JKSimMet

Steady State Processing Plant

Simulator
Review 2.0 of the 31-03-15

Split Engineering LLC. Split Engineering Chile Ltda.

2555 N. Jackrabbit Avenue CP 85745
Tucson, Arizona, USA
Fono: (1)-(520)-3273773
http://www.spliteng.com
General Salvo #331 oficina 201
Casilla 16807 Sucursal Panormico
Providencia Santiago, Chile
Fono: (56)-(2)-25978200
http://www.spliteng.com
Mathematical Modelling

Why bother?
What is a mathematical model?

Process
Measured Inputs Model
Predicted Outputs

Model Parameters
 Example of a Model

Feed Ball Product

Mill

Pi = Fi - Ri Ci + Aij Rj Cj

Measured Data Model Parameters

Sizings etc Appearance (Ore)
Breakage Rate (Machine)
 Simulation by Computer
Models of the required unit operations

A method of combining the models to

predict circuit performance

A software system which is easy to use

 Applications of Simulation
Process optimization studies
What if - - - - ?

Process design studies

Green field studies
Existing plant modifications
Methods for Optimization Studies
Experience and/or inspired guess work

Plant test work following an experimental design

Modelling and simulation to assess options and

identify likely solutions
Process Optimization Path
Define objectives and constraints

Measure (Sample)

Analyse (Mass Balance & Model Fit)

Simulate (Optimize)

Adjust Circuit (Equipment)

Measure (Sample)
 For Useful Simulation Studies
Process knowledge
Suitable models and an understanding of the
model limitations
Good quality data to develop parameters
A useable computer/software system
Engineering judgement to assess results
 Process Design Studies
Based on data from sources other than the
operating plant
Ore - laboratory testing
Machine - other operations (JKTech Data
Base)
Less accurate than optimization
Gives information about likely circulating loads
Allows sensitivity analysis
 JKSimMet Development - I
JK - from Julius Kruttschnitt Mineral Research
Centre
Sim - from Simulation (50 years of JKMRC
Research)
Met - from Metallurgical Processes (perhaps a
little optimistic)
 JKSimMet Development - II
JKSimMet is useful for
crushing and screening

grinding and classification

mass balancing
 JKSimMet Development - III
1970s Fortran IV and punched cards
1981/2 Fixed flowsheet simulator
1983/4 JKSimMet V1 (Hitachi + PDP11)
1985 JKSimMet V2 (PC AT + PGC)
1988/9 JKSimMet V3 (Halo)
1992/3 JKSimMet V4
1999 JKSimMet V5.0 for Windows
2001 JKSimMet V5.1 for W 2000 & NT
2003 JKSimMet V5.1 for XP
2006 JKSimMet V5.2
2012 JKSimMet V5.3
2012 JKSimMet V6.0
 JKSimMet Development - IV
JKSimMet V6
Move into the more modern JKSimFloat structure
Provision for multi-component modelling
Possibility of expanded capability across processes
 JKSimMet V6 Enhancements
New drawing package
Better control of positioning of flowsheet items
Can still use V5 icons
Auto labeling of streams and equipment
Control of icon and stream properties (colour, thickness etc)
Conversion of all experimental sizings to master sieve series
Simplified simulate, balance, model fit and graph interfaces
Data input and editing through configurable stream overview and info
blocks
More flexible info blocks
Enhanced SD control and data entry
Extensive Help files
Simulation manager
2D Mass Balancing
 Simulation Process
Build flowsheet or use existing flowsheet
Assign characteristics
Machine dependent parameters
Engineering/Geometry (from measurements or

drawings)
Model Parameters (from model fitting or data

base)
Ore dependent parameters (from ore testing)
Simulate
Assess the results
 Important Concepts
Project
Flowsheet
Equipment
Streams
 System, Project file, Flowsheet

Equipment
list

Flowsheet
list

Stream
Equipment labels
label
 Project
The block of data which is a pair of identifiable
files (with .jksm6 and .jksysdb extensions)
Can contain several independent flowsheets
 Flowsheet
A combination of equipment and streams
connecting the equipment

Can be bigger than the screen but can not be

connected to other flowsheets
 Equipment
Icons comprising mathematical models
Each equipment item contains
Combiner port (the sum of the streams flowing
in)
Can and should be renamed from the default
names
 Special Equipment
Feeder
a feeder is an item of equipment and its
equipment properties are flow and size
distribution data
Liquid feeder
a liquid feeder is also an equipment item and
its properties are % solids or liquid flow
Can and should be renamed from the default
names
 Streams- I
The place in the equipment where the feed and product
information (flows and size distributions) are stored.
The Combiner stream
stores the sum of all the streams feeding the
equipment
can not usefully contain experimental data (mostly)
The Product Streams
stores the product data
can contain experimental, simulated, balanced and
fitted data
 Streams- II
Take their name of the equipment item of which
they are a product

Can be renamed
 Cell Colours
Black text on white background - User entered

Black text on grey background - System

generated
Toolbars - I
Main Toolbar
Toolbars - II
Flowsheet Toolbar
Toolbars - III
Engine Room Toolbar
 Flowsheet Colours
Blue Outline - on the select list
 Simulation - I
Convergence

Unknown

Known
 Simulation - II
Convergence Controls
Assumption about circulating stream
Zero

Measured

Last time

Convergence Limit
0.1 to a very small number x Volume flow of

circulating stream
 Assess Results
Data in streams and equipment
Data in labels
Graphs
Overview
Standard and configurable
Streams and equipment
Print
Copy and Paste
 Build a Flowsheet Walk Through
Open a new file
Choice of Icons V5 or V6
Add equipment
Moving, rotating, flipping, changing size of icons
Naming equipment
Icon properties
Labels
Add streams
Single click or right click to add/remove nodes
Moving streams
Must have product streams
Labels
 Entering Data
Lock the flowsheet
Set up sieve series
For simulation, just need the master series
For analysing survey data, may need multiple sieve series
Can copy and paste data into groups of streams using Survey Data entry

screen but must be in correct sequence in Excel (Will change later).

Streams
Enter directly or copy and paste
Equipment
Enter directly or copy and paste
Simulate
 V5 V6 Changes I
Master sieve series
Users choice
Up to 40 size fractions 10 m to 13 m
If converting from V5, default will be the series containing the coarsest
particles
Click OK converts all sizings to the master sieve series using the interpolation
method in the drop down box. Choose linear if unsure of effects
Survey data entry
Can set up many sieve series to accept survey data
Enter data on the relevant sieve series
Click Transfer converts all survey data to master sieve series for use in
JKSimMet Original survey data are preserved for later retransfer if necessary
 V5 V6 Changes II
System properties
Set solids and liquid density values
Define Element data and units if required
Accessing models is a two step process
Click on icon to open Equipment window
Click to open Model window
Can access other equipment items or streams from this window
Configurable Equipment Manager
Allows easy access to selected parameters for all equipment of one type in a
flowsheet for data entry or reporting
Stream data entry or viewing
Double click on stream to open Stream Window
 V5 V6 Changes III
Stream data entry or viewing
Double click on stream to open Stream Window
Four tabs
Totals (used in JKSimMet fitting, simulation and balancing)

Sizing Data (used in JKSimMet fitting, simulation and balancing)

Elemental assay data (used in balancing only)

Size by elemental assay data (used in 2D balancing only)

Columns displayed on each tab controlled by Data View Type

Automatic SD Calculation
Click on SD button on Stream Data window
Select streams required, Select Property as basis of SD calc, Select SD option
Click Calculate
 V5 V6 Changes IV
Automatic SD Calculation
Click on SD button on Stream Data window
Select streams required
Select Property
Select SD option
Many to choose from
Fixed = 0.001
Poor = 20% of exp value
Average = 10% of exp value
Good = 5% of exp value
Excellent = 2% of exp value
Whiten = 10% of exp value +0.1 with max value of 1.0 (Sizings only)
Others explained in manual/help files
Click Calculate
Repeat for other properties and/or streams
 V5 V6 Changes V
Configurable Stream Overview
Columns
are properties selected by clicking on title to open selection window
can be added or deleted
Rows
are streams
Can be added or deleted
On adding, selection of all available streams requested
Can be used for data entry and/or reporting
Can be exported to Excel
Can be cloned
 V5 V6 Changes VI
Simulation Manager
3 tabs
Simulation Scenario
Columns control parameters to be varied
Rows control values of parameters
Results Streams
Displays selected stream data
Results Equip
Displays selected equipment data
Reporting
Very similar to V5
Difference is that report is exported directly to Excel
 V5 V6 Changes VII
Graphing
No quick graph but flash graph easier and quicker
Similar structure to V5
Configurable graphing window
Select stream data for graphing
Global data type and Y-axis type
Format
Axis and Graph Labels
Axis max and min, linear or log, number format
Grid on or off
Custom lines
P80 highlight
 V5 V6 Changes VIII
Info Blocks
Similar to V5 but more flexible
For streams
Select multiple streams to apply
Select from 2, 4, 6 or 8 cells per info block
Expanded choice of variables for display
For equipment
Select multiple equipment items of same type using same model
Select from 1 to 4 cells per info block
Selection of parameters for display using same structure as equipment
model window
Can enter data through info block
 V5 V6 Changes IX
Select Lists (Simulate, Model Fit or Balance)
Same as for V5 items outlined in blue on select list
Can select or deselect equipment or streams by click on item
Whole Circuit is special case entire flowsheet always selected including new
streams or equipment added
Whole Circuit is default
Model fitting
One main window
Select for inclusion in simulation with Model Fit Case list
Whole Circuit is special case
Cursor on Equip item in list displays parameters for that equipment item and
automatically selects streams for error calculation (Can be manually set if required)
Parameter fit list automatically built by selecting parameters
 V5 V6 Changes X
Mass Balancing
Different algorithm from V5
Selection and Control in a single window
Allows balancing of assay and size by assay data
Staged process for operating
Select required equipment and streams
Set TPH Solids and size distribution data to Adjust, all else to missing
Run Balance
Set TPH Solids SDs to Fixed, TPH water to adjust and % Solids to Influence
Run Balance
For TPH Solids figures that were guessed or estimated, replace Exp guessed values
with balanced values with average SDs
Run Balance
Continue process until Total RMS error reaches minimum
 V5 V6 Changes XI
Mass Balancing continued
Stage processing continued
If assay data and or size by assay data are to be balanced as well, set
TPH Solids, TPH Water , Sizes to fixed, % Solids to unused and
Elements to adjust
Run Balance
Set Elements to Fixed and Size by Element to adjust
Run Balance
Balancing is definitely an iterative process and takes practice
 Manual Structure
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
Thanks for your attention!