Mills

Ch 12 Screens & Hydrocyclones

Ch 13 Optimisation of Comminution Circuits



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Steps to Building a Circuit Simulation

5. Review results.

1. Draw the flowsheet.3. Setup the models.

2. Setup the feed.

4. Run the simulation.



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JKSimMet

FLOWSHEETING



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Starting with JKSimMet

• 1. Create a new ‘Project’ and save it.

• 2. Press No when prompted about V5 icons

• 3. Should now have a blank project on screen:

V5 used bitmap icons;

V6 uses vector images.Can’t mix so need tomake a decision. Best just to go with ‘No’.



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JKSimMet Flowsheeting

Flowsheet drawing area

List of Flowsheets in project

List of models available



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Ex F1: Sandbox Flowsheet

Experiment with:

1. Adding models to the drawing area by dragging anddropping;

2. Connect models using streams (red ports are outputs,blue ports are inputs – connect red to blue);

3. Adjust stream lines to be aesthetically pleasing (rightclick ‘Add/Remove stream node’).

4. Name the flowsheet ‘Ex F1: Sandbox’



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SAVE

• Save, and save often.• JKSimMet can often crash seemingly right when you

have significant unsaved changes.

• Network licenses can cause increased frequency of

crashes (compared to a local dongle).• Become OCD about saving!

• CTRL + S does not work. Must use the disk icon.



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Ex F2: Ball Mill Circuit

Experiment with:

1. Adding nodes to streams

(right click ‘Add node to stream’)

1. Resizing units

(drag and drop) 2. Changing unit orientations

3. Naming streams and equipment

(double click on unit/stream) 4. Adding autolabels

5. Adding water feeders where

appropriate for this circuit

NOTE:

A JKSimMet flowsheet must have atleast one ‘feed’ unit and one ‘finalproduct’



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Ex F2: Ball Mill Circuit



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Ex F3: SABC Circuit

Draw the following circuit:

• Ore is fed into a SAG mill.

• SAG mill has a pebble crusher (closed with a

screen on SAG Discharge).

• SAG Discharge screen U/S feeds a cyclone

cluster.

• Cyclone underflow feeds a ball mill in closedcircuit.

• There are water additions to the SAG feed,

Cyclone Feed, and Ball Mill Feed.

Experiment with

adding Info Blocks to

your flowsheet



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Ex F3: SABC Circuit



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JKSimMet

SIMULATE I



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Steps to Building a Circuit Simulation

5. Review results.

1. Draw the flowsheet.3. Setup the models.

2. Setup the feed.




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Ex SIM1: Simple Models1. Draw the flowsheet.

2. Setup the feed.

3. Setup the models.


5. Review results.

Clone your Ex F3: Flowsheet Layout Design



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2. Setup the feed.



5. Review results.

Feed Needs:

1. Feed Rate

2. Feed Size Distribution

• Feed Sieve Series

• Feed PSD

Required Feed Size Distribution:

Screen Aperture WEIGHT

mm %

190 0.0

165 0.0

140 4.1

125 4.3

100 23.9

63.0 23.6

45.0 12.231.5 3.0

25.0 0.5

19.0 2.2

13.2 8.4

9.50 4.7

6.70 3.0

4.75 2.0

3.35 1.2

2.36 1.1

1.70 0.8

1.18 0.80.850 0.5

0.600 0.5

0.425 0.4

0.300 0.3

0.212 0.3

0.150 0.2

0.106 0.2

0.075 0.2

0.053 0.2

0.038 0.1

-0.038 1.3



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2. Setup the feed.



5. Review results.

Feed Needs:

1. Feed Rate



• Feed PSD

Setting the Ore Feed Rate

Set to 500 tph



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2. Setup the feed.



5. Review results.

Feed Needs:

1. Feed Rate



• Feed PSD

Feed Sieve Series

• JKSimMet uses one master sieve series for

the entire simulation.

• However survey data from the lab will use

different sieves for different streams.

• JKSimMet allows each stream can have a

custom sieve series.

• JKSimMet will then convert all streams to

the master series by interpolation.

JKSi M V6



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2. Setup the feed.



5. Review results.

The Root 2 button is a quick

way to set a sieve series.

Add sieve series here

Specify which serieseach stream is to use

here

TIP: Entering a size of 0 will delete all size fractions below.

Feed Needs:

1. Feed Rate



• Feed PSD

JKSi M t V6



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2. Setup the feed.



5. Review results.

Feed Needs:

1. Feed Rate



• Feed PSD

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2. Setup the feed.



5. Review results.

Feed Needs:

1. Feed Rate



• Feed PSD

PRESS Transfer to perform theconversion to master sieve

series.

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2. Setup the feed.



5. Review results.

Ball MillHydrocyclonesWater addition

Need to specify models for:

SAG MillSAG Discharge ScreenPebble Crusher

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2. Setup the feed.



5. Review results.

Water Feeders

Use a simple model to set a specified % solids in thedownstream unit.

Parameter SAG Ball Mill Cyclone

Req. %S 65 70 30

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Ex SIM1: Simple ModelsSAG, BALL, PEBBLE CRUSHER

Simple model that creates a product PSD by movingit sideways on a Cum % Passing vs size plot to give auser specified product P80.

1. Draw the flowsheet.

2. Setup the feed.



5. Review results.

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2. Setup the feed.



5. Review results.

SAG, BALL, PEBBLE CRUSHER

Simple model that creates a product PSD by movingit sideways on a Cum % Passing vs size plot to give auser specified product P80.

Parameter SAG Pebble Ball Mill

Req P80 (mm) 10.0 5.00 0.500

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2. Setup the feed.



5. Review results.

SAG Discharge Screen, Hydrocyclone

Efficiency (partition) curve that describes whatfraction of a particular particle size reports to theproduct stream.

• The underflow and overflow curves

are complementary.

• Traditionally the underflow curve is

used for efficiency curves

• JKSimMet uses the overflow curve

given that this is the product

stream in a grinding circuit

classifier.

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2. Setup the feed.



5. Review results.


Efficiency (partition) curve that describes whatfraction of a particular particle size reports to theproduct stream.

Efficiency Curve:

0

50= .

+ ⋅ ∗ ⋅ 50

⋅ −

⋅∗⋅

+ −

Parameters• Sharpness of Efficient Curve – α• Initial Dip in Efficient Curve –

• Water Split to Fine Product (%) -

• Corrected d50c (mm) – 50(∗is calculated internally and is not a parameter)

For more on Efficiency curves see:

1. JKSimMet Manual – pp. 346

2. JK Blue Book – pp. 276

Alpha Beta

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Ex SIM1: Simple Models1. Draw the flowsheet

2. Setup the feed.



5. Review results.


Parameter SAG DischScreen

Cyclones

Alpha 1.5 2.5

Beta 0 0

C (%) 90 75

d50c (mm) 10 0.10

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2. Setup the feed.



5. Review results.

PRESS START TORUN SIMULATION

PRESS THESIMULATE ICON

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2. Setup the feed.



5. Review results.

DO NOT TRUST A BLACK BOXThis is where you use your subject matter knowledge to reviewand interpret the results.

• Do they make sense?• Are they realistic?• What needs to be improved/changed/corrected?

JKSimMet Tools:1. Data Blocks2. Graphing3. Reports (Export to Excel)

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2. Setup the feed.



5. Review results.

Data Blocks:• What is the final product P80?

• What is the circulating load in the ball mill circuit?

• What are the reduction ratios for each comminution

machine?

• Are there any concerning numbers?

(HINT: Pebble crusher tph, ball mill % solids)

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2. Setup the feed.



5. Review results.

Graphs:

• Can’t print from JKSimMet, can copy toclipboard and paste into Word, Excel,PowerPoint etc.

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2. Setup the feed.



5. Review results.

Graphs:• Plot all the feed/products for comminution machines (SAG,

Ball, Pebble)

• Plot Feed/US/OS for Cyclone

• Plot Fresh Feed – SAG Screen US

• Plot SAG Screen US – Final Product

• Plot Fresh Feed – Final Product

Review Graphs:

• What do these charts tell you?

• Where is the most size reduction taking place?

• Which machines are working harder than others (too hard?)?

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2. Setup the feed.



5. Review results.

Reports:

• Allows you to export data for analysis in Excel

(Can’t view reports within or print from JKSimMet)

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2. Setup the feed.



5. Review results.

Baseline Scenario 1 Scenario 3Scenario 2

• This has described the process of running a single simulation.• Having reviewed the results of the model we can then:

1) make appropriate changes to our model parameters, our feed, our circuit configuration;

2) rerun the simulation; and,

3) compare the results.

Documents

Jksimmet 20v6 Intro 2bsim1 140403001229 Phpapp02 Gs