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49. MASS BALANCING AND DATA RECONCILIATION EXAMPLES

This manual gives examples how to solve different kind of mass balancing problems. Please have a look of the manual 48. Sim Mass Balancing for detailed information of different buttons and menus.

49.

MASS BALANCING AND DATA RECONCILIATION EXAMPLES .................................................... 1 MASS BALANCING AND DATA RECONCILIATION ....................................................................................... 1 EXAMPLE 1 - 1D COMPONENTS ................................................................................................................. 2 EXAMPLE 2 1D CHEMICAL COMPONENTS ............................................................................................. 20 EXAMPLE 3 1D MINERALS .................................................................................................................... 24 EXAMPLE 4 1.5D MASS BALANCING .................................................................................................... 36 EXAMPLE 5 2D CHEMICAL COMPONENTS ............................................................................................. 41 EXAMPLE 6 MULTIPLE DATA SETS ....................................................................................................... 46

49.1. 49.2. 49.3. 49.4. 49.5. 49.6. 49.7.

49.1. Mass Balancing and Data Reconciliation

Mass balancing is a common practice in metallurgy. The mass balance of a circuit is needed for several reasons: 1) To estimate the metallurgical performance of the circuit. 2) To locate process bottlenecks and for circuit diagnosis. 3) To create models of the processing stages. 4) To simulate the process. The following steps are often required to simulate a process: 1. Collecting experimental data (experimental work, sampling, sample preparation, assaying) 2. Mass balancing and data reconciliation of the experimental data 3. Model building 4. Simulation HSC7 allows the user to solve the following mass balance problems (Table 1): 1. Reconcile measured or estimated component flowrates (1D components). 2. Mass balance and reconcile chemical analyses (1D assays) 3. Mass balance minerals in minerals processing circuit (1D Minerals) 4. Mass balance size distribution and water balance (1.5D) 5. Mass balance assays and components in 2- or 3-phase systems where the bulk composition is not analyzed (2D Components) 6. Mass balance minerals or chemical assays size-by-size (2D Assays) 7. Mass balance particles, MLA assays (3D) This manual includes mass balance and data reconciliation examples of following problems: 1. 1D Components (chapter 49.2) 2. 1D assays (chapter 49.3) 3. 1D minerals (chapter 49.4) 4. 1.5D (chapter 49.5) 5. 2D analyses (chapter 49.6) 6. Multiple data sets (chapter 49.7)

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Table 1. Mass balance cases that can be solved with HSC Sim. The red X indicates that data is necessary and defines the case. In order to solve the 3D-mass balance, the particle tracking module of HSC is required. This is currently available only for AMIRA P9O Sponsors.
Assayed or | Case estimated values | Total stream flowrates Total solid flowrates Liquid flowrates Component flowrates Component distributions %Solids Bulk chemical compositions Minerals and their chemical composition Particle size distribution Chemical composition of size fractions Particles (MLA data)
1D Components 1D Assays 1D Minerals 1.5D 2D Assays 2D Minerals 3D

X X X X X

X (X)

X (X)

X (X)

(X) X

(X) X X

(X)

(X) X

(X) X X

(X) X X X X X

X X

X X

49.2. Example 1 - 1D Components

The 1D components balancing exercise can be found in C:\HSC7\Flowsheet_MassBalancing\Example 1D Components. To jump over the drawing and bringing the experimental data just open the 1D Component Example.fls file. In this exercise we have a circuit with five units and eleven streams. We want to get the balance for arsenic and copper flowrates through the circuit. We have measured the flowrate information only from the input and output streams. In addition we have the knowledge on the distribution of the component between the output streams of each of the unit. This data could be metallurgical knowledge of specific process stages.

Figure 1. Example 1D can be found in your computer.

49.2.1.

Draw the flowsheet

Open HSC Sim.

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Turn the HSC mode to Experimental (Figure 2) Draw first the units; the example has five units named as U1, U2, U3, U4 and U5 (Figure 3) Draw the streams; the example has eleven streams called as letters form A to J. Be sure that the Source and Destinations are correct (Figure 3) Finally check the stream connections using the Overlay and Route Check button as shown below. The input streams are shown blue, the output streams red and the intermediate streams black . Save the drawing.

Figure 2. Turning the mode to Experimental.

Figure 3. Flowsheet of Example 1.

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49.2.2.

Bring in the experimental data

The experimental data is collected in the Analyses.xls file which is to be stored in the very same folder you saved the flowsheet drawing file. To import the data using Excel: 1. 2. 3. 4. 5. 6. Open the Analyses.xls file in MS Excel. In HSC go to the Analyses window (Experimental Analyses, Figure 4). Create Stream Properties sheet: Select from the menu Create Stream Properties Sheet Horizontal (Figure 6) In the MS Excel copy the experimental data into the clipboard. The cell Stream must be the first cell on top left (Figure 6). In HSC Sim go to the Experimental data and select Edit Paste Special Assays (Figure 7). To visualize the data in the flowsheet create the value labels: press Visualize and select Create Stream Value Labels (Figure 8). In the Analyses window select column to visualize the variable in the flowsheet (Figure 9).

Figure 4. Experimental data.

Figure 5. Creating Stream Properties Sheet.

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Figure 6. Copying data into clipboard. The first cell on left top corner has to be the Stream cell.

Figure 7. Pasting assays.

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Figure 8. Creating Stream Value Labels.

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Figure 9. Visualizing variable in the flowsheet.

49.2.3.

Mass Balancing Wizard

To mass balance the data: 1. 2. 3. 4. Press Mass Balancing and Data Reconciliation>>> in the Analyses window (Figure 10). Check that As and Cu flowrates are identified correctly as CD Component Flowrates and As and Cu distributions as CD Component Distribution (Figure 11). Press Next. In the second wizard window (step 2 of 5) check that all streams are selected for the mass balancing (Figure 12). Press Next. In the Step 3 you can edit the error models. Here we use the default values, i.e. flowrates the relative error is 10%, detection limit is 0.1 and max standard deviation is 10 tph. For distribution the relative error is 10%, detection limit 1% and max standard deviation is 10 percentage values. (Figure 13). Press Next. Step 4; the reference stream is A. Press Next (Figure 14). Step 5. Errors and mass balance nodes. There should not be any errors. Press Next (Figure 15).

5. 6.

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Figure 10. Press Balance and Data Reconciliation >>> button.

Figure 11. The Mass Balance wizard, step 1.

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Figure 12. Step 2.

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Figure 13. Step 3.

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Figure 14. Step 4. Reference stream

Figure 15. Step 5. Nodes, node 4 is visualized: blue streams are the feed streams of the node, red ones are the output streams. Narrow black streams are not included in the node 4. Number oif errors is zero.

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49.2.4.

Mass Balancing Window

After the mass balancing wizard you can see the Data Balancing and Reconciliation window (Figure 16). The left part of the window shows Dimension selector and Step Navigator (Figure 17) and Data indicator (Figure 18). In the middle you can see the Data Sheet (Figure 19). On right hand side you can see the Balance/Report Options. To solve the mass balancing problem press or button.

Figure 16. Mass Balancing and Data Reconciliation window.

Figure 17. Navigator including dimension selector and step navigator.

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Figure 18. Data indicator.

Figure 19. Data sheet.

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Figure 20. Balance/Report options.

Once you press the press or button HSC Sim solves the mass balance problem. Balanced (Bal) columns become visible, i.e. now you have visible measured values (white background) and balanced values (grey background). To see more columns check the ones you want to see in the report options / column selector (Figure 22). To visualize the balance in the flowsheet click the column in the data sheet (Figure 23) and see the flowsheet (Figure 24). Use copy/paste to report out for example in MS Word. Now HSC Sim has adjusted all arsenic tonnages, but we would like to see the feed tonnages, 100 tph, remain unchanged. There are two options for that: 1) set the standard deviation for the stream A / As tph very small, say 0.01 (Figure 25); 2) set the minimum and maximum values to 100 and 100 and select the solution method to CLS (Constrained Least Squares) (Figure 26). To report result as Stream Tables, Select from the menu Flowsheet Create Stream Tables (Figure 27), select the components (Figure 28) and items (Figure 29). In the next window answer Yes to remove the tables with no values (Figure 30). Oranize the tables in the flowsheet in a way that all tables and streams can be seen (Figure 31). Use copy/paste to report out. Click Report and in the StreamSummary sheet select reported items and press Copy to get the data into the clipboard (Figure 32). Paste into for example MS Excel.

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To save the full result select File Save and give a name for the file (Figure 33).

Figure 21. Mass Balance solved and data reconciled.

Figure 22. Report options; column selector.

Figure 23. Clicking As tph to visualize in the flowsheet (see next figure).

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Figure 24. Selected item reported in the flowsheet.

Figure 25. As tph for the stream A set to 0.001. Now balanced As tph is practically equal to the measured one.

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Figure 26. Setting min and max values for As to 100 and 100 and pressing Balance will solve the As flowrate using constraints. Remember to change the solution method to CLS (Constrained Least Squares).

Figure 27. Create Stream Tables.

Figure 28. Selecting components to be reported.

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Figure 29. Selecting items.

Figure 30. Tables with no values are removed.

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Figure 31. Balance result reported as Stream Tables which are placed on Balance Layer.

Figure 32. Reporting.

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Figure 33. Saving balance file.

49.3. Example 2 1D Chemical Components

The 1D Chemical Components example can be found in C:\HSC7\Flowsheet_MassBalancing\Example Copper Circuit. The file is Copper Circuit.fls (Figure 33). In the Experimental Data select sheet 5 1D with ERROR (Figure 34). In the Mass Balance Wizards keep the default values, or you can even Skip the wizards (Figure 35). In the Data Balancing and Reconciliation press button to solve the mass balance. With the basic options you will find that there are some negative numbers and %Solids and Water have not been solved (Figure 36). To overcome the negative values select NonNegative Least Squares (NNLS) method. For solving also water and %solids select Solids+water of Water Independently. The former solves all simultaneously the latter solves first solids and then solves %solids and Water using Solids solution as constraints. Now mass balance result does not have any negative values and Water and %Solids are also solved. However, the Mill Water has 0.65 t/h solids and ROM has been adjusted to 114 t/h. For the former we set min and max to zero and latter min=max=112 t/h (Figure 39). The solutions is showed in Figure 40. or

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Figure 34. Select sheet 5 1D with ERROR.

Figure 35. Press Skip Wizard, the default values will be used.

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Figure 36. Negative results and %Solids Balanced values are zeros.

Figure 37. NNLS and Water Independently selected.

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Figure 38. Total Solids flowrate, balanced. Mill Water has 0.65 t/h solids which is not right.

Figure 39. Constraints for totals solids t/h.

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Figure 40. Mass balance of the 1D case.

49.4. Example 3 1D Minerals

In 1D minerals we use the vary same example as above, i.e. C:\HSC7\Flowsheet_MassBalancing\Example Copper Circuit. The file is Copper Circuit.fls (Figure 33) and the sheet 5 1D with ERROR (Figure 34). When mass balancing with minerals the steps are: 1. Convert elemental grades to mineral grades using HSCGeo 2. Bring the mineral matrix into HSC Sim 3. Solve mineral balance using constraint Sum=100. 4. Bring the solution back to Analyses. 5. Calculate Minerals to Element. To convert elemental grades to mineral grades select the correct sheet and select Tools Element To Mineral Conversions Using HscGeo (Figure 41). In HscGeo press Define >>> to define minerals (Figure 42). Type chalcopyrite and select the stoichiometric one and press Add (Figure 43). Continue by adding pyrite and quartz (Figure 44) and press OK to return to Modal Calculation window. Now select Ccp (chalcopyrite) and press > -button to move it to calculation list (Figure 45). Press Cu to define that chalcopyrite is calculated from copper (Figure 46). We are confident of copper assays and that chalcopyrite is the only copper mineral and its composition is stoichiometric. For pyrite we are not so sure. Therefore we will calculate pyrite on the second round using both S and Fe (Figure 47).

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The remaining, quartz, is calculated from 100-others, use right mouse button for selecting that option (Figure 48). Press Run to calculate the modal composition (Figure 49). In two samples the mineral sum is higher than 100% (Figure 50). This is due to uncertainties in S and Fe assays which means that our estimate on pyrite is too high. To fix that we use Normalize button (Figure 51) define that pyrite is adjusted by selecting Py, Total sum is and 100 and press Calculate (Figure 52). Now the modal calculation is ready. Select from the menu Edit Copy the Whole Sheet (With Headers) (Figure 53). Now move back to HSC Sim, activate the Experimental Data and select Edit Paste Special Assays (Figure 54). Mineral analyses are now pasted to HSC Sim (Figure 55). To have the possibility for calculating back to elements go once again back to HscGeo and select Edit Copy Mineral Matrix (Figure 56), move back to HSC Sim and select Tools Paste Mineral Matrix (Figure 57). HSC Sim crates a sheet named MinrealMatrix and brings the chemical composition of minerals on that sheet (Figure 58). Now get back to the sheet 5 1D with ERROR and press

-button. In the first Balance Wizard step select Total Solids Flowrate, %Solids, Water, Ccp, Py, and Qtz (Figure 59). You can skip the other steps (press Skip Wizard). In the Data Balancing and Reconciliation window set the method to CLS, check the Component Sum=100, Solve Water Independently, set the min and max values for water streams to zero and for ROM to 112. Press solve; the result is shown in Figure 61. For graphical presentation select Graphics Assays Stacked Bar (Figure 62, Figure 63). To calculate back to elements result has to be moved back to Experimental Data; use File Save Result into Experimental Sheet (Analyses.xls) (Figure 64). Give name for the balance sheet (Figure 65) and complete the balance by selecting Tools Calculate Minerals To Elements (Figure 66). Now the balance is ready. In the final mineral and elemental balance minerals sum up to 100% and elemental balance is fully compatible mineral balance and the Mineral Matrix (Figure 67).

Figure 41. Element to Mineral Conversions, starting HscGeo.

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Figure 42. In HscGeo press Define >>> to define minerals.

Figure 43. Adding chalcopyrite.

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Figure 44. Chalcopyrite, pyrite and quartz added.

Figure 45. Moving Ccp (chalcopyrite) to calculation list.

Figure 46. Chalcopyrite Cu selected for the first round, pressing UP-button to move to the second round.

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Figure 47. Second round: pyrite using both Fe and S.

Figure 48. Quartz is calculated on third round using Is Total-100. Use right mouse to select the option.

Figure 49. Press Calculate to run the modal calculation.

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Figure 50. In two samples the total is higher than 100%.

Figure 51. To adjust pyrite select Normalize and

Figure 52. select Py and Total sum is, 100 and press Calculate.

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Figure 53. Copy the modal composition to the clipboard.

Figure 54. In HSC Sim select Edit Paste Special Assays.

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Figure 55. Mineral analyses are brought to HSC Sim (use Format Auto to set autoformat and Window Freeze Panes to fix the top row and left column).

Figure 56. In HscGeo select Edit Copy Mineral Matrix

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Figure 57. Paste Mineral Matrix to HSC Sim; select Tools Paste Mineral Matrix.

Figure 58. In HSC Sim Mineral Matrix is brought to a sheet MineralMatrix.

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Figure 59. Select flowrates and minerals.

Figure 60. Calculation conditions.

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Figure 61. Balanced mineral grades and flowrates.

Figure 62. For bar chart select Graphics Assays Stacked Bar.

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Figure 63. In the Graph window you can see the balanced modal composition.

Figure 64. Save balanced result back into Experimental Data by selecting File Save Result into Experimental Sheet (Analyses.xls).

Figure 65. Give name for the balance sheet.

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Figure 66. Complete the balance by selecting Tools Calculate Minerals To Elements.

Figure 67. Final mineral and elemental balance; minerals sum up to 100% and elemental balance is fully compatible mineral balance and the Mineral Matrix.

49.5. Example 4 1.5D Mass Balancing

In 1.5D mass balance example we use the vary same example as above, i.e. C:\HSC7\Flowsheet_MassBalancing\Example Copper Circuit. The file is Copper Circuit.fls (Figure 33) and the sheet 3 Grinding Survey (Figure 68). This example demonstrates: Vertical data in Experimental Data Particle Size distribution balancing Drawing includes the whole flowsheet but mass balance is only for part of the circuit. Open the file and select the page 3 Grinding Survey in the Experimental Data. Check that the data is Vertical. Please notice that for the water streams you need to give data also for size distribution (zero values); otherwise the water streams can not be included in the mass balancing. If some of the measured values is zero in all samples (for example the mass proportion of very coarse size fraction) you should take that out in the mass balancing. Press the -button and in the first window uncheck Cu % and S % (you can later on repeat the example with elemental assays too). In the

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second step select only streams: ROM, Mill Water, Mill Sump Water, SAG Discharge, Cyclone UF and Cyclone OF (Figure 70). In the following windows you can Skip or just accept by pressing Next. In the Data Balancing and Reconciliation window select the data dimension to 1.5D (Figure 71). Running the mass balance with default options will give negative solid flowrates for the Mill Sump Water (Figure 70). Again, we need to use CLS method. Set min and max values for the Mill Water (0 and 0), Mill Sump Water (0 and 0). Figure 73 gives the result of the mass balancing. To draw cumulative passing graphs select Graphics Cumulative Passing (Figure 74 and Figure 75).

Figure 68. 1.5D example: 3 Grinding Survey of the Copper Circuit . Vertical (on the bottom of the window) indicates that data is vertical, i.e. each sample is a column.

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Figure 69. Select components; uncheck Cu and S in this exercise.

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Figure 70. Selections for the streams to be included in the mass balancing.

Figure 71. Dimension is 1.5D.

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Figure 72. Solution with basic options: negative flowrates.

Figure 73. 1.5D Balance result with constraints (min & max).

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Figure 74. Studying result as cumulative passing graph.

Figure 75. Cumulative passing graph.

49.6. Example 5 2D Chemical components

2D example can be found on the sheet 7 2D with ERRORS in the vary same Copper Circuit flowsheet (Figure 76). Activate the sheet and press -button. In the second window uncheck the water streams (Figure 77). Other options you can leave as default (i.e. Skip Wizard). Run the 1D mass balance (Figure 78); in the example NNLS method was used. Once you are happy with the 1D balance, change the dimension to 2D (Figure 79) and run the balance again. Now 2D

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balance is solved using 1D balance as constraints (Figure 80). Check the difference between balanced and measured with the partity chart (Figure 81, Figure 82). Finally save the results into Experimental Data (Figure 83, Figure 84)

Figure 76. 2D example.

Figure 77. Uncheck Mill Water and Mill Sump Water in the mass balancing.

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Figure 78. Runnin 1D mass balance with NNLS method.

Figure 79. Click 2D.

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Figure 80. 2D mass balance solved.

Figure 81. Parity Chart.

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Figure 82. Parity Chart, copper assay, measured vs. balanced.

Figure 83. Saving result.

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Figure 84. Result in Experimental Data.

49.7. Example 6 Multiple Data Sets

Multiple data sets example can be found on the sheet 8 Several Sets in the vary same Copper Circuit flowsheet (Figure 85). Activate the sheet and press -button. Use the default options, i.e. press Skip Wizard. In the Data Balance and Reconciliation window select NNLS method. You can change the other options like standard deviation, sampling error, min and max values, if you like. Press or button to solve the mass balance. Check the result and if you are happy you can check what is the balance with other cases: change the case in the Case combo box (Figure 86). In this exercise the standard deviation for the ROM solids flowrate was set to 0.1. When you are ready to run all the cases in one go select from the menu Tools Solve All Cases (Figure 87). Give name for the result sheet (Figure 88) and HSC Sim will create the sheet and run the balance for all cases. After finishing the mass balance HSC Sim will show the Experimental Data, where you can identify the streams (Figure 89), calculate recoveries (Figure 90) and adjust formatting (Figure 91, Figure 92).

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Figure 85. Data with several sets; Sheet 8 Several Sets.

Figure 86. Changing to second case.

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Figure 87. Solving all cases.

Figure 88. Naming the result sheet.

Figure 89. Identify Streams and

Figure 90. calculate the recoveries.

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Figure 91. Formatting the result sheet.

Figure 92. The result.