Outotec Webinar Simulation of Minerals Processing Circuits 210995

Simulation of minerals processing circuits
Toni Mattsson, Process Metallurgist, Flotation

October 27, 2016
Today’s speaker
Toni Mattsson, Process Metallurgist, Flotation
• Worked at Outotec for 5 years mainly with green and

brownfield studies and engineering projects
• Experience from metallurgical and hydrodynamic
performance testing at all scales to process sizing and
simulation
• Led hydrodynamic and metallurgical performance
testing of Outotec’s largest flotation cell currently in
operation, Outotec TankCell® e500, with 500m3 of
flotation volume
• Published papers in major minerals processing
conferences
• Hobbies: weight-lifting and mountains
2 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

© Outotec – All rights reserved
Agenda
1. Minerals processing process simulation

development history
2. Static simulation
3. Dynamic simulation
4. Future opportunities in use of simulation

1. Minerals processing process simulation
development history

Types of simulators
• Training process simulators and emulators
Fermi 2 nuclear plant simulator

www.mapps.l-3com.com Virtual Experience Environment, Outotec

Types of simulators
• Hardware-In-the-Loop (HIL)
J. Tichon and P. Diver, “Plant operator simulation: Benefits and drawbacks for a construction
Outotec mill relining machine simulator (IVRS)
training organization,” Cogn. Technol. Work, vol. 12, no. 3, s. 219–229, 2010.

Types of simulators
• Engineering simulators (e.g. HSC Sim by Outotec)

Types of simulators
• Dynamic for training and automation tuning (e.g. Virtual Experience by

Outotec)

Types of simulators
• Virtual Reality (VR) (e.g. Outotec cPlant VR simulator)

History of process simulation
Virtual Reality
(VR)
Dynamic for
automation tuning
Engineering simulators
Hardware-in-loop (HiL)
Training simulators
1960 1970 1980 1990 2000 2010

Unit models - Emulation
Often empirical Requires existing process
BLACK BOX
RECORDED IN 1
RECORDED OUT 1
RECORDED IN 2 RECORDED OUT 2

Do not know what happens inside
Like a tape recorder

Unit models - Static or steady-state
Often empirical or Requires process

semi-empirical in the laboratory
BLACK BOX or at a plant
IN 1
OUT 1
IN 2 OUT 2
Observation-based relations
between inputs and outputs

Unit models - Dynamic
Often semi-empirical Universal, but require tuning

Can be constructed
FUNCTIONAL ZONES without working
plant
IN 1
ZONE 1 OUT 1
ZONE 2
ZONE 3
IN 2 Knowledge-based relations between OUT 2

inputs, outputs and zone contents

Basic model types – Theoretical models
• Theoretical models are based on fundamental physical, logical or
mathematical cause and effect relations. They may be used to describe a
single physical or chemical reactor (unit operation).
Josiah Willard Gibbs 1839-1903 – “Founder of thermodynamics”

Basic model types – Empirical models
• Empirical models are usually based on experimental data which is fitted to

some flexible mathematical functions or model using parameters.
• A lot of data may be needed to fit the model to a wide range of process
conditions.

Basic model types – Semi-empirical models
• Semi-empirical models combine

the advantages of theoretical and
empirical models.
• Semi-empirical models automatically
take into account kinetic and
dynamic reactions, non-ideal
solutions as well as composition,
temperature and pressure gradients
Weather models are typical

examples of semi-empirical models

HSC changes theory into reality
More than 1000 kg of scientific

publications, journals and books
have been utilized in HSC
development within the last 40 years.

From unit models to process models
HSC Sim is the flowsheet simulation module

Allows creation of static and dynamic process models

Minerals processing dynamic unit model development
at Outotec
Static unit and flowsheet models for minerals processing, hydro- and pyrometallurgy based on HSC
Chemistry and HSC Sim
Mixer-settler,
SAG, Ball mill,
Thickener and filter, electrolysis for
Flotation cell, dynamic hydrocyclon dynamic
dynamic model Cu solvent
model in HSC Sim, models in HSC Sim,
in HSC Sim, extraction and
bulk Cu flotation primary & secondary
concentrate thickening electrolysis
grinding circuit
circuit
Leaching/
adsorbtion circuit
(CIL)
Pressure
leaching
2009-2010 2011 2012 2013 2014 2015 2016

2. Static simulation

Static process model
• Modeling of steady-state
• Metallurgist day-to-day tool
BLACK BOX
• Converting process or laboratory
data to relations and vice versa IN 1
• Can be used for guesstimating OUT 1
unknown process values

IN 2 OUT 2
Observation-based relations
between inputs and outputs

Testing for the metallurgical response
• Sampling campaign and/or laboratory

testing
• Simulation can be built either from data
obtained from process survey or laboratory
tests
• Kinetic Flotation Model

• Model fitting to test data
• Fast (mF), Slow (mS) and Non-Floating (mN)
particles with kinetic rate constants (k)
R  mi , F 1  e   ki , F t
  m 1  e 
i,S
 ki ,S t

Particle based modeling
• Fast, slow and non-floating Non-floating

Slow floating
Five minerals x seven size fractions x three behavioural types = 5 x 7 x 3 = 105 particles
Fast floating
particles
What happens to chalcopyrite of one size fraction?
• Particle size fractions
TankCell
Conditioner
CycloneOF
• Elements are converted to NF

SF
NF
SF
NF
SF
minerals: FF FF FF
ConditionedFeed Tail
Mineral Chacopyrite Pyrite Sphalerite Galene Quartz
ID M/Ccp/52 M/Py/66 M/Sp/49 M/Gn/50 M/Qtz/53
Concentrate
O% 53.257
Si % 46.743 NF
S% 34.945 53.454 32.903 13.402
SF
FF
Fe % 30.429 46.546
Cu % 34.626
Zn % 67.097
Pb % 86.598
SG 4.350 5.013 4.096 7.580 2.650

Flotation equations in HSC Sim
• Detailed calculation of recovery (Savassi eq.):

𝑘𝑐 𝜏 𝑘𝑡𝑅𝑓 1 − 𝑅𝑤 + 𝐸𝑛𝑡𝑅𝑤
𝑅𝑇 = 𝑅=
1 + 𝑘𝑐 𝜏 1 + 𝑘𝑡𝑅𝑓 1 − 𝑅𝑤 + 𝐸𝑛𝑡𝑅𝑤
𝑘
𝑅𝑓 =
𝑘𝑐
• Kinetic rate constant:
𝑘 = 𝑃𝑆𝑏 𝑅𝑓
• Bubble surface area flux and superificial gas velocity λ = air residence
6 𝐽𝑔 𝑄𝐴𝐼𝑅 time in froth
𝑆𝑏 = 𝐽𝑔 = • Froth recovery
𝑑𝑏 𝐴𝑐𝑒𝑙𝑙
• Entrainment as a function of water recovery:
𝑅𝑓 = 1 − (1 − exp −𝛼 · 𝜆𝑎𝑖𝑟
𝑅𝐸 = 𝐸𝑛𝑡 ∙ 𝑅𝑤
Applications for static simulation

Laboratory test data to operating industrial scale flotation
circuit
• Outcome of simulation work:
• Retention times
• Flotation cell configuration
• Valuable elements grade and
recovery
• Mass balance for the circuit
…in a full scale process

Process auditing and bottleneck identification
• Built snap-shot model

presenting the process
Solids t/h Yield %
Volumetric flow rate m3/h %Solids RT6 RF Cond
Control room RF1
453
RF3 RF2 Feed
Cu % Cu Rec % RF4 512
453.21 88.52 RF5 RFF
Au ppm Au Rec % RF6 RT1 512.00 100.00
661.93 45.60 RT2 525
RT3
at the time of the survey

RT4 524.64 102.47 867.70 41.20
As % As Rec % 0.13 7.64 RT5 504 RC1
489 1.54 100.00
0.29 41.35 467
477 RC2 20.5 907.76 40.60
460 RC3
0.08 76.87 RC4 14.8 1.59 105.99 0.63 100.00
RC5 12.2
RC6 9.72
Solids t/h 6.33
7.82 RC1-2 0.68 110.91 0.10 100.00
CS1 CS Cond 35.4 PS1
0.12 129.93
CS2
• Gives good over-all

CS3 35.37 6.91
CS4 36.06 7.04
CST7 CS6 CS5
CST1 CSF 118.92 24.41
28.3 CS7 CST2 Process water to CF1 126.91 23.53 RC3-6 PS2
CST3 70.1 36.1 14.81 66.40
28.32 5.53 CST4 51.8 CSC1 6.99 31.96
CST5 45.8 70.10 13.69
200.92 12.80 CST6 41.0 CSC3 CSC2 18.3 3.35 36.75
37.0 291.84 20.46 2.93 32.81
0.17 0.61 30.8
33.7 CSC4
4.83 6.01 18.29 3.57 0.27 CF1-5
19.50
CSC5 0.46 33.56
picture of the process CSC6 3.96 35.68 37.41 5.52 49.02

0.33 2.86 CSC7 3.32 CF1-1
2.85 12.86 29.81 2.43 52.88 CF1-2
0.08 4.42 2.52 CF1-3 CF1-4
PS7 4.45 25.26 0.57 81.46 CF1F
CSC4-7 CSC2-3 CF1T1
CF1-6
0.77 28.36 129 CF1T2
PS8 12.6 10.8 CF1T3 CF1T6
PS9 12.64 2.47 10.84 2.12
CF1 Cond 129.18 25.23 111 CF1T4 70.3
98.3 CF1T5
performance and Final Tails

Cyclone
Cyclone overflow
70.1
70.10 13.69
40.05 25.65
3.74
2.78
1.17
5.99
10.91
29.93
15.19 47.04
9.18
4.12
0.86
12.62
13.86
18.75
359.99 28.48 CF1C1
11.71 191.72
4.13 165.55
0.54 140.20
17.9
C1C1
17.9
17.87 3.49
CF1C2
13.0
CF1C3
10.1
88.2
CF1C4
7.39
80.8
CF1C5
5.90
74.9
CF1C6
4.61
70.30 13.73
292.40 20.48
5.51
2.94
49.11
64.05
291.84 20.46 16.49 60.46 Process water to CF2
bottlenecks.
482 0.59 83.28
481.53 94.05 Cyclone underflow 5.52 49.02 PS3 22.12 50.10
862.85 39.62 130 2.43 52.88 8.33 46.14

CF2 Cond
0.14 8.24 Regrinding 0.57 81.46 0.55 19.72
CF2-2 CF2-1
CF2T7 CF2-3 PS4
0.30 44.21 CF2-4 CF2F C1C2
28.6 CF2-5
• Outcome of the
0.08 81.29 CF2-6 77.0 41.0
28.62 5.59 CF2-7 CF2T1
CF2T3 CF2T2
48.36 41.73 CF2T4 76.99 15.04 41.01 8.01
CF2T5 69.3
14.04 50.94 CF2T6 61.9 CF2C1 111.35 46.12 51.09 50.81
54.6 CF2C2
47.6 CF2C3 18.07 176.34 17.80 92.51
6.41 56.88 40.9 CF2C4 7.47
Mill discharge 34.6 CF2C5 7.25 7.67
130 0.69 40.03 CF2C6 6.99 4.85 115.80 4.35 55.36
Falcon CF2C7 6.69
simulation largely
Cyclone feed 6.35 0.40 62.27 0.45 37.20
5.95
200
Falcon Conc Water to Col

Process water to CF3 Distribution Box Col Feed Box Column
0.20 0.200.04 CF
0.56 28.75 33.4 Column Conc
depends representability Falcon T

130
3.52
176.46 11.17
4.40
0.09
1.82
CF3T6
18.1
18.11 3.54 CF3-6 CF3-5
CF3-4 CF3-3 CF3-2 CF3-1
Feed Box
CF3F
CF3Feed
15.0
15.00 2.93
19.53 49.17
33.38
59.07 39.99
20.45 86.53
3.93
6.52
40.65
10.3
10.34 2.02
23.32 33.33
26.80 35.11
of the ore during the

36.15 36.90 20.45 38.87 0.23 15.35 Column Tails 5.75 18.42
CF3T2 CF3T1 38.0
CF3T4 CF3T3 23.0 0.33 6.98
14.69 33.74 CF3T5 3.93 18.26
PS10 30.5 34.2 38.04 7.43 23.04 4.50
2.55 14.29 23.9 27.1 0.23 6.90
20.9 CF3C4 CF3C3 CF3C2 CF3C1 70.89 38.60 35.75 43.93
CF3C6 CF3C5
0.15 5.35 3.22 3.45 3.66 3.86 18.73 90.30 17.61 51.42
2.75 2.99
survey.
3.43 40.50 3.11 22.24
Final Conc
0.20 15.27 19.93 3.89 0.18 8.37 30.3
34.74 40.29 30.26 5.91
CF3C 22.39 56.56 58.06 37.61
PS5 19.9 PS6
4.24 26.21 23.90 91.67
0.25 9.91 4.76 44.62
0.28 16.89

Investment justification
Source: P. Lamberg, P. Bourke, C. Kujawa, Impact of flash flotation on grinding and main flotation circuits - design by
simulation and case studies, Recent Advances in Mineral Processing Plant Design 2009, 396-405

3. Dynamic simulation

Dynamic process model
• Modeling of transition states (from

steady-state to steady state)
FUNCTIONAL ZONES
• Operator and metallurgist training
of process responses and rarely
IN 1
occurring events ZONE 1 OUT 1
• Automation and Expert ZONE 2

ZONE 3
system tuning
• Clarification of safety and inputs, outputs and zone contents
operational procedures

Flotation cell dimension parameters
Cell dimensions
and volume
Launder setup
Air valve size
Mixing mechanism
Dart valve sizes

Dynamic flotation equation
• Differential equation of mass transfer kinetics
 M i , Feed  M i ,Tails   ki , F mi , F  ki , S mi , S  M i
dM i
dt
+ Entrainment
+ Froth recovery
+ Dart valve dynamics
 Response to operating variables

Air
Froth thickness
Feed slurry composition
Sampling methods
Cut sampler Lip sampler
Pump sampler
Dip sampler
Courier automatic sampler

Gas dispersion measurement
• Bubble size, superficial gas velocity and gas hold up as a function of cell
operating parameters

Dynamic process model & automation system

Dynamic process models in personnel training

Process models in personnel training
Comprehensive …to safe virtual

training program training environment.
for concentrators It combines benefits
that moves of individual hands-
hands-on training on training with a
from control small group resource
room and lost efficiency.
production…

How can personnel benefit from simulator-based training?

Training references
Easy and intuitive interface which
guides training and allows students
to practice hands-on tasks
Best technical
content for
operators I've
Really enjoyed
seen of different
simulation
trainings
exercises but
would have liked
By offering this training, we our reagents and
have strengthened the bond circuit
between the operators and
the company. I would
recommend this training to
other operators as well

Dynamic simulation in ramp-up optimization

Ramp-up optimization
• Traditional approach, 1,5 – 2 years
Data APC Process

DCS
collection SCADA simulation
Beginning of
automation system
development Plant ramp-up
DCS = distributed control system

APC = advanced process control
SCADA = Supervisory control and data acquisition
Ramp-up optimization
• Example project, China, 2015, 8-9 months
DCS
APC
Data
collection SCADA
Process
simulation
Plant ramp-up
Beginning of automation
system development
Use of dynamic simulators for process control

Adaptive dynamic process models
• Predicting process behavior into

the future
• Assisting operator in process FUNCTIONAL ZONES
control
• Substituting operator during stable IN 1
ZONE 1 OUT 1
operation ZONE 2
ZONE 3

inputs, outputs and zone contents

Case: dynamic process models for
predictive process control
• Project ”Crystall ball”, 2010-2013
• Currently looking for further pilot partners
• Construction of as precise process model as possible to predict how will

process behave with different ore in the feed
• Result: consultant system, evaluating into the future process response

based on feed properties
• Precise prediction over next 30 minutes (future)
• Calculation and suggestion for 3-5 process operation scenarios

Laboratory model scale-up
• Kinetic laboratory flotation

parameters are scaled up based on
plant sampling campaign
 next phase: on-line tracking of

the process by continuous
parameter re-calibration

On-line model calibration
Mineral floatability
properties
Cu flotation
Process inputs Process outputs
process
• Feed flow rate • Tailings grades
• Feed grades • Concentrate
• Process Parameter grades
+
setpoints control
algorithm -
Flotation parameters k
Process Simulated outputs

simulator

Continuous on-line calibration results
A) Stable operation B) Feed disturbances
Cu Tails Rec-%
Cu Tails Rec-%
8h 12 h
Cu Conc Grade%
Cu Conc Grade%
Webinar | Simulation of minerals processing circuits, Toni Mattsson
Final Concentrate Cu recovery SEP ≈ 0.3 % Final Concentrate Cu recovery SEP ≈ 1.0 %
Final Concentrate Cu grade SEP ≈ 0.3 % Final Concentrate Cu grade SEP ≈ 1.7 %
48 10/27/2016
4. Future opportunities in use of simulation

Future opportunities for use of process simulation
• Test new process flowsheets and advanced
process controls in virtual environment prior
to plant use
• More precise risk calculation for
concentrator projects with reduced amount
of drill core samples
• Addition of plant 3D model to the process
model - aim immersive training for rarely
occurring safety events, field personnel and
critical maintenance tasks
• Fully automatised process control with only
maintenance personnel present at the plant

Additional reading
• A property based model of flotation and application in a dynamic simulator

for training purposes, P.Lamberg, S.Paloranta, A.Aaltonen, H. Myllykangas, 2009
• Using a Virtual Flotation Process to Track a Real Flotation Circuit, J.
Kaartinen, J. Pietilä, A. Remes, S. Torttila, 2013
• Modelling and simulation of SkimAir® flash flotation as a part of grinding-
flotation circuit – case study in Esperanza, Chile, P.Lamberg, L.Bernal, 2009
• An operator training simulator environment for hydrometallurgical processes,
M. Loponen, 2016
• Modeling and Simulation of Mineral Processing
Systems, R.P.King, Butterworth-Heinemann, Oxford, 2001

Outotec contact
Presenter
Toni Mattsson
Process Metallurgist, Flotation
Espoo, Finland
toni.mattsson@outotec.com
Local office contact details www.outotec.com/Contacts
Follow us:
/outotec
/company/outotec
www.outotec.com


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Simulation of minerals processing circuits

Toni Mattsson, Process Metallurgist, Flotation

Toni Mattsson, Process Metallurgist, Flotation

• Worked at Outotec for 5 years mainly with green and

2 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

1. Minerals processing process simulation

4. Future opportunities in use of simulation

3 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

4 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Training process simulators and emulators

Fermi 2 nuclear plant simulator

5 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

6 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Engineering simulators (e.g. HSC Sim by Outotec)

7 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Dynamic for training and automation tuning (e.g. Virtual Experience by

8 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Virtual Reality (VR) (e.g. Outotec cPlant VR simulator)

9 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

1960 1970 1980 1990 2000 2010

10 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

Often empirical Requires existing process

RECORDED IN 2 RECORDED OUT 2

11 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

Often empirical or Requires process

12 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

Often semi-empirical Universal, but require tuning

IN 2 Knowledge-based relations between OUT 2

13 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

Josiah Willard Gibbs 1839-1903 – “Founder of thermodynamics”

14 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Empirical models are usually based on experimental data which is fitted to

15 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Semi-empirical models combine

Weather models are typical

16 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

More than 1000 kg of scientific

17 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

HSC Sim is the flowsheet simulation module

18 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

2009-2010 2011 2012 2013 2014 2015 2016

19 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

20 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

unknown process values

21 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Sampling campaign and/or laboratory

• Kinetic Flotation Model

22 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Fast, slow and non-floating Non-floating

• Elements are converted to NF

23 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Detailed calculation of recovery (Savassi eq.):

25 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

…in a full scale process

26 10/27/2016 Webinar | Simulation of minerals processing circuits, Toni Mattsson

• Built snap-shot model

at the time of the survey

• Gives good over-all

picture of the process CSC6 3.96 35.68 37.41 5.52 49.02

performance and Final Tails

862.85 39.62 130 2.43 52.88 8.33 46.14

Falcon Conc Water to Col

depends representability Falcon T

of the ore during the