MODSIM Lab Manual
MODSIM Lab Manual
MODSIM Lab Manual
&
MODELING
of
Mineral Processing Systems
LABORATORY MANUAL
for
CONTENTS
SL. NO.
DATE
EXPERIMENT
About MODSIM
II
III
IV
Simulation of Screen
Simulation of Hydrocyclone
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.
Solid
flow
kg/s
1.00
1.00
cms
.821E-03
.05
.581E-03
.03
.411E-03
.02
.290E-03
.02
.205E-03
.01
.145E-03
.01
.000
.00
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
.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
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
.799
.565
.399
.282
.200
.000
31.23
22.90
16.85
12.40
9.13
.00
: 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
.282
.200
.000
.00
.00
.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 %
12
.231E-01 m
.119E-01 m
.408E-02 m
SIMULATION OF HYDROCYCLONE
* MODSIM
.000
.00
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
PARAMETERS:
.600 tonnes/kWhr
616. kW
.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
.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
Date_______
Stream
number
1
2
3
Solid flow
kg/s
0.20
0.06
0.14
Date___________________
Stream
number
1
2
Solid
flow
kg/s
1.00
1.00
* MODSIM UNIT DESIGN REPORT *
1.00 m
20.0 cm
20.0 degrees
2.00 m/s
35.0 degrees
1600.0 kg/m^3
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