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1. Fig 6 Structure of HSC Sim flowsheets for minerals processing Copyright Outotec Oyj 2014 Lamberg HSC 8 Sim Minerals Processing Qutotec November 20 2014 Research Center Pori Antti Hemes Pertti 14022 ORC J 45 1 4 HSC Sim file structure 8 35 HSC Sim flowsheet models must always be saved in a separate folder each of them This is because the same file names may exist in the flowsheets and they must not be mixed between flowsheets The folder name can differ from the flowsheet name they are not related to each other The process flowsheet model is in a Sim file and can be opened in HSC Sim 8 by double clicking it Table 1 summarizes the simulation model files located in the model folder NB A flowsheet model can be copied or sent elsewhere just by sending zipping the whole simulation model folder Table 1 HSC Sim files in minerals processing flowsheet models Model Component Corresponding Files What They Are Flowsheet ProcessName Sim8 Flowsheet layout description ProcessName Sim8bin Unit icons data etc related to the flowsheet Unit Unit 1 xlsx Each unit has a separate file Unit 2 xlsx to store its parameters state Unit N xlsx and settings Feed Stream Feed 1 HSCStream Each feed strea
2. HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J Maenpaa Matti Hietala Jussi Pekka Kentala Process Errors Panel n x Class Unit Error text Fig 47 Process Errors Unit Icons X D p SE EST L t Process Tree Log viewer Unit Icons 24 26 Fig 48 Unit Icons Unit List Panel With this docking bar the user can add Unit pictures to the flowsheet The unit pictures are of generic type see section 40 2 2 The user can switch the view browse picture location search by name or change unit directory top bar or zoom icons bottom bar Main Process Info Links Trainings Fig 49 Info and Links The user can add for example instructions on how to use the flowsheet here Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 25 26 Maenpaa Matti Hietala Jussi Pekka Kentala E usc sims Ele View Select Tools Drawing Tools Window Help E CG HR amp Amunt th 8 ISERP P is Le ee Geen x x StreamViewr a x Temperature SC 70 00 Ex Pressure bar 1 00 je S H20 g t h 0 00 KR ZER 02 g th 1 64 im N2 g t h 10 79 4 Solution b 3 Leaching I a 2 7174 Abe We Temperature C d 10 10 Pressure bar l
3. S i HSC Sim 8 File View Select Tools Drawing Tools Window Help O E H RH 4 H2504concentration 9 sl BBS BiG gt iba Hydro example3 X Stream Viewer la Te Li 20 Li EJ Li 40 49 i NM All Solids Liquids Gas Partides JC O e H2S04 concentration g l I Temperature C 70 00 T Amount 12 43 t h 1 Pressure bar 1 00 Oh t h Offgas Fes 000 t h H20 g th 0 00 oi be aal ow AE O n FeS N2 g t h 0 00 A A O 0 00 Abc d me Temperature C 70 00 iz Re Pressure bar 1 00 aes H20 th 51 84 S O H2SO4 t h 0 00 0 00 Fe 2a t h 5 72 H a t h 0 00 3 Air SO4 2a t h 9 89 E T EA Fes 0 00 t h PurePhase t h 428 E Temperature C 70 00 i Pressure bar 1 00 eli l m t Hire th 100 Pset Page Pages el Outotec C bar kWh 10 O 4 E Fig 15 Stream Tables and Stream Viewer to visualize calculation results Copyright Outotec Oyj 2014 V Persist Tool V Snap to Grid 146 29 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 1 35 Lamberg 45 Sim Minerals Processing Ms Feed ok x ER Soles ph go E x v kb es E v qum Liquid iph s a i 7e S Lv ove Update Discard J t Element to Uguid and Close andCose QN Ges toh Mneral Phase a At v Analyzed Properties s BE sos C D t F em
4. Copyright Outotec Oyj 2014 2 35 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 3 35 Lamberg 45 1 Introduction 45 1 1 Particle based modeling HSC Sim has a special set up and approach for processes where minerals are treated This approach should be used for processes such as crushing grinding flotation gravity separation and screening Mineral based models treat particles that have at least the following properties e Size diameter e mineral composition in wt In addition they may have additional parameters like composition by volume mineral composition by surface area whiteness hardness etc Each mineral has a certain chemical composition and specific gravity on the basis of which HSC will calculate these properties for each particle and also for each stream Fig 1 illustrates the solids phase set up as a particulate material the approach HSC Sim minerals processing models are based on Fig 1 Particles of different sizes consisting of one or more minerals A colored SEM Scanning Electron Microscope graph Outotec Research Pori Finland HSC Sim supports a versatile set up of the particle based feed streams according to the desired modeling complexity Each mineral can be a fully liberated material that can be further be divided into several size classes with particles in them With a more elaborated feed set up the degree
5. Automatic Class Li True Ze 100 _Mineral Bulk Unit 20 um 20 75 um 75 125 um 125 250 um 2508 Total Flow Rate iniii 2 E Cep 6 137089 3 4656 3 4656409 346564091 3 465640914 3 SCHER Sae Casses 3 E Py 21 189531 19 997 19 996666 19 996666 19 99666601 19 Sae Dstrbubon 4 Qu 7267338 76 538 76 537693 76 5376931 76 53769308 76 Top Size 10000 Ges z Conditioner Lderabon Dest 6 Distribution NT oe n ort compiten bel Gnda Flotation Cel 4 T ea A B C D t F G H d Gau n Schuhman 0 00 Flotation Feed Ee 1 Analyzed Element Bulk Unit 20 um 20 75 ym 75 125 um 125 250 um 25d Compositio 2 WI Cu 24250000 1 2 1 2000001 1 20000011 1 200000112 1 3 i Fe _11 73045 10 362 10 362307 10 3623071 10 36230707 10 Kop dusniera 040 qos 4 ci o 387033 40 761 40 761303 40 7613025 40 76130254 40 NEUE en Total Flow Rate s IC Ss 13 47117 11 9 11 9 11 8999997 11 89999974 11 mponents Ca si 33 97007 35 776 35 776391 35 7763905 35 77639054 35 LE 7 Cumalative Size Distribution 8 9 E Contentrate 4 gt H Elemental Composition m D amp a014 Outotec 1000 10000 10000 0 Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J Lamberg TOC 45 1 Iotroduchon nennen nennen nennen nnne nnne nnn rn 45 1 1 Particle based Modeling ressarra ensendi niinn EnE
6. f you want to keep some concentration lower than a set point 8 g l change the bleed stream amount valve 0 100 Please use an external control since the bleed amount will not change the concentration unless the whole process is calculated This is possible when the bleed and concentration cells are in different units he RecoveryX add in function cannot be used in the Target cell because it is recalculated only after all the calculation rounds have been completed The large number of thermochemical add in functions StreamH Streams etc may reduce the calculation speed if the argument value changes in each control iteration round because the data search from the H S and Cp database takes time Use these add in functions only when needed Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 12 15 Kotiranta 43 6 Adding Raw Materials In both input and output sheets if the cells are white it means that the user can edit them 43 6 1 Input Sheet In the input sheet temperature row 7 pressure row 8 and the raw material amounts are given In the example in Fig 6 the amount of H2O and FeS is known and the O2 g and N2 g amounts are calculated using equations whereas the H2SO amount is calculated using the control The user can give an initial guess of the sulfuric acid value in cell F20 or it can also be empty before the s
7. 17 Pressure 1 00 Cut 0 00 84 22 Insert Heat Loss 18 Fix Total 20000 Copy 0 00 8422 Q3 Insert Energy Feed E C 98 00 Min 0 00 0 00 20 SiO2 2 00 0 00 84 22 21 Format Cell s 22 SRC Air 1 00 Copy cell reference Content H Total H 23 DST Temperature 25 00 Paste cell reference kWh 24 Pressure 1 00 0 00 0 00 Total 100 00 Insert new species to this stream 0 00 0 00 26 N2 g 79 00 piespeoes 0 00 0 00 27 O2 g 21 00 Delete Column s 0 00 0 00 28 Insert Control Delete this input stream M gt H Input Output Dist Controls Model Fig 24 Copy cell reference of the air feed Shaft Furnace ox File Edit Insert as v Input D22 Normal Distributions sheet 3B Th Convert to Equilibrium Mode A Convert to Mixer Distributions 1 3 Show Distribution Sheet j Teos Y TARGET NAME 02 in Output Hide Non essential Columns 9 Process unit Shaft Furnace Dist Sheet Rows Visible Measurement Unit vol 96 i Set Point 5 00 12 Measured 140 16 Add New Control KE Tolerance Science 15 X VARIABLE NAME Air Feed J Process Unit Shaft Furnace Measurement Unit Nm3 h SS Insert Heat Loss Value Cut gt Insert Energy Feed X Min Limit X Max Limit X Max Step Copy Paste Format Cell s CONTROL METHOD Auto Smart Copy cell reference Active ON Paste cell reference
8. Insert row s Delete row s Delete Column File Edit Insert View Tools Variable List Editor A Chemical Reactions Wizard Insert Custom Sheet E Add New Control L3 Show Controls Sheet L3 Unit format Leaching unit Enthalpy CR Cooler Enthalpy Heat Balance uper Paste Format Cell s Copy cell reference Insert row s Delete row s Delete Column Fig 8 Copy cell reference from the Leaching unit and paste cell reference to the extra sheet Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta a Cooler File Edit variable List Editor e Add Mew Control gt Show Controls Sheet gt Unit format E Cooler a Flo De Variable List Editor i Chemical Reactions Wizard g Insert Custom Sheet E Add New Control Show Controls Sheet gt Unit format Fig 9 Copy cell reference from the Cooler unit and paste cell reference to the extra sheet Insert View Tools Help HSC 8 Sim Reactions Example November 25 2014 14022 ORC J 10 15 rum mm Ka Phases Species Temperature Pressure Amount Enthalpy Volume 0 00 Exergy 2820 69 Heat Capacity CH 0 00 Gas Phase 0 00 Water Phase 195 83 H20 195 83 Pure Phase 0 00 195 83 195 83 195 83 195 83 0 00 195 83 0 00 863052 94 855088 14
9. Outotec Oyj 2014 e LL e e l Variables Sum Solution II Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta 43 6 2 Output Sheet HSC 8 Sim Reactions Unit November 25 2014 14022 ORC J 14 15 In the output sheet temperature row 7 and pressure row 8 are given see Fig 8 Values in the output sheet are calculated according to the settings in the Dist and Model sheets Bim Leaching File Edt Insert View Tools Variable List Editor 4X Chemical Reactions Wizard e Insert Custom Sheet e Add New Control gt Shaw Controls Sheet La Unit format Help EF A 18 Pis 24 P3s 27 A1 28 A2 29 A3 20 V1 21 vi 23 V3 33 D2 34 F2 35 F2 36 U 37 M 4M ZU B Temperature Pressure Amount Enthalpy Volume Exergy Heat Capacity Gas Phase H20 g O2 g N2 g Water Phase H20 H2504 Fe 2a H a SOA 2a Pure Phase Fes 5 Amount Phase 1 Amount Phase 2 Amount Phase 3 Volume Phase 1 Volume Phase 2 Volume Phase 3 Density Phase 2 Fe5O4 H2504 c e t h kWh m3 h kWh kWh Nm3 h Nm3 h Nm3 h Nm3 h t h t h t h t h t h t h t h t h t h t h t h t h m3 h m3 h m3 h kg m3 Fe 2a H a H2504 concentration g l Input Output Dist Controls Model D 4 E 70 001 1 o0 84 16 71 74 254763 42 254922 58 55 62 56 60 25999 19 25854 79 9779 74 0 00 0 00 0 00 1147 34 0 00 86
10. he RecoveryX add in function cannot be used in the Target cell because it is recalculated only after all the calculation rounds have been completed The large number of thermochemical add in functions StreamH StreamS etc may reduce the calculation speed if the argument value changes in each control iteration round because the data search from the H S and Cp database takes time Use these add in functions only when necessary Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Qutotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 1 22 Roine 42 Sim Distribution Example Magnetite Oxidation Example Pelletized magnetite Fe3O4 ore can be oxidized to hematite Fe2O3 in a shaft furnace The typical magnetite content of the ore is approx 95 Oxidation is usually done by feeding air into the shaft furnace Some excess oxygen is needed to complete the reaction the free oxygen in process gas is usually approx 5 About 1 of the iron does not react Coal is used as a fuel to keep the product temperature at 700 C This kind of unit process can be controlled by air and coal feeds The ore feed can be fixed to approx 200 t h Now please create a process model of the shaft furnace with oxygen and coal controls Walkthrough steps Draw the flowsheet Draw the streams on the flowsheet Rename the units and streams Save the process Specify the raw material streams Speci
11. November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 13 15 Kotiranta Eu Leaching EL File Edit Insert View Tools Help zi me Variable List Editor ERE B WS D E s RUNI 5 4 go 000 0 07 44 Chemical Reactions Wizard 6 Variables Sum e 7 T Temperature C 70 001 70 00 8 Pr Pressure bar 1 00 1 00 3 Insert Custom Sheet i gt ie DUUM t h EE SE E 10 H Enthalpy kWh 254763 42 254922 58 159 16 11 NM Volume m3 h 55 62 56 60 0 00 xs 12 Ex Exergy kWh 25999 19 25854 79 144 40 Gi Add New Control 13 Cp Heat Capacity kWh gt Show Controls Sheet 14 Plg Gas Phase Nm3 h 9779 74 0 00 9779 74 TS 15 H20 g Nm3 h 0 00 0 00 0 00 16 O2 g Nm3 h 1147 34 0 00 1147 34 17 N2 g Nm3 h 8632 40 0 00 8632 40 18 P2a Water Phase t h 67 45 67 45 0 00 19 H20 t h 51 84 51 84 0 00 20 H2504 t h 0 00 0 000 0 00 21 Fe 42a t h 5 72 5 72 0 00 22 H a t h 0 00 0 00 0 00 23 SO4 2a t h 9 89 9 89 0 00 24 P3s Pure Phase t h 4 28 4 28 0 00 25 Fes t h 1 00 1 00 0 00 26 S t h 3 28 3 28 0 00 A7 A1 Amount Phase 1 t h 12 43 0 00 12 43 _28 A2 Amount Phase 2 t h 67 45 67 45 0 00 29 A3 Amount Phase 3 t h 4 28 4 28 0 00 20 V1 Volume Phase 1 m3 h 31 Mi Volume Phase 2 m3 h 55 62 56 60 0 00 32 V3 Volume Phase 3 m3 h 23 D2 Density Phase 2 kg m3 1212 69 1191 81 977 71 34 F2 FeSDA4 Fe 2a 0 23 0 23 0 00 35 F2 H2504 H a 0 00 0 00 0 00 36 U H25O4 con
12. Qutotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 20 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 3 40 3 1 Toolbars In the View Toolbars menu the user can check and uncheck toolbars It is also possible to reset docking bar positions back to their default places Toolbars are divided into two lists Docking bars and Drawing toolbars see Fig 31 El HSC Sim 8 LB IS File View Select Tools Drawing Tools Window Help il mg OC Y N Flowsheet Settings lisualization ei Name Labels k D a3 x f 5 lar zr en m T an Value Labels La a Je 70 B 50 Process Stream Tables by E Toolbars b h Us Reset docking bar positions Reset Docking bars X Log viewer f Process tree bm X Properties Process errors e OCOLO Lhe Bl C Unit List Panel Info and Links lt Stream content viewer Log viewer Dm x a0 Drawing toolbars OU Units and Streams Calculations On Visualization 110 Drawing Tool Height and Width Align 130 Layers k s sss mm Rotate and Flip 28 de al Warnings 3 Find errors Ei LS Se X MM Ze SS Paget Fagez Pages Process Tree Log viewer Unit Icons n Outotec C bar kWh 10095 A Hiv Persist Tool Fi Snap to Grid 7 0 Fig 31 List of toolbars Drawing toolbars The Drawing toolbars are listed and guidance on their usa
13. C8 Extra sheet C4 Desired Heat balance kWh Measured Heat balance kWh Tolerance C9 Tolerance for Heat balance Value C14 Input E16 H20 input to the process t h D X Min Limit C15 Minimum amount for H2O input X Max Limit C16 1000 Maximum amount for H20 input Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Example Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 12 15 Kotiranta 44 2 6 Setting Feed Streams to the Process All the feed streams to the process should be set If the feed to the process is not set the stream will be ignored Input sheets of both Leaching and Cooler units FeS stream H20 is 50 t h and FeS is 10 t h in the FeS stream HSO stream sulfuric acid feed an initial guess of 1 t h can be given Real value 10 1 t h is calculated using the control see Table 1 Air stream consists of 21 vol of O g and 79 vol of N2 g Oxygen efficiency is 50 96 which means that 2 times the stoichiometric amount is needed The formulas made for oxygen and nitrogen are ABS Model F16 2 and G16 21 79 respectively Cold water stream feed an initial guess of 10 t h can be given Real value 195 8 t h is calculated using the control see Table 2 Output sheets of both Leaching and Cooler units Temperature of solution and offgas streams should be set to 70 C see Fig 12 Temperature of hot water stream should be set to 60 C EU Lea
14. Copyright Outotec Oyj 2014 kIT Paste cell reference Outotec un dM Research Center Pori Lauri M enp Antti 14022 ORC J 16 22 Roine For this target parameter you must assign the Set Point value which will be the goal that the control tries to reach In this example the Set Point value will be 5 00 vol It is also recommended to add the process unit and measurement unit to the control Fig 23 Having the units in the controls helps to keep track of their operation Eu Shaft Furnace e a x File Edit Insert Calculation Mode ee j Normal Distributions sheet A B C D E F G TA Convert to Equilibrium Mode 1 TR Convert to Mixer Distributions 5 L gt Show Distribution Sheet 6 T 8 Y TARGET NAME 02 in Output Hide Non essential Columns 9 Process unit Shaft Furnace Dist Sheet Rows Visible 10 Measurement Unit vol 11 Set Point 12 Measured amp 9 Add New Control 13 Tolerance E 14 L gt Show Controls Sheet 15 X VARIABLE NAME x Cassin 17 Measurement Unit amp 9 Insert Heat Loss 18 Value 3 Insert Energy Feed 19 X Min Limit 20 X Max Limit 100 21 X Max Step 22 23 CONTROL METHOD Auto Smart Auto Smart 24 Active ON ON 25 Iterations Max Limit 26 27 Operation Light fast Light fast 28 I4 4 gt b Input Output Dist Controls Model 4 Fig 23 Assign Set Point value for the control Next set the variable cell reference that will regulate the target
15. Normal Distributions sheet A B C D E F G TA Convert to Equilibrium Mode 1 2 IR Convert to Mixer 3 Distributions 5 L gt Show Distribution Sheet 6 joe 3 7 8 Y TARGET NAME 02 in Output I Hide Non essential Columns 9 Process unit 9 Dist Sheet Rows Visible 10 Measurement Unit 11 Set Point 12 Measured Add New Control 13 Tolerance E 14 L gt Show Controls Sheet 15 X VARIABLE NAME ES EE 17 Measurement Unit 89 Insert Heat Loss 18 Value e Insert Energy Feed 19 X Min Limit 0 20 X Max Limit 100 21 X Max Step 22 23 CONTROL METHOD Auto Smart Auto Smart 24 Active ON ON 25 Iterations Max Limit 26 27 Operation Light fast Light fast 4 4 gt M Input Output Dist Controls Model d Fig 20 Controls can be added to the sheet with the Add New Control button Next set the cell reference for the target parameter For this control the correct cell can be found on the Output sheet cell D13 Output D13 To set this cell reference you can go to the Output sheet right click the correct cell and select Copy cell reference Fig 21 Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Outotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J Roine 15 22 E Shaft Furnace Ee File Edit Insert Y Calculation Mk D13 100 SAFEDIV Output G13 Output G11
16. system boundaries will be defined for the analyzed system System boundaries define which Unit Processes phases will be included in the LCA e Cradle to Grave Full Life Cycle Assessment e Cradle to Gate Exclude transportation part to customer e Gate to Gate One process in the production chain The depth and breadth of an LCA depend on the goal of each particular LCA The reason for making the LCA and the target group usually define the goal of the LCA 2 Inventory analysis phase This phase is also called the Life Cycle Inventory LCI phase which is the 2 phase of LCA This phase is usually the most time consuming phase where the input and output data regarding the system are studied and collected LCI answers the question How much of everything flows where Usually input and output can be classified into the following main fields e energy inputs raw material inputs ancillary inputs other physical inputs e products co products and waste e releases into air water and soil and e other environmental aspects All calculating procedures should be explicitly documented and all assumptions should be explained carefully It is good to check the data validity during the LCA process A production flow definition should be made using the real production distribution For example in the case of electricity details such as fuel combustion mix conversion etc should be included Copyright Outotec Oyj 2014 HSC 8 Sim L
17. y Name Date modified Type Size Jr Favorites RE Desktop Magnetite Oxidation 2 9 2014 8 16 File folder jg Downloads Recent Places n i3 Libraries d Documents Music i Pictures RB Videos ks Filename Magnetite Oxidation Save as type HSC Sim 8 files Sim8 Hide Folders Cancel Fig 4 A process has to have a folder of its own It is better to save the process too often rather than too seldom because a saved process allows you to recover the earlier design stage in case of user or computer errors It is necessary to create a separate file folder for each process using the Create New Folder tool see Fig 4 The process name is also the most logical name for the file folder In this case the folder name is Magnetite Oxidation and the process name is Magnetite Oxidation A process can consist of several files and all of these files will be saved into this same folder Copyright Outotec Oyj 2014 Qutotec Research Center Pori Lauri M enp Antti Roine 42 5 Shaft Furnace File Edit Insert HSC 8 Sim Distribution November 25 2014 14022 ORC J Step 5 Specify the Raw Material Streams 6 22 ze Al Normal Distributions sheet A C D E F G H l J K L U V W A Convert to Equilibrium Mode 1 1 Input 1 Convert to Mixer E 4 Flags Input streams Value B us Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 5 kg Nm kmol kWh kWh JkWh mol kWh mo
18. 10 10 0 00 67 45 67 45 0 00 27 Amount Phase 3 t h 5 72 10 00 10 00 0 00 0 00 4 28 4 28 0 00 28 Volume Phase 1 m3 h 0 00 0 00 0 00 29 volume Phase 2 m3 h 3 68 60 28 50 15 10 13 0 00 56 60 56 60 0 00 30 Volume Phase 3 m3 h 0 00 0 00 0 00 31 Density Phase 2 kg m3 821 33 2990 85 996 95 996 95 996 95 2169 52 1191 81 977 71 32 Feso4 Fe 2a 0 23 0 00 0 00 0 00 0 00 0 23 0 23 0 00 33 H2s04 H a 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 34 H2504 concentrz g l 1 00 0 00 0 00 0 00 0 00 1 00 1 00 0 00 em M 4 gt M Unit Balance Stream Balance 4 m Fig 18 Stream balance sheet of the report file Bu Flowsheet report en ll EE NE EK h DI ei LA Lal Le L i Save Print Add custom Cells sheet A B D EF WE e H 35 i P 1 2 Leaching Streams Type Total tons Enthalpy e Fe H N 0 5 d Fes Input 60 00 2889 17 0 00 6 35 5 59 0 00 44 41 3 55 H2504 Input 10 10 102 95 0 00 0 00 O21 0 00 6 59 3 30 6 Air Input 14 07 487 52 0 00 0 00 0 00 10 79 3 28 0 00 L 7 Solution Output 71 74 3198 03 0 00 6 35 5 80 0 00 52 63 5 95 8 i Offgas Output 12 43 436 33 0 00 0 00 0 00 10 79 1 64 0 00 9 BALANCE 0 00 154 72 0 00 0 00 0 00 0 00 0 00 0 00 10 11 12 Cooler 13 Streams Type Total tons Enthalpy H Oo 14 Cold Water Input 195 83 10870 06 21 91 173 91 V 15 Hot Water Output 195 83 10870 06 21 91 173 91 16 BALANCE 0 00 0 00 0 00 0 00 if e L t 1 J S M 4 Hj Unit Balance Stream Ba
19. 12 43 1 64 28 A2 Amount Phase 2 t h 60 10 67 45 7 36 29 A3 Amount Phase 3 t h 10 00 4 28 5 72 30 V1 Volume Phase 1 m3 h 0 00 0 00 31 V2 Volume Phase 2 m3 h 60 11 55 62 32 V3 Volume Phase 3 m3 h 0 00 0 00 33 D2 Density Phase 2 kg m3 999 80 1212 69 34 F2 FeSO4 Fe 2a 0 00 0 23 35 F2 H2S04 H a 0 00 0 00 36 U H2S04 concentration g l 0 00 1 01 M 4 gt H Input Output Dist Controls Model d LA Fig 3 Model sheet shows user defined chemical reactions Unit Model Editor Excel Wizards Ready made Excel wizards for some units like Filter and Thickener were used in HSC7 These wizards are also available in HSC8 however they will no longer be supported in the future so we recommend users not to use them any more New dll units can be used for this purpose Unit model editor is activated from the Tools menu in the main flowsheet window or right mouse click over any unit In the editor the user can choose a unit double click the wizard and click OK The user then specifies the streams and after that the model is ready to be used see also Chapter 40 section 40 2 2 Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit November 25 2014 Qutotec Research Center Pori Petri Kobylin Tuukka 14022 ORC J 8 15 Kotiranta 43 4 Distributions The Dist sheet is filled because the user must divide the products into the output streams If there is only one output stream then 10096 of the products enter this stream Th
20. 14022 ORC J 40 2 Menus in the flowsheet window In this section the Sim flowsheet menus File View Select Tools Drawing Tools Window and Help are introduced HSC 8 Sim Common Tools File menu This menu is similar to many other programs where the user can see also Fig 12 1 Start New Process which opens an empty flowsheet 2 Open Process which is a Sim8 HSC8 or fls file HSC7 flowsheet 3 Save Process quick save process overwrites previous version 4 Save Process as save process with the file name and location given by the user 5 Save Backup process should be saved first before a backup can be made It is recommended to save a backup from time to time during the simulation 6 Backups lf the user has saved backups they can be managed checked restored deleted here f Recent Processes shows the 10 most recent simulations made by the user 8 Export Flowsheet Image he user can export the flowsheet as an image png vdx odf svg dxf or copy a flowsheet picture to the clipboard to use it in reports and presentations 9 Print flowsheet prints the flowsheet 10 Exit HSC Sim will close the Sim program Ed HSC Sim B ID x File View Select Tools Drawing Tools Window Help New Process Ctrl N gualization eil BIS El gt X ES OpenProcess Ctr O om x H Save Process Ctrl 5 d Process Fy Save Process As 3 lg Save BackUp Ctrl B e b i Backlps Recent Processes
21. 14022 ORC J 26 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 4 Importing HSC Sim 7 models HSC Sim 6 models are not supported In HSC Sim 8 there is a built in support for importing HSC Sim 7 models and then using them in Sim 8 However there are some points and limitations that the user should take into consideration when importing Sim 7 models into Sim 8 If points listed here do not help please contact the developers Major points oim 8 calculations have dramatically stricter error checks than Sim 7 When the user imports an old model and tries to run it often the calculation will notify of an error in the flowsheet The user can locate the errors using the log viewer and then fix them manually There are some changes in the Sim 8 hydro variable list logic when compared to oim 7 If the imported model variable list contains species not found in the database the user needs to go through them case by case in the Sim 8 variable list editor The user can add entries to the database use a different database entry or delete the species from the variable list to fix this see Chapter 43 section 43 2 1 oim 7 solvent extraction hydro Excel Wizards are no longer supported in Sim 8 If the imported model contains them in Sim 8 the user will not be able to run the model successfully There is a completely new DLL unit operation system in Sim 8 which has been implemented for some Mineral Process unit operation models Sim 8 has part
22. 45 2 1 Units and unit icons The process units can be placed by dragging and dropping them from the Unit Icons panel on the right the library includes several ready made process device icons Alternatively you can just draw a rectangle unit without a figure by selecting it from the left side button bar The unit figure can also be changed and replaced with your own drawing or photograph if desired Selecting and drawing the unit on the flowsheet are shown in Fig 7 NB Unit figures do not contain calculation models just the graphics to illustrate them on the flowsheet The calculation model is selected and loaded separately in a later step A Unit Icons EE Unit Icons i FEB Grinding 7 se Iron Steel aj Minerals Others s Others Physical Separators y Precious Metals i qd Pyro Ausmelt Lars Raab SCH ira DEui m Process Tree Log viewer Unit Icons Fig 7 Unit model icons can be A dragged and dropped from the HSC Sim library B the library folder can be changed from the menu or C just a generic unit with a rectangle box icon can be drawn 45 2 2 Connecting streams The streams area drawn on the flowsheet by selecting the stream drawing tool from the bar on the left Fig 8 The streams area is automatically connected to the nearby unit to from which they are directed The streams can be redirected and connected elsewhere on the flowsheet HSC Sim will then ask you to confirm whethe
23. 610 A Sag Hazardous waste D Popercip Tutorial 2012 C ProgramDats PE Internatonal Gal 61 alf Carbon mononode Inorganic emezons to ar p Professional Extensions 2012 C ProgramDatalPE Internatione alf Dust containing heavy metals Hazardous waste ilf Pig ron Fe carrier Metals Last change System 09 10 2014 09 01 27 GLAD cef70021 3966 4e0a 8354 487414f8c337 No Object Edit Vien Help JB BBx EA EIERb Nickel Pig Iron Furnace Process pian Energy net calorfe value MI The names of the basc processes are shown ID Nike Pig iron Xd Je Nickel Pig Iron Furnace Balances Balance Smelling Object Edit View Tools Help I EAL EAR fE 1D PE UE lli aco Julh scra cme 200 Qv 20 ul a mac ul cta ill ReOPe 9 Balance n ireport Ul outoteootoent i 4 af OutotecFootprnt i Nickel Pig Irom Furnace gt L Nickel Fig Iron Furnace gt 4 dal Goda Warming Potential kg CO2 Equiv fv dil Nie Pig tron Furnace GWP 100 years 4 dil Acdification Potensal ug SO2 Equv 6 I ahi Niche Aig tron Furnace 4 dij Eutrophication Potental kg Phosphate Equiv IV Ji Nickel Pig iron Furnace x Di Ji Niche Pig fron Furnace 4 Ji Freshwater Aquatic Ecotoxidty Pot kg DCB Equv 7 4 Nickel Pig fron Furnace a Al Hunan Toxicity Potential kg DCE Equv Al ciel Pig tron Furnace hil Nickel Pg tron Furnace Nickel Pig Iron Furnace Nickel Pig Iron
24. Default Abc 2 Value General D m a Air of x Value ve S lUnits by Type v Search for units is x Cold Water Hot Water O EN sl e Value Value Gu n H e Page Page Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 100 i i W Persist Tool E Snap to Grid 149 26 Fig 1 Sim Reactions Example flowsheet Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Example Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J Kotiranta 44 2 Steps to Successful Sim Reactions Simulation Draw units and streams oave process and save backup Create variable list Add reaction equations opecify distributions Set controls opecify raw material amounts Save process Run process 22 X D SU dw DIM rm Copyright Outotec Oyj 2014 2 15 HSC 8 Sim Reactions Example Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 3 15 Kotiranta 44 2 1 Drawing a Flowsheet See Chapter 40 section 40 1 44 2 2 Draw Reactions units blue Draw input and output streams Left mouse click to start and make corners and double click to end the stream For editing the stream afterwards see section 40 1 2 Name the units and streams see Fig 1 and Chapter 40 section 40 1 3 Check that the source and destination for the streams are correct Setting the Variable List See Chapter 43 section 43 2 A Import Ready Made Variable
25. Ey Export Flowsheet Image gt ih Portable Metwork Graphics Tae Lnd H o x g3 Print flowsheet Ctrl P mp Microsoft Visio file wdx ipe a TH 34 Exit HSC Sim Alt Q my Portable Document Format pdf Ef Qin Salt ep Scalable Vector Graphics file svq Sai GR e AutoCAD DXF file dxf EA d M Copy Flowsheet Picture To Clipboard hi V t Paget Page rae em i pum g viewer Unit Icons Outotec C bar kWh ol Persist Tool F Snap to Grid 31 0 100 Fig 12 File menu Copyright Outotec Oyj 2014 Outotec Research Center Pori Petri Kobylin Lauri Maenpaa Matti Hietala Jussi Pekka Kentala View menu HSC 8 Sim Common Tools December 10 2014 14022 ORC J 9 26 In the View menu the user can see also Fig 14 1 View and edit Flowsheet settings where the user can change or restore default settings of the flowsheet Exit saves the settings and leaves this editor see Fig 13 EM Flowsheet Settings General Marker Size pt 2 5 Marker Color ES 70 130 180 Link Hit Distance pt 2 Flowsheet Background Color L1 255 255 255 Auto Resize AllDirections Persist Tool True Grid Grid Style Points Show Grid True Grid Color 176 196 222 Grid Width 2 Grid Height 2 Snap To Grid True Auto Align Nodes False Header Label Font Name Arial Font size 16 Font Bold False Font Italic False Font Color EN 0 0 0 Default Unit Settings Label Font Name Arial Font size 8 F
26. Fig 41 Phase Total Amount Unit I Gas flow rate 3 4 th Fig 41 Total gas total flow rate Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 29 35 Lamberg 45 4 Selecting unit models The unit models are selected for the unit icons of the flowsheet by using the Select Unit Models tool Fig 43 which can be opened by v HSC Sim menu bar Tools gt Select Unit Models Y Right clicking the unit Fig 42 v Double clicking the unit Flotation Cell gH zac Tails Select Unit Models d ms ae ey p pl SSES Fig 42 Selecting a unit model for a unit The unit models are selected from the model library simply by double clicking the model which is then assigned to the selected unit s Fig 43 All the HSC Sim minerals processing unit models are shown under the Particles tab on the model list The Select Unit Models dialog is also described in Chapter 40 section 40 2 2 E Select Unit Models x Select unit Select model Double Click to Select Model Properties Unit Active Model Reactions Distributions Partides Others Import Flotation Cell Ball mill Fixed PSD Model Type Modi Partide Conditioner Conditioner Batterham Screen Efficiency Curve DLL Type Code MU 310 11 Cydone Efficiency Curve Conditioner DLL Technology Flotation Flotation Cell Flotation Cell Cydone Plitt DLL Sub Technology Sump Perfect Mixer E
27. Insert Energy Feed IM 4 gt vM Input Output Dist Controls Model 4 Fig 10 Distribution of elements to streams Next the elements in the streams will be distributed to the available species All the species within a stream need to be assigned an element in column Y and a Fixed or Rest value in column X which shows how the element amount is distributed to the species In this example H2O can be assigned with all of the hydrogen distributed to the second stream For the stream with gaseous species all of the nitrogen will be distributed to the N2 g all of the hydrogen to the H2O g and the remaining oxygen to the O2 g Fig 11 E Distribution Pyro Unit a x File Edit Insert s 7 Ret Normal Distributions sheet A B C D J X Y BK CA CH S ER Convert to Equilibrium Mode 1 Distributions Elements 4 N o 2 IR Convert to Mixer 3 Total H Shift 4 Flags Balance kWh 7 63 Balance 5 Input kWh 18 70 Input Dist Sheet Rows Visible 6 Output kWh 26 34 Output L gt Show Distribution Sheet 7 8 Stream 4 Stream Dist 9 Dist Type E Q Hide Non essential Columns 10 11 Species 100 00 100 00 GJ Insert Custom Sheet 12 N2 g m Ge 14 H20 g G3 Add New Control 15 L Show Controls Sheet 16 Stream 5 17 Dist Type 18 Amount gt Insert Heat Loss 19 Species Total 20 H20 Rest H 100 00 100 00 85 Insert Energy Feed IM 4 gt M Input Output Dist Controls Model 4 Fig 11 Elem
28. Iterations Max Limit Insert row s Operation Light fast Delete row s Delete Control E H Input Output Dist Controls Model 3 Insert Control Fig 25 Set cell reference for the variable parameter Finally it is recommended to adjust the minimum and maximum limits for the variable parameter and to set a tolerance value for the target parameter Fig 26 After that the O2 control is ready Copyright Outotec Oyj 2014 HSC 8 Sim Distribution utotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 18 22 Roine Sky Shaft Furnace wm ac File Edit Insert v Pyro Calculation Mode Normal Distributions sheet CH Convert to Equilibrium Mode ES TR Convert to Mixer i E 4 5 3 Show Distribution Sheet e Toos Ea 8 Y TARGET NAME 02 in Output Hide Non essential Columns 9 Process unit Shaft Furnace Dist Sheet Rows Visible Ki Measurement Unit 11 Set Point Controls O O 12 Measured Add New Control 13 Tolerance F 14 a 15 X VARIABLE NAME Air Feed eur 16 Process Unit Shaft Furnace 17 Measurement Unit Nm3 h Insert Heat Loss 18 Value 1 00 Insert Energy Feed 19 X Min Limit 10000 20 X Max Limit 100000 21 X Max Step 22 23 CONTROL METHOD Auto Smart Auto Smart 24 Active ON ON 25 Iterations Max Limit E 26 27 Operation Light f
29. Maenpaa Matti Hietala Jussi Pekka Kentala 40 1 3 40 1 4 Renaming units and streams Choose the Select icon and rename units and streams by double clicking the name or click the name label and edit properties process sheet NamelD cell see Fig 5 SU HSC Sim 8 SSC File View Select Tools Drawing Tools Window Help amp A RM amp seectvisualization i xi Bi P gt 5 Main Process X ofp x a SR de e lt a Tr Zeg na s oa AM 2 dn ad Em i T ai ii eg 2 PS i e a ui Pu E i D j Process Drawings e General Unit 1 Unit 2 e 3 NameID Stream 1 ES i Input stream Stream 3 General i gt Value Value Value S D q x gt FB Units by Type Search for units 19 gt H ES Page Page2 Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 100 1 VY Persist Tool V Snap to Grid 178 1 Fig 5 Renaming units and streams Inserting tables and stream tables typically done after simulations The user can add tables to visualize important parameters of the results Choose the Table icon and draw the table in the same way as you draw the units The user can open table editor by double clicking the table where the user can add more rows and columns It is important to uncheck Size lock when adjusting the table size It is typical to use this table to show a summary of the results The user can insert header labels and add any process values as cell refere
30. Normal Distributions sheet L a 6 C BENT e TE c uH I J K E a xw w 44 Convert to Equilibrium Mode A Output 2 IR Convert to Mixer 3 al Output streams Total H Heat Cont H TotH Chem Ex kWh kWh mol kWh mol kWh 33790 98 299041 52 8 Process Gas Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Hide Non essential Columns 9 DST Temperature 700 00 C kWh kWh mol kWh mol kWh kWh kWh Dist Sheet Rows Visible 10 Pressure 1 00 bar 997 52 9907 17 11 Fix Total 100 00 vol 115 203 997 52 9907 17 135 98 478 90 34292 _ coros e N2 g 0 02 0 99 0 79 0 04 0 20 0 20 5 72 572 0 01 0 10 0 10 p x x Add New Control 13 O2 g 140 16 Eu 1721 18 1721 18 6 05 6 05 313 85 837 56 1151 41 14 colg 0 00 Copy 0 00 0 00 5 78 2492 0 00 0 00 0 00 b gt Show Controls Sheet 15 CO2 g 40 14 d 723 46 8186 19 8 88 100 43 449 82 358 57 808 39 16 nsere ys FomstCel s 17 SRC Hematite Pellets 206 52 ontent H Total H Heat ContH Tot H Chem Ex PhyEx Tot Exergy Insert Heat Loss 18 per Temperature 700 00 kWh kWh mol kWh mol kWh kWh kWh insert Energy Feed 19 Pressure 1 00 Paste cell reference 34788 50 289134 35 20 Fix Total 100 00 34788 50 289134 35 4362 51 17414 83 21777 34 al Fe203 94 23 cti iode 32444 77 246741 02 26 62 202 48 3970 62 16239 23 20209 85 22 Fe304 0 92 wee 32615 2216 57 39 24 27012 270 11 16327 433 38 23 sio2 4 85 a
31. Pori Markus Reuter Matti 14022 ORC J 5 15 Peltom ki 49 2 LCA in HSC Sim The HSC Sim LCA tool covers LCA phases one and two Subsequent phases are performed by 3 party LCA software When the LCI has been completed via HSC Sim the process and or flowsheet is are exported to a separate file that can be imported into GaBi LCA software the file is in Ecospold format In GaBi software other Scope 2 and 3 processes transportation etc are added as will be shown in the example below Please consult www pe international com for more information and details about GaBi at http www gabi software com The HSC Sim LCA tool can also be used to capture in a black box summary how much of a compound is released into the environment without the use of GaBi software However GaBi provides mid and end point analyses of the impacts of these flows materials compounds etc providing a detailed impact analysis of the flows HSC Sim LCA analysis is always based on a complete HSC Sim process model where the input and output streams represent the data for the LCIA phase In LCA analysis the substances of interest are only the input and output streams to the environment Internal streams are not taken into account because they are not relevant when analyzing the process as one black box As LCA does not generally base its analysis of complete systems on closed mass and energy balances it is always advisable to create a detailed process model to make
32. V Main Process X O g x vi 10 20 2n n zn en 70 on on 100 110 120 120 149 E 16n 1 4 e T Er E T T t ge CH S ci P ir op e Process Drawings General x Magnetite Ore Coal NameID Hematite Pellets Value Number Alias ERR Source Shaft Furnace lt gt We Destination LJ Process Gas e n Value General 5 Shaft Furnace bi LE O A x iis al RER Ee gr 4 H Main Process 4 Iliz j Page Page2 Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 100 lul VY Persist Tool V Snap to Grid 153 1 Fig 3 Renaming units and streams makes flowsheet easier to read You can relocate the unit and stream name labels by dragging them with the mouse Select the unit or stream and rename it using the NamelD property This property is used to identify unit and stream objects Please use short and illustrative names The Drawings tab lets you change the label text formatting Formatting options can be applied to the labels one by one or you can select multiple labels and change the formatting for all of them The Select menu at the top bar offers options to select all certain types of labels from the flowsheet Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Qutotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 5 22 Roine 42 4 Step 4 Save the Process EM Save As QC gt SIM gt v p Search SIM Organize v New folder
33. and editing their elemental composition v To open the HSC Geo Select Minerals tool click Add Mineral oO e from DB Sek v You can search for the mineral from the database once the Add Mineral selected list is ready click OK to accept Fig 20 from DB Select Find Mineral Database Data MineralName Pyrite Mineral N Mineral Sy Mineral For Mineral Den Location Mineral Key Statistics Reference MineralSymbol Py pyrite b pyrite m d Fes 5 0100002 stoichiome FeS2 MineralDensity 5 01000022888 Pyrite Py FeS2 5 0100002 Neves Corvo Graca 1990 NAR Istoichismnrhir MineralKey FeS2 Pyrite Py FeS2 5 0100002 Suurikuusikko Kojonen amp J Note3 Fes2 Pyrite Py FeS2 5 0100002 Suurikuusikko R465 52 0 Kojonen 1997 athens HSC Pyrite Py FeS2 5 0100002 Suurikuusikko R470 161 0 Kojonen 1997 SG 5 01300001144 Dia weien ns cac E n1nnhn Ex a melen manilla NAPIT NA Vajancen 1007 Fe 96 46 5464210510 X Y Starts with Mineral Name pyrite e Edit Filter _ Im 4 Recordiof75 M4 SC Graphs Selected Minerals Data o0 o Mineral Name Mineral Sy Location Mineral Key Fe Cu S 9 gt Chalcopyrite Ccp stoichiome CuFeS2 30 429428 34 625633 34 944938 OK Cancel Fig 20 Selecting minerals from the database Once the minerals are added they will appear on the list where the name code S G and formula can be edited Fig 21 The element composition of the minerals i
34. and the difference from it The value in the corresponding cell shows the element wt obtained in the mineral to element back calculation with the HSC Geo Modal Calculation tool Analyzed Element Bulk Unit 20 Um 272 E E oer Cu 078852 Lader Fe 1284813 S 14754 Si 3347239 36 164 33 605607 24 6192 Fig 38 Elements back calculated from the minerals after modal calculation in HSC Geo Liquid feed The total liquid flow rate and its unit can be set in the Total Liquid Flow Rate view see Fig 40 Also the liquid flow rate can be automatically calculated and kept updated based on the given solids flow rate and solids percentage Fig 39 when the Solids Target button is held down Otherwise the Sol text field indicates the calculated solids percentage based on the given solids and liquid flow rates Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Qutotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 28 35 Lamberg 430 Solids Target Gol Se 97 00 Fig 39 Solids target value for calculating the required liquid t h Phase Total Amount Unit k Liquid flow rate 4 18 t h SLARRRRRRARRRSERERARSRARESEARREAEREAARHSERSRARHAARSAARREAESERERESSSRSESSESAREREERSSARRERSEREASREASEHSRRESARSEEARSEREREE Fig 40 Total liquid flow rate 45 3 3 Gas feed The total gas phase flow rate is set from the Amount field shown in
35. are conserved and thus the elemental balance is maintained A B C D J X Y AO BE CA CH DC 1 Distributions Elements E Fe N Oo Si 2 3 Total H Shift 4 Balance kWh 2575 91 0 00 0 00 0 00 5 Input kWh 296465 61 Input kg 980 00 137483 73 0 99 57852 87 4683 70 6 Output kWh 299041 52 Output kg 980 00 137483 73 0 99 57852 87 4683 70 7 100 00 100 00 100 00 100 00 100 00 Fig 19 Zero values indicate that all the atoms are conserved Copyright Outotec Oyj 2014 Outotec un dM Research Center Pori Lauri M enp Antti 14022 ORC J 14 22 Roine 42 8 Step 8 Create the Controls Controls are often used to regulate distribution values output stream compositions and heat balances For each control we have to specify A target cell and a Set Point value for this cell A variable cell used to regulate the target cell ND The variable cell must have some effect on the target cell parameter If this is not true then the control will not work The situation is exactly the same when you control real processes and plants In this example two controls are used one to regulate the O2 content in the Process Gas stream and another to ensure that the heat balance is maintained First add two controls to the sheet by clicking the Add New Control button in the left hand panel and type the name of the first control Fig 20 E Shaft Furnace w mn File Edit Insert vro Calculation Mode D8 v 02 in Output
36. are linked to one or more impact category for example CH belongs to the Global Warming Potential GWP category e Characterization Converts reference substance of the category by multiplying the quantities by the characterization factor which means that the result unit is changed to the reference unit of the category where the quantity belongs For example CH has a factor of 25 which means that CH contributes 25 times more than CO to the global warming potential The most common factor developers are the Institute of Environmental Science CML in Europe and TRAICI in the United States e Normalization Converts and possibly aggregates the indicator results across impact categories using numerical factors based on value choices The aim is to understand the relative magnitude for each indicator result e Evaluation Gives better understanding of the reliability of the collected indicator results More like a quality control step 4 Interpretation phase In this 4 and final phase of the LCA procedure the results of the LCI or LCA or both are summarized The main idea here is to identify significant issues based on the LCI and LCIA phases of LCA Not all of these phases are always mandatory Sometimes sufficient information is already assimilated by carrying out only the LCI and LCIA phases This is usually referred to as an LCI study Copyright Outotec Oyj 2014 HSC 8 Sim LCA utotec November 20 2014 Research Center
37. can be specified in X max step Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 11 15 Kotiranta 43 5 1 Internal and External Controls 1 Internal control in which the target and variable cells exist in the same process unit FAST 2 External control in which the target and variable cells exist in different process units SLOW Calculation of an internal control is fast because only one unit is calculated Usually you can create a large number of internal controls in a process without a dramatic drop in calculation speed because they do not increase the number of calculation rounds of the process Calculation of an external control might take more time because material must be recirculated within the whole process several times to reach a stable target value Usually only a few external controls can be used in one process without a considerable decrease in the calculation speed because external controls might multiply the calculation rounds of the process sometimes it is easier to set controls using additional sheets where some calculations may be done You can insert new sheet using left column quick link Insert Custom Sheet or by using menu Insert Sheet 43 5 2 Advices When Using Controls tis recommended to moderate large changes of the variable with the use of X Max Step when using external controls with slow responses
38. cceccceecccseeeceeeeseeeeeeeeeeeeseeeeeaes 6 49 3 2 Adding Manual Streams not Defined in the Process Simulation Model 8 49 3 3 Mapping of Process Simulation Flows with GaBi Flow Definitions 00000n00nn0na000annaa 9 49 3 4 Main Product Selection and Normalization of Data 10 49 3 5 Exporting as an Ecospold File to GaBi and as an Excel ie 11 49 3 6 Importing a Process to GaBi and Further Analysis in the GaBi Plan Functionality 12 AGA BOIOJADNY EE 15 Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 3 15 Peltom ki 49 1 Introduction to Life Cycle Assessment LCA Calculating a LCA is defined in the ISO 14040 and 14044 standards which belong to the ISO environmental management standards family ISO 14000 According to the standards the calculation is divided into the four main phases presented in Fig 1 f Life cycle assessment framework N Si Ni Goal and scope definition Direct applications Product development and improvement Invento Y Strategic planning analysis Interpretation Public policy making INDIRECT Marketing fa 3 Other N Ce ESSEN Impact op assessment M A Fig 1 Steps of Life Cycle Assessment to capture Scope 1 to 3 emissions and impacts on the environment 1 Goal and scope definition phase In this 17 phase
39. change the position of overlapping units ao We Fig 39 Rotate and Flip With this toolbar the user can rotate or flip units Outotec C bar kWh 10096 zl Persist Tool V Snap to Grid 128 5 Fig 40 Status bar With the status bar the user can zoom the flowsheet and check and uncheck the Persist Tool and Snap to Grid options The Persist Tool remembers the last used drawing tool so that the user does not have to select the same tool again separately The Snap to Grid option aligns the streams and units according to the grid on the flowsheet thus making it easier to draw professional looking flowsheets j ES BI M Fig 41 FileBar The user can start a new open an old save the current process and save a backup of the current process using this toolbar EH Fig 42 TableBar The user can insert a table using this toolbar see also section 40 1 4 Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools Qutotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 22 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 3 2 Docking bars Log viewer O g x rem Hide all fi warnings H Find errors a Process Tree Log viewer Unit Icons Fig 43 Log viewer This docking bar shows the user possible warnings and errors found during the simulation Process Tree O E x Process Tree Log viewer Unit Icons Fig 44 Process Tree In this docking bar the user sees
40. e A compound which is found in Density Database Ale SO4 s ZnSO4 e A compound aqueous ion which is found in the variable list Al 3a Zn 2a Other opecify Name e g Solid concentration opecify Unit e g g l User Formula opecify Name e g Solid concentration Specify Unit e g g l Insert an Excel type formula in Column D e g D13 D7 1000 HSC functions like Molecular weight MW H20 can also be used in the formulae Importing Ready Made Variable List A custom made variable list allows you to utilize the HSC Sim module in many different types of simulation applications such as mineralogical chemical hydrometallurgical pyrometallurgical economic biological etc Only your imagination sets the limits The custom made variable list gives a lot of flexibility but the drawback is that the users have to know what they are doing This is also the main reason why the specification of the variable list is one of the most important tasks in the new model development stage It is easy to add delete modify the Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit utotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 5 15 Kotiranta variable list later on but it may still be best to try to specify a complete variable list right at the beginning or at least before you start to create the calculation models If you have a ready made variable list available you can use the Impor
41. in use Unit Limits ed Run time parameters 4 A D63 2 119 119 um gt 0 Charact Variables that can be setbyuser 5 B Slope 0 9 0 9 um gt 0 Slope o Variables that can be read 6 Tolerance 0 0001 0 0001 gt 0 For min All variables 7 Max Iteration 25 25 gt 1 For min 8 User defined calculations AJT 9 Custom 1 10 Custom 2 11 12 4 Fig 44 Dialog to enter and view the unit model parameters stream content stream connections and model controls Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Qutotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 31 35 Lamberg 45 5 Run simulation and view the results 45 5 1 Simulate To run the simulation from the HSC Sim upper bar buttons Fig 45 v Set the number of calculation rounds This is how many sequential calculations are repeated through all the units v Click the Simulate button v If the flowsheet is not yet in balance stream content is still changing round by round repeat the simulation you may also increase the number of calculation rounds i5 Simulation in progress Fig 45 Simulating the process 45 5 2 Visualization tables graphs scenarios In the Visualization mode gr the stream content and listing of all the variables calculated from the particles can be seen with the Stream Viewer Fig 46 A mineral processing stream consists of the following variables e
42. kg l or behaviora LX Blue text in AN 5 No of minerals 8 Bed text which should not be touched or BM Mineraino ee Code Au Ccp Bn Py Qtz Ab Or Amp 8 Mineral Gold Chalcopyrite Bornite Pyrite Quartz Albite OrthoclaseAmphibole 9 Formula Au CuFeS2 Cu5FeS4 Fei SiO2 NaAlSi308 KAISi308 10 No of behavioral types 0 0 0 0 0 0 0 0 11 Name of type 1 12 Name of type 2 E 13 Name of type 3 M Au 39 M Ccp 52 M Bn 322 M Py 66 M Qtz 53 M Ab 46 M Or 359 4 Amp 482 17 Au 100 00 18 Fe 30 43 11 13 46 55 28 15 19 Cu 34 63 63 31 20 s 34 94 25 56 53 45 21 Si 46 74 3213 3027 19 82 53 26 48 81 45 99 38 71 7 4 HI H Fig 52 Mineral Setup for HSC 7 imported models 45 6 4 Editing model parameters and reloading the unit models Open the unit model editor by double clicking the unit It opens a similar view as in HSC 7 Fig 53 consisting of e Input list of input streams of the units e Output list of output streams of the unit e Dist material distribution calculation form e Control model controls sheet e Model model parameters sheet e Wizard sheet containing the Excel Wizard initial data e Other sheet sheets that the model may contain e g Tank D63 2 1 088572968 alpha 0 594803749 Total 1 000 P80 124 5000 Iterations 25 Number of iterat Input Output Dist Controls Model Wizard Tank Fig 53 Example of unit editor navigation tabs for HSC 7 imported models Cop
43. manually and regulated further with controls The Distribution unit also offers Mixer and Equilibrium wizards which allow you to produce the output species without defining the element distribution Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Units utotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 2 12 Roine 41 1 Steps to Successful Sim Distribution Simulation 41 2 It is important to add the necessary information before simulation can be started It is good to follow this list while making your Sim Distribution models Steps 2 to 5 are explained in more detail here 1 Draw units and streams 2 Specify input streams 3 Specify output streams d Specify distribution 5 Set controls 6 Save process 7 Run process Specify Input Streams The unit editor for a distribution unit is shown in Fig 1 Information about the input streams is specified on the Input sheet The data of the streams are presented in rows For the input streams you should specify the total amount of the stream the measurement unit for the total amount temperature pressure species and composition fim Distribution Pyro Unit x File Edit Insert Help M id Normal Distributions sheet A B C D E F G H I J K L U Mi Tk Convert to Equilibrium Mode 1 Input 2 IR Convert to Mixer 3 4 Flags Input streams Value Units Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy 5 kg Nm kmol kwh
44. of Sqrti2 Classes a ee Fig 28 Creating of a predefined sieve series Both the size class and size distribution properties are summarized on the right hand panel Fig 29 The user editable values in Properties are Size Classes v Select whether the size class labels are generated automatically or edited manually in the size class list Fig 27 These labels can be used in the unit models when you need to enter model parameters by size Yv Measurement unit m or mm this affects how the size data is shown in the Stream Setup tool but for stream particles the base unit for size is always the micrometer v Top size can be given or left empty oize Distribution v Type user given size assay data or automatically gene ated distribution based on Rosin Rammler or Gaudin Schuhmann equations Y Rosin Rammler equation parameters a 63 2 96 passing size b distribution slope v Qaudin Schuhmann equation parameters k 100 passing size m distribution slope The calculated values and information presented in the Properties are Fig 29 Size Classes e Number of size classes e Indication if the feed is Unsized bulk or Sized e Indication if the Top Size is given Copyright Outotec Oyj 2014 Qutotec HSC 8 Sim Minerals Processing November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 22 35 Lamberg oize Distribution e Calculated 5096 passing size P50 e Cal
45. of liberation and association between different minerals in each size class can be defined Fig 2 gives examples of different particle set ups liberated 100 one mineral binary two minerals ternary three minerals and complex four or more minerals all of these are possible in HSC Sim The feed composition and mineralogy are defined with the HSC Sim Stream Setup tool complemented by HSC Geo s extensive mineral database mineralogical calculation tools and MLA Mineral Liberation Analysis data file importing and handling possibilities Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 4 35 Lamberg Liberated Ternary Complex Fig 2 Different complexities of minerals according to their liberation HSC Sim assigns several properties to each particle A stream consists of a certain ton per hour amount including that particle type All the stream properties such as the element wt in it solid specific gravity or total solids tons per hour for example are always calculated based on the particle composition of the stream The particle properties and most common stream properties are listed below These stream properties are also at the same time the initial data for setting up a feed stream for which the particles are automatically generated 1 Particle properties Each particle has its own specific properties that are set when
46. section 40 3 E HSC Sim 8 mJ File View Select Tools Drawing Tools Window Help IG E El e s amp Align dE EIE IN 1 Fa i LG MainProcess X fy Make Same Size E A x b in ES LGS Rotate and Flip 70 an an m C Gh Layerand Order y k le oe El omg x yi Edit Pages and Layers EN EZ Hideal d Warnings Find errors a4 i geed z z z _ Pagel ee Pages Process Tree Log viewer Unit Icons Outotec C bar kWh 10 P vd Persist Tool I5 Snap to Grid ei Fig 26 Drawing tools Edit Pages and Layers x Pages Layers Diagram Items Visibility Pagel d Layer 0 Default All Diagram Items Page2 Wi Layer 1 M All Units Page3 V Layer 2 V all Streams v Layer 3 A All Labels V Layer 4 M All Value Labels M Layer 5 VW All Name Labels M All Unit Name Labels WV All Stream Name Labels M All Other Text Labels VW All Tables M All General Tables M Al Stream Tables M Other Diagram Items Move Up Move Down Add New Delete Rename Hide All Show All Rename Add New Layer Hide All Show All Stream and Unit Names Use Number Alias Names Rename Alias Names Fig 27 Edit Pages and Layers window Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 19 26 Maenpaa Matti Hietala Jussi Pekka Kentala Window and Help menus The Window menu shows the user the name of
47. software and not part of HSC Chemistry software http tutorials gabi software com Extending the GaBi process database is possible by selecting Database Import Ecospold producing functional GaBi processes Copyright Outotec Oyj 2014 Outotec tango Research Center Pori Markus Reuter Matti 14022 ORC J 13 15 Peltomaki We Gabi 6 o g x1 xe E Ee 2 Obyect Fw arch p e 4 KE Ga Bi a 4 rantak Produet Soie Welcome to GaBi 6 P Balances Software San B Linkedin User Groug Facebook Learning Cantar Tutorals M Us Rec Connect Local Database Username System Role Administrator Ufe Cycle Ausmett Benches OutetecBenchm 4 OutotecFootpnnt Activate Database APOE Reutertodels Copper 300000tps Copier example 2012 ProgramData PE I NationalGahi 6 Dstabases Copier example 2 Gabo s 9 Exargies amp Paperdip Tutorial 2012 ProgramData PE Intemational Gabi 6 Patabases Papercip Tutora 2 GabO8 e FeCr 240000tpa Ws Professional Extensions 2012 C ProgramData PE IntemabonahGaBi 6 Databases Professonal Extensions 2012 Gab08 Ze 200000 eS cesses Poo BS9SS3 77 LOZ RhwOPS eec EF 3 em pec Fig 14 Importing a new process to the GaBi database from the directory into which the XML file was exported A file searching window opens for the exported HSC Sim file search as shown in Fig 14 File selection first opens the process summary where the user is also informed of the process export path in the GaBi proc
48. the LCA results more accurate Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 6 15 Peltomaki 49 3 49 3 1 Using the LCA Tool in HSC Sim When the process simulation model is ready the LCA tool is started by selecting Tools gt LCA Evaluation from the main menu as shown in Fig 3 Paz Page Foged Pages Papi Papet Page Fig 3 Starting the LCA tool from the main menu also showing a Sankey diagram for total mass flow and some extra information required for slag chemistry to check the results Automatic Import of All Input and Output Streams The LCA tool creates up to five sheets namely Input Output Manual Input Manual Output and Indicator as shown in Fig 4 The Input and Output Streams Info sheets contain all the process input and output streams in HSC Sim format for the process or complete flowsheet In these sheets stream detail content is available and imported directly from the simulation model NOTE No internal streams are captured through this as only streams that can interact with the environment and flow out from the system into the environment are used in the assessment Copyright Outotec Oyj 2014 HSC 8 Sim LCA utotec November 20 2014 Hesearch Center Pori Markus Reuter Matti Peltomaki 14022 ORC J 7 15 ER LCA Evaluation Jm ls Av a Save Input Output Manual Manual In
49. the flowsheet see Fig 28 The Help menu shows a list of software developers and technical advisors and a link to the Sim manual see Fig 29 and Fig 30 E HSC Sim 8 Sa th E a File View Select Tools Drawing Tools Window Help LG RH e Ph Main Process X Properties a e L a m d I Tid A T E Ir l go LI ui A T V b 1 ijt id LL EE Lio rrtiiblretitri LL EE Li Jd n Dreceee Unit Icons Process Tree op viewer Unit Toons Qutotec C bar kWh 10075 5 4 E VI Persist Tool W Snap to Grid Ki 16 Fig 28 Window menu EN HSC Sim 8 J m Lx File View Select Tools DrawingToos Window kHelp ES H Eb 9 CC Select visualization S Help gt oi Eh About HSC Sim amp I RE Unit Icons Pa a rere red Process Tree lan viewer EA HSC Chemistry 8 HSC Sim Flowsheet Module User Petri Kobylin Module ver 8 0 1 Licensee Qutotec 1974 2014 Authors Software Developers Technical Advisors Jussi Pekka Kentala al Pertti Lamberg Matti Peltom ki Antti Remes Matti Hietala Peter Bj rklund Bishal Karki Tuukka Kotiranta Jarkko Mansikka aho Heikki Eerola Pertti Lamberg Markus Reuter Antti Remes Reijo Ahlberg WEE 5 Fig 30 About HSC8 Sim Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools
50. they are created e g in the feed Stream Setup They consist of e A list of minerals their composition in a particle and properties including Name Code name shortening Chemical formula Specific gravity Chemical composition Optional Database reference Optional additional properties user defined e Size class information including v Lower and upper boundary of each class and geometric average v Name label of the size class v Optional number of particles in a class in case of MLA file imported particles e Optional particle floatability parameters for flotation kinetics based separation e Optional particle type indicating its mineral association group typically with MLA file imported particles 2 Stream properties feed otreams consist of numerous properties and calculated values derived from their particle composition The feed stream particles are generated by HSC Sim based on the following data CN S D e E e Total solids input of the stream t h e Weight percentage of each size class totaling 100 e Weight percentage of each mineral in each size class totaling 10096 and in bulk calculated e Chemical composition of fractions and bulk calculated e Optional mineral liberation and association data for each size class Only if non liberated particles are to be set up and used in modeling Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori
51. visualization E We ase X Amount Phase 1 t h 4 mi o Ip 20 Amount Phase 2 t h EN ba J SE Amount Phase 3 t h E i j Amount t h es iD Density Phase 2 kg m3 Object Type Unit ef Enthalpy kWh NameID Leaching His Number Alias ES E Mode D g FeS Type L1 Bm Value 5 n Leaching Solution O Value Process Tree Abe e L Hydro example3 Value b I A z Air lj e Ion b Value A Process Tree Log viewer Unit Icons Outotec C bar kWh E M Persist Tool W Snap to Grid 142 1 Fig 13 Selecting visualization from the list i Stream Table Editor Available variables Visible variables Amount Phase 1 t h a Temperature 7C Amount Phase 2 t h Amount t h Amount Phase 3 t h Density Phase 2 kg m3 Enthalpy kWh Exergy kWh Fe5O4 Fe 2a Gas Phase Mm3 h H2504 concentration 9 1 H2504 HI tel Heat Capacity kWh Pressure bar Pure Phase t h Water Phase Uh oil Check all the stream tables visible View made Column 1 Color Column 2 color Number Format Name value and unit C 255 255 255 C 255 255 255 0 00 OK Cancel Fig 14 Stream Table Editor to modify Stream Tables Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta HSC 8 Sim Reactions Example November 25 2014 14022 ORC J
52. 0 00 Cut 3254 77 Copy 0 00 Paste 0 00 Format Cell s Copy cell reference Paste cell reference 0 00 Insert rows Delete rows Delete Column Leaching unit Enthalpy 7964 432 kW Cooler Enthalpy LL a Heat Balance Copyright Outotec Oyj 2014 Cut Copy Paste Format Cell s Copy cell reference Insert rows Delete rows Delete Column Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta Bim Cooler File Edt Inset View Tools Help l Hk Chemical Reactions Wizard 3 4 5 S 6 ge Insert Custom Sheet s 8 H iso Add Mew Control 10 Remove Control 11 La Show Controls Sheet 12 13 gt Unit format 14 15 16 BS 18 19 20 21 22 23 24 Z Variable List Editor C8 M amp Hi Dist Controls Model Fig 10 Controls sheet of the Cooler unit 14022 ORC J Extra sheet C4 B Y TARGET NAME Process unit Measurement Unit Set Point Measured Tolerance X VARIABLE NAME Process Unit Measurement Unit Value X Min Limit X Max Limit X Max Step CONTROL METHOD Active Iterations Max Limit Operation HSC 8 Sim Reactions Example November 25 2014 Heat bal kWh 0 00 n Static ON Fi Robust slow Table 2 Data for controlling the Heat balance Measured value is calculated in an additional sheet Row name Cell Filled value or formula Set point C7 H Measured
53. 32 40 0 00 67 45 67 45 51 84 51 84 0 00 0 00 5 72 5 72 0 00 0 00 9 89 9 89 4 28 4 28 1 00 1 00 3 28 3 28 12 43 0 00 67 45 67 45 4 28 4 28 55 62 56 60 1212 69 1191 81 0 23 0 23 0 00 0 00 1 01 1 00 m Fig 8 Output sheet temperature and pressure of the streams can be changed Copyright Outotec Oyj 2014 70 00 1 00 12 43 159 16 0 00 144 40 9779 74 0 00 1147 34 6632 40 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 12 43 0 00 0 00 0 00 977 71 0 00 0 00 0 00 d 5 type OUTPUT m 5 Variables Solution HSC 8 Sim Reactions Unit Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 15 15 Kotiranta 43 7 Save and Run simulation and visualize results It is good to Save Process and Backup often It is good habit to save process after each step Remember to save at least before starting the simulation see Fig 9 and Fig 10 There are many ways to visualize the simulation results see Fig 11 and Chapter 40 section 40 3 O E amp Ak Fig 9 Save Process and Save Backups icons gt 1 Fig 10 Run simulation and give iteration rounds to calculations i amp Select visualization ee A ET D Fig 11 Visualize results and change units add stream tables visualize stream connections add header or copy flowsheet to clipboard Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Example utotec November 25 2014 Research Center Pori Pet
54. 4 Research Center Pori Lauri M enp Antti 14022 ORC J 21 22 Roine 42 9 Step 9 Run the Process Model The process model is now ready and you can start the simulation by pressing the Simulate button at the top bar Fig 32 Next to the Simulate button you can set the number of iteration rounds Processes with recycling streams and controls may require several iteration rounds in order to reach steady state El HSC Sim 8 Jm jx File View Select Tools Drawing Tools Window Help ES HR e selectvisualization sl BR sz BM gt N 10 L Magnetite X Simulate E gy X 4 T 10 20 30 40 50 S0 70 80 30 10 no Ia Ian Ian METET HEI Process W Fu Magnetite Ore Coal zm W Value Value imam el Process Gas O Value Shaft Furnace 5b Hematite Pellets ol Value Ah Process Tree D q x c jp ll Shaft Furnace Value Lf Air f Coal al Hematite Pellets wl Magnetite Ore all Process Gas S Page Page2 Pages Process Tree Log viewer Unit Icons Outotec C bar kWh 100 iv Persist Tool V Snap to Grid 138 0 Fig 32 Simulate the process Results of the simulation can be shown on the flowsheet by selecting the Stream Visualization Mode Fig 33 The selected property in the adjacent dropdown menu is shown in each of the stream value labels Fig 34 e Select visualization T Toggle Stream Visualization Mode Fig 33 Stream Visualization Visualization can be used
55. 4 H a 0 00 0 00 0 00 0 00 26 U H2504 concentration g l 0 00 0 00 0 00 0 00 e Em M Input Output Diet Controls Model Tel Fig 6 Input sheet raw material amounts Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta EIL Unit 1 File Edit Insert View Tools Help E15 Variable List Editor _ 1 I 3 4 2 CTS D ad Insert Custom Sheet ES S E Add New Control ew Contra 10 L3 Show Controls Sheet 11 La Unit format te 13 36 M4 HSC 8 Sim Reactions Unit November 25 2014 14022 ORC J IT Temperature C 25 00 Pr Pressure bar A Amount t h 0 00 H kEnthalpy kWh 0 00 V Volume m3 h 0 00 Ex Exergy kWh 0 00 Cp Heat Capacity kWh Pig Gas Phase Nm3 h 0 00 H20 g Nm3 h 0 00 O2 g Nm3 h 0 00 N2 g Nm3 h 0 00 P2a Water Phase t h 0 00 0 00 H20 t h 0 00 H2504 t h 0 00 Fe 42a t h 0 00 H a t h 0 00 504 2a t h 0 00 P3s Pure Phase t h 0 00 0 00 Fes t h 0 00 5 t h 0 00 Al Amount Phase 1 t h 0 00 0 00 A2 Amount Phase 2 t h 0 00 0 00 AZ Amount Phase 3 t h 0 00 0 00 V1 Volume Phase 1 m3 h V2 Volume Phase 2 m3 h 0 00 0 00 V3 Volume Phase 3 m3 h D2 Density Phase 2 kg m3 999 80 996 95 F2 FesO4 Fe 2a 0 00 0 00 F2 H2504 H a oni 0 00 U H2504 concentration g 1 0 00 0 00 t ni Input Output Diet Controls M a Fig 7 Input streams of the second unit cannot be edited Copyright
56. 47 kwh No Mapping residues in life cyde Electricity Heat Coke oven gas from external supply MJ Services FromNature abase Coke C carrier FromTechnosphere bstances Coke product x ee Fig 8 Selecting a stream for mapping by drag and drop from the right into the LCA Equivalent box as shown in red Please note that here you also have to select where this stream comes from using the dropdown menu Selection of the flow group is always a very important step The flow group defines the nature of the stream i e where it comes and where it flows to There are specific group types for input flows and output flows The flow group is selected from the dropdown menu as shown in Fig 8 Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 10 15 Peltomaki 49 3 4 There are two possibilities to search for the LCA equivalent of each stream A keyword search is one option during which the hits are listed below the search word Fig 8 and the second option is a tree view for manual searching Fig 9 In both cases double click on the stream name to make a selection With the keyword search it is possible to limit the search by selecting some tree view node before the search so that the search is performed under the selected node All hits below that node will be presented Also shown is the pulldown menu for the LCA Group Fig 8 and the possible
57. 48 0 00 12 66 0 00 26 11 102 45 0 00 102 45 29 Ni3S2 15 00 12 00 0 00 0 05 0 00 3 00 0 00 60 09 24 10 0 00 24 10 30 NiO 30 00 24 00 0 00 0 32 0 00 21 39 0 00 6658 2 94 0 00 2 94 31 v M 4 gt HI Input Output Dist Controls Model d d Fig 12 Using the Mixer wizard Pyro Mixer Wizard nmi x E12 90 A B C D E F G Hi 1 Mixer Unit DISTRIBUTIONS 2 Input Streams Output Streams 3 4 Input Streams Value Units Output 1 Output 2 WARNINGS 5 kg h kg h 6 7 Total Input 8 Input 1 100 kg h 9 Total 100 wt 10 CuS 25 95 5 11 Cu25 65 95 5 12 CuO 10 10 so 13 Input 2 120 kg h 14 Total 100 wt 15 tes 35 95 5 16 FeS2 60 95 5 17 FeO 5 0 100 18 Input 3 80 kg h 19 Total 100 wt 20 NG 55 90 10 21 Ni3S2 15 100 0 22 NiO 30 15 85 M gt HI Mixer 4 5 Ho Define by streams OK Cancel Fig 13 Distributing species with the Mixer wizard Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Units utotec November 25 2014 Research Center Pori Lauri Maenpaa Antti 14022 ORC J 9 12 Roine 41 4 3 Equilibrium Wizard The composition of output streams can also be calculated with the Equilibrium wizard This allows you to distribute the elements from the input sheet to species in the Output streams based on their chemical stability at the specified output temperature The Equilibrium wizard option is found on the left hand panel Fig 14 and the equilibrium results
58. 6 98 0 00 626 98 8 SRC Input 1 100 00 kg h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 9 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh kmol KkWh kmol kWh kWh kWh Hide Non essential Columns 10 Pressure 1 00 bar 0 00 18 80 11 Fix Total 100 00 wt 100 00 0 02 0 80 0 00 18 80 139 33 0 00 139 33 Qi bases Custom Sheet 12 Cus 25 00 25 00 0 01 0 26 0 00 3 86 0 00 14 76 50 00 0 00 50 00 13 Cu25 65 00 65 00 0 01 0 41 0 00 9 45 0 00 23 14 89 17 0 00 89 17 14 CuO 10 00 10 00 0 00 0 13 0 00 5 49 0 00 43 70 0 17 0 00 0 17 _ 3 Add New Control 15 5 3 Show Controls Sheet 16 SRC Input 2 120 00 kg h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 17 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kwh kWh 18 Pressure 1 00 bar 0 00 49 13 insert Heat Loss 19 Fix Total 100 00 wt 120 00 0 02 1 16 0 00 49 13 358 17 om 358 17 20 FeS 35 00 42 00 0 01 0 48 0 00 13 27 0 00 27 78 117 27 0 00 S NB estime rend 21 FeS2 60 00 72 00 0 01 0 60 0 00 29 71 0 00 49 51 237 84 0 00 22 FeO 5 00 6 00 0 00 0 08 0 00 6 15 0 00 73 63 3 06 0 00 23 24 SRC Input 3 80 00 kg h Amounts Heat Content H Total H Heat ContH Tot H Chem Ex Phy Ex Tot Exergy 25 DST Temperature 25 00 C kg Nm kmol kWh kwh kWh kmol kWh kmol kWh kwh kWh 26 Pressure 1 00 bar 0 00 37 05 27 Fix Total 100 00 wt 80 00 0 01 0 86 0 00 37 05 129 48 0 00 129 48 28 NiS 55 00 44 00 0 01 0
59. 6845268 21009 03232 369 0766204 22510 04883 393 1768471 24020 63691 421 6357929 25507 35205 446 0516297 27008 57612 467 416563 28509 91114 491 9015658 30011 9324 Copyright Outotec Oyj 2014 e x eel Createa Edit chart new chart data E q T5 Chartsi X 5 6 T 8 9 10 Ore Feed t h Ore Feed t h HSC 8 Sim Common Tools Qutotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 17 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 2 4 Show Process Tree With this option the user can see the flowsheet information and connections of the process streams with colors If a stream is not connected to the unit it will not be visible in this process tree Bim Hydro example3 Solution Hot Water Ka 4 n t Set color 1 Set color 2 Get color 3 Remove color Select All Fig 25 Show process tree Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 18 26 Maenpaa Matti Hietala Jussi Pekka Kentala Drawing Tools menu The user can edit the flowsheet using Drawing Tools by aligning sizing rotating grouping and drawing see Fig 26 One handy way of editing the flowsheet is Edit Pages and Layers where you can set layers and properties which are visible or invisible on your flowsheet see Fig 27 The user can find more details about Drawing Tools in
60. 79769835 aO o Lasel 41 203 38 288052 28 0495422 40 53475392 Ho TEE ENDS s manm 36 164 33 605607 24 6192176 35 57754773 7 Elemental Composition Fig 33 Mineral and elemental composition tables When the tables shown in Fig 33 are clicked a graph will show either the mineral or elemental composition by size see Fig 34 Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 25 35 Lamberg Mineral Composition 20 um 20 75um 75 125um 125 250 um Elemental Composition Fig 34 Bar graphs of A mineral and B elemental stream composition for bulk and each size class A Setting mineral composition elements are calculated The mineral composition can be simply entered in the upper table by each size class One of the minerals is always selected with 100 to be calculated as 100 minus all the other minerals Fig 35 The elements are automatically calculated and updated but only if they are not marked Analyzed The analyzed elements are the initial values for element to mineral conversion explained in B 1 06857251515991 A B co D MM 100 Mineral Bulk Unit O ep 2 277274 O pe 2611407 Fig 35 Entering the mineral wt and selecting the 100 mineral Copyright Outotec Oyj 2014 HSC 8 Sim Minera
61. Antti Remes Pertti 14022 ORC J 5 35 Lamberg Particle handling in process units When a stream is directed to a certain unit in a flowsheet the particular unit operation of that unit can treat the particles as follows 1 Mix the particles of all the incoming streams and direct the mixture to one or more outputs 2 Break down the particles This is the only unit operation where some of the incoming particles are destroyed and do not exist in the output Instead new particles are generated so that the total flow rate and mineral balance are held over the unit 3 Particles can be separated according to several properties typically size specific gravity mineral composition resulting in the overall flotation kinetics for that particle for example etc The above main particle stream phenomena and examples of the unit operations for these are shown in Fig 3 Mixing d Ke e Pump sump 7 e Feed box a gt e Mixing tank e Breaking Down e Crushing e Grinding Separation by e Size e g screening hydrocyclones e Specific Gravity e g Knelson concentrator hydrocyclones e Mineral Composition e g flotation e Shape Color etc Fig 3 Examples of unit operations based on the stream particles Outotec W Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Qutotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 6 35 Lamberg 45 1 2 Levels
62. B C Y TARGET NAME Process unit Measurement Unit Set Point Measured Tolerance X VARIABLE NAME Process Unit Measurement Unit Value X Min Limit X Max Limit X Max Step CONTROL METHOD Active Iterations Max Limit Operation 4 4 gt gt I Input Output Dist Controls Model Fig 16 Controls sheet with two controls 14022 ORC J Liquid water output Distribution Pyro Unit kg h 1 00 1 00 0 05 H Distribution to Stream 4 Distribution Pyro Unit wt 85 73 0 100 Static ON A Light fast 4 10 12 Heat Balance Distribution Pyro Unit kWh 0 00 0 00 0 05 Input Energy Feed Distribution Pyro Unit kWh 3 50 0 10 Static ON 4 Light fast The HSC Sim Controls sheet makes it possible to create controls that regulate the target parameter cell value using another variable cell value Fig 16 In principle Sim Control works exactly like a real process control For example in a real process unit you can give a set point to the process unit temperature and regulate the temperature by changing the fuel oil feed To create a control on the Controls sheet you have to set at minimum the Set Point the Target cell reference Variable cell reference the limits for the variable and the tolerance You can type this information on the Controls sheet using the following procedure 1 Type the name and the measurement unit into Controls sheet cells D9 to D10 optional 2 Type
63. CA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 4 15 Peltomaki 3 Impact assessment phase The 3 phase of LCA is also known as Life Cycle Impact Analysis LCIA LCI results allow you to calculate the LCIA of the system LCIA identifies and evaluates the amounts and significance of the potential environmental impacts of the product system LCIA answers the question What are the resulting impacts Calculating is usually done using four steps where the first two are mandatory Fig 2 describes the steps with example values GWP for 100 year time horizon IMPACT LCI CATEGORIES FACTORS 4 assessment report AR4 Emissions to air 1 3kg CO 1 1 3kg GWP 3kgCO 3 160 3 kg CO Eq 3 kg 6 kg 2 0 001 kg NO 0 08 kg 6 kg CH 25 CFC 11 CChF 3 800 4 750 0 001 kg SO 1 CFC 12 CCLF 8 100 10 900 HCl 0 9kg 0 08 kg NO 0 7 0 849 kg SO Eq em eor 14 400 gt 0 9 kg HCI 0 88 CFC 113 CCLFCCIF 4 800 6 130 CFC 114 CCIF CCIF 10 000 Emissionsto water CFC 115 CCIF CF 7 370 PO 2 kg 0 08 kg NO 0 13 Halon 1301 CBrF 5 400 7 140 NH 0 1 kg 2kg PO 1 2 043 kg PO Eq Halon 1211 CBrCIF 1 890 0 1 kg NH 0 33 Halon 2402 CBrF CBrF 1 640 l Carbon tetrachloride CCL 1 400 1 400 Methyl bromide CHBr 5 CLASSIFICATION CHARACTERISATION m Fig 2 Life Cycle Impacts Analysis steps and a few impact factors for CO Eq e Classification All emissions
64. Cont H Tot H Chem Ex Phy Ex Tot Exergy 5 kg Nm kmol kWh kWh kWh mol kWh mol kWh kWh kWh L gt Show Distribution Sheet 6 Hae 1 7 0 00 0 00 0 00 0 00 8 Process Gas 0 00 Nm h Amounts Heat Content H FF i Heat Cont H Tot H Chem Ex Phy Ex Tot creme Hide Non essential Columns 9 DST Temperature 700 00 C kg Nm kmol kWh kWh kWh mol kWh mol kWh kWh kWh II Dist Sheet Rows Visible 10 Pressure 0 00 0 00 11 0 00 0 00 0 00 0 00 0 00 0 00 0 00 c 0 00 om 5 72 0 00 om 6 05 6 05 0 00 0 00 0 00 24 92 100 43 eu N G Add New Control 5 78 Y 8 88 14 colg 0 00 gt Show Controls Sheet 15 0 00 0 00 Hematite Pellets Insert Heat Loss 18 per Temperature 7oo colc 3 Insert Energy Feed 19 Pressure 1 00 bar 20 Fi Total 21 Fe203 0 00 22 Fe304 0 00 39 74 27012 0 00 om 23 SiO2 0 00 12 0 240 97 0 00 0 00 24 C 0 00 312 312 0 00 0 00 25 M 4 EH Input Output Diet Controls Model Fig 7 Output streams are specified on the Output sheet You need to specify the species temperatures and the measure units of the output streams Please note that the output stream amounts and species distributions cannot be edited manually as they will be calculated later The Output and Dist sheet streams have been synchronized with each other This means that when you type species on the Output sheet they will also appear on the Dist sheet Copyright Outot
65. Controls Model E i T nd r Fig 27 Copy cell reference of the total enthalpy balance Then paste this cell reference to the Measured cell of the Heat Balance control and assign 0 00 as the Set Point Fig 28 Copyright Outotec Oyj 2014 Outotec Vries dria Research Center Pori Lauri M enp Antti 14022 ORC J 19 22 Roine ey Shaft Furnace JB IS File Edit Insert d Pyro Calculation Mod v Dist J4 Normal Distributions sheet A amp C D E F Gi A Convert to Equilibrium Mode L i 2 TR Convert to Mixer 2 ee 3 Ea 2 Show Distribution Sheet 6 7 8 Y TARGET NAME 02 in Output Heat Balance Hide Non essential Columns 9 Process unit Shaft Furnace Shaft Furnace Dist Sheet Rows Visible 10 Measurement Unit vol kWh 11 Set Point 5 00 0 00 12 Measured 140 16 2575 91 Cut Add New Control 3 Tolerance 0 01 Cio E LZ p Be Show Controls Sheet 15 X VARIABLE NAME Air Feed ges me OO 16 Process Unit Shaft Furnace Keen 17 Measurement Unit Nm3 h Copy cell reference insert Heat Los Di Value 10 VI Pesecelrderence 19 X Min Limit 10000 0 Insert Energy Feed i EA d d z Insert row s 20 X Max Limit 100000 100 ie 21 X Max Step Delete row s 22 Delete Control 23 CONTROL METHOD Auto Smart Auto Smart Insert Control 24 Active ON ON 25 Iterations Max Limit KR a 26 27 Operation Li
66. DO 20 SiO2 2 00 ee See 0 00 84 2 21 Paste cell reference 22 SRC Air 1 00 i at Content H Total H 23 DST Temperature 25 00 Insert new species to this stream h kWh 24 Pressure 1 00 Delete species 0 00 OO 25 Fix Total 100 00 Delete Column s 0 00 OO 26 N2 g 79 00 Insert Control 0 00 0 00 27 02 g 21 00 Delete this input stream 0 00 0 0 E M H Input Output Dist Controls Model Ia la Fig 29 Copy cell reference of the coal feed Copyright Outotec Oyj 2014 Qutotec Research Center Pori Lauri M enp Antti Roine HSC 8 Sim Distribution November 25 2014 14022 ORC J ey Shaft Furnace File Edit Insert Normal Distributions sheet v Input D15 B X Convert to Equilibrium Mode A Convert to Mixer D I IN B L3 Show Distribution Sheet Hide Non essential Columns Dist Sheet Rows Visible 3 Add New Control L3 Show Controls Sheet Insert Heat Loss Insert Energy Feed Y TARGET NAME 02 in Output Heat Balance Process unit Shaft Furnace Shaft Furnace Measurement Unit vol kWh Set Point 5 00 0 00 Measured 140 16 2575 91 Tolerance 0 01 X VARIABLE NAME Air Feed Coal Feed Process Unit Shaft Furnace Shaft Furnace Measurement Unit Nm3 h t h Value 1 00 X Min Limit 10000 0 X Max Limit 100000 100 X Max Step CONTROL METHOD Auto Smart Auto Smart Active ON ON Iterations Max Limit Operation Light fa
67. Excel Export xlsx Microsoft Excel quum ecu euo Home Insert Page Layout Formulas Data Review View Add Ins PDF XChange 4 E SEE SE E z B d ds Tahoma 7185 A AC cy Wrap Text Text kb E ad Normal Bad Good E KI Een 21 EA 9 Fill L Paste I WC Oe A Emm BE merges center gt S n 9 Conditional Format Neutral Calculation Insert Delete Format Sort amp Find amp VP Format Painter m U amp o A E a ie Formatting asTable V Le M x X Clear 7 Filter Select Clipboard fa Font fa Alignment E Number fa Styles Cells Editing L Input Streams C G H 1 J K L M N o P Q R S T 2 Unit Name Stream Name Amount Unit Lca Equivalent Lca Group T 3 NiPigIronEF Laterite 5700 00 kg Nickel ore 1 596 FromTechnosphere 4 NiPiglIronEF Coke 356 65 kg Coke metallurgic FromTechnosphere 5 NiPigIronEF Limestone 869 41 kg Limestone FromTechnosphere 6 NiigIronEF Infilitrate Air 128 67 kg Air FromNature 7 NiPigironEF Power kWh 5300 47 kwh Energy unspedfic Electricity Heat 8 In M Input Streams Output Streams Manual Input Streams Manual Output Streams Indicator Streams Normalized Streams Ee Ready Calculate Fig 13 The Excel export of all the information for further use by other software Importing a Process to GaBi and Further Analysis in the GaBi Plan Functionality GaBi software is 3 party LCA
68. Fe 2a S H20 90 efficiency HSO H a SO 2a 100 efficiency can be added with the Chemical Reactions Wizard In the Leaching unit open the Excel editor Chemical Reactions Wizard You have to write the Progress Reactants Products and press the Balance button which checks the coefficients for the reactions see Fig 4 Eu Hydro Reactions Editor dulizx x o OO i 5 Activate Exit and Balance Cancel A B C D E T BE H i j 1 Progress Reactant Reactants Products Product Balance H K 2 KC Solid Phase Separated with Separated with 4 Solid Phase kcal be 3 90 2FeS 4H a O2 g 2Fe 2a 25 2H20 OK 131 4208359 3 93824E 75 4 100 H2504 2H a 504 2a OK 22 852 3462533170 IM VI Reactions Dynamic 4 mt Fig 4 Reactions sheet in Chemical Reactions Wizard 44 2 4 Specify Distributions Remember to complete the Dist sheets of the units In the Leaching unit 100 of the gas phase goes to the Offgas stream and 100 of the liquid and solid phase goes to the Solution stream Fill in the percentages for both streams see Fig 5 In the Cooler unit there is just one output stream so fill in 100 to each phase Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Example Outotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 6 15 Kotiranta 44 2 5 Sim Leaching ES e K Ele Edit Insert View Tools Help F25 F24 Variable L
69. Fig 10 Fixing elements N Fe and Si in the output streams Copyright Outotec Oyj 2014 Outotec un dM Research Center Pori Lauri Maenpaa Antti 14022 ORC J 10 22 Roine For elements that are present in several streams distribution can be done e g by fixing a value for one stream and letting the remaining amount go to the other For example you can define that 0 1 wt of carbon C goes into the Hematite Pellets stream and the rest will be distributed to the Process Gas stream To do this set the status of carbon to Fixed in the Hematite Pellets stream and give the wt value as 0 1 then set the status of carbon in the Process Gas stream as Rest Fig 11 E Shaft Furnace E x File Edit Insert v Normal Distributions sheet A X R Convert to Equilibrium Mode Elements IR Convert to Mixer Shift Distributions 1 kWh 296465 61 Balance 980 00 137483 73 99 57852 87 kWh 296465 61 980 00 137483 73 E 57852 87 M pw dum Sint kWh 0 00 Output 0 00 0 00 0 00 Hob 1 s 0 00 Stream Dist 4 Hide Non essential Columns Dist Type o Dist Sheet Rows Hidden Amount Species Total 17 Hematite Pellets Stream Dist 3 Add New Control Dist Type Amount 0 98 137483 73 ae a Species 0 00 0 00 ES Insert Heat Loss Insert Energy Feed i4 at Hi Input Output Dist Controls Model Lal Fig 11 Fixed fraction of carbon in the pellets stream and rest in
70. Fig 23 After specifying the variables enter the SET variable values add charts and run the scenario Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Lauri Maenpaa Matti Hietala Jussi Pekka Kentala HSC 8 Sim Common Tools December 10 2014 14022 ORC J 16 26 The calculation results will then be presented in the spreadsheet as well as in the charts Fig 24 SN Scenario editor p Ww Q Run chosen Run all t scenario scenarios C20 X A B 1 Scenario 1 2 Unit Name 3 Variable Name 4 Measure Unit 6 Cell Reference 8 Rounds per mn 5 1 9 Run 1 10 Run 2 11 Run 3 12 Run 4 13 Run 5 14 Run 6 15 Run 7 16 Run 8 17 Run 9 18 Run 10 19 Run 11 20 di d 29 M 4 NI Scenario 1 a New scenario sheet scenario C Unit 1 Ore Feed t h SET 10 5 5 5 6 6 5 7 7 5 8 8 5 9 9 5 10 D LX Delete selected scenario sheet D Unit 1 Heat Loss 1 kWh GET 8536 963461 4268 035812 4694 363385 5121 266146 5548 44002 5975 330432 6402 264725 6826 822733 7253 676798 7680 529491 8110 402158 8536 963461 Fig 24 Results of the scenario Create new SET GET Delete selected Create a new data column data column chart tab E F Unit 2 Unit 2 Heat Loss 2 Offgas kWh Nm3 h GET GET 491 9015658 30011 9324 244 2096148 15013 898 269 6784563 16513 13578 294 0258175 18014 42588 320 2963713 19507 84426 344
71. Furnace gt a dl Photochem Ozone Creston Potenta kg Ethene Ecur gt X I ail ice Pig tron Furnace 3 EP a dil Teresinc Ecotowoty Potental kg DCS Eguv i E Magie tean Eesen D LI 1D Becticty grid eux PE 2 6e 3kgPhosphate Equiv E Electrcty gri Last change System 09 10 2014 11 37 05 2 No d Last ci 09 10 2014 11 36 02 GUID d9235053 b89e 4f4f bfOb d42290db3cd4 Selection Nickel Pig Iron F Completeness No statement D Colour Change ed No mage Energy net calorfc value CH Maximus flow width 40 Piyes per unit Dei 214 ar a Fig 17 The imported process can now be linked to other GaBi processes e g energy and the calculated environmental impacts Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 15 15 Peltomaki 49 4 Bibliography 1 E Worrell and M A Reuter 2014 Handbook of Recycling Elsevier BV Amsterdam 595p ISBN 978 0 12 396459 5 2 SFS EN ISO 14044 SFS EN ISO 14040 4 J Gediga Life Cycle Assessment pp 555 562 In E Worrell and M A Reuter 2014 Handbook of Recycling Elsevier BV Amsterdam 595p 5 GaBi Paper Clip tutorial Handbook for Lifecycle Assessment Using the GaBi software http tutorials gabi software com Ge Copyright Outotec Oyj 2014
72. HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 1 26 Maenpaa Matti Hietala Jussi Pekka Kentala Sim Module Common Tools E usc Sim 8 eye File View Select Tools Drawing Tools Window Help LI uS i kei 6 amp 5 Select visualization e e IN ig ua V 4 Main Process X Propertie cas x Em wm 20 30 40 so eo 7 80 30 100 110 120 130 wp ba me 170 180 ecd RTI OQOL O B Lie tis D ql x IP Units by Type v Search for units C TE _ Clem m LI d H i e l Page Page2 Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 10 H M Persist Tool v Snap to Grid 179 110 Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools Qutotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 2 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 1 Drawing flowsheets and adding tables to flowsheets This chapter explains how to draw and add tables to a flowsheet In addition to the instructions chapter the user should also read unit specific Chapters 41 47 of this manual before running the simulations 41 42 Distribution Units 43 44 Reactions Units 45 46 Minerals Processing Units and 47 Converter Units which are needed if different units are combined in the flowsheet The most important icons for drawing are Hg pu me gm eg Fig 1 Icons for drawing Units and St
73. Hide Non essential Columns Measurement Unit vol kWh Set Point 5 d Insert Custom Sheet Measured 5 00 0 00 controle jean a0 Add New Control XVARIABLENAME AirFeed Coal Feed Remove Control Process Unit Measurement Unit Nm3 h t h ai iiia Citi nene Value 53093 82 2 28 HeatHow ooo ER 10000 9 X Max Limit 100000 100 Insert Heat Loss X Max Step n Insert Energy Feed CONTROL METHOD Static Static Active ON ON Iterations Max Limit 10 18 Operation Robust slow Robust slow Fig 35 Controls after simulation Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta 43 November 25 2014 14022 ORC J EL HSC Sim 8 File View Select Tools Drawing Tools Window Help ES El RM Select visualization sl FA e EI SS rw gt Ses Hydro manual2 X Gr zz ch Offgas KZ Value imma O o pen O r ec Stream 1 51 Leaching Soliton O Te Value Value Abc Us Value Air Value c Paget Page2 Page3 Outotec C bar kWh 100 oim Reactions Hydro Unit HSC 8 Sim Reactions Unit a x on x Process Unit Icons D q x ve EB Units by Type v Search for units Lo ER au Process Tree Log viewer Unit Icons t V Persist Tool z Snap to Grid 220 71 The Reactions unit calculates chemical reactions based on unit operations in solid liquid and gas systems This unit was
74. In this example it is assumed that almost all of the magnetite is oxidized This can be simulated by fixing 196 of stream s iron content to Fe3O4 and distributing the rest to Fe2O3 Fig 15 Eu Shaft Furnace Em a File Edit Insert Pyro Calculation Mode BE22 v Normal Distributions sheet A B C D J X Y AO BE CA CH DC EA L Convert to Equilibrium Mode 1 Distributions Elements C Fe N Oo Si 2 IR Convert to Mixer 3 Total H Shift 4 Flags Balance kWh 7331 26 Balance 979 02 0 00 0 99 6498 59 5 Input kWh 296465 61 Input 980 00 137483 73 0 99 57852 87 M cM UE 6 Output kWh 289134 35 Output 0 98 137483 73 0 00 64351 46 f 8 Process Gas Stream Dist wt 100 00 Hide Non essential Columns o Dist Type a Rest 9 Dist Sheet Rows Visible 10 Amount kg 6498 59 11 Species Total 5 N2 g EJ Add New Control 13 O2 g 14 colg L2 Show Controls Sheet 15 CO2lg incerta 16 17 Hematite Pellets Stream Dist wt Insert Heat Loss 18 Dist Type Fixed Float insert Energy Feed 19 Amount kg 137483 73 64351 46 20 Species Total wt 21 Fe203 Rest Fe 99 00 90 89 22 Fe304 Fixed Fe 1 00 0 82 23 SiO2 Fixed Si 8 29 100 00 24 C Fixed C 100 00 25 M 4 EM Input Output Dist Controls Model d Fig 15 Iron distribution to the pellets stream Next the elements can be distributed to the Process Gas stream Again an easy way to start is to distribute the nitrogen N atoms to the
75. Indonesia v Location Comment Developer Author Reuter Date 09 10 2014 M Version Number 1 0 Cancel OK Fig 11 Process Info dialog for entering process detail It is not mandatory to complete all process information fields but it is worth filling well in order to export the process in a form that is best usable in GaBi After completion of the process information save it by clicking Process info can also be used without the LCA tool to describe the process well hence providing a good summary for use in a process design The To GaBi exporting button is found on the button menu to the right of the Normalize button If normalization has not been done the LCA tool will automatically ask you to perform normalization first Exporting opens a file search dialog where the location and Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 12 15 Peltomaki 49 3 6 name of the exported file is defined entered The Export done popup window will inform the user when the export is ready as shown by Fig 12 There is also an option to export the information to Excel which can be used as an input for other applications reports publications etc as shown in Fig 13 j zk Computer Local Dikit i e Notification x Fig 12 Selection of export directory and file name MNT ys NPI
76. L D Fee Tal b 2 pee ol SS oe fn Sand LE L L SS L 6 EN Run chosen Run all New scenario Clone Delete selected Create new SET GET Delete selected Create anew Create a scenario scenarios sheet scenario scenario sheet data column data column chart tab new chart C6 e lt Insert reference gt Charte li X Unit Name Variable Name Measure Unit SET GET Cell Reference M 4 gt HI Scenario 1 dh Fig 50 Scenario Editor for running different simulation set ups and recording the simulated values Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Qutotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 34 35 Lamberg 45 6 Opening an HSC 7 flowsheet in HSC 8 The old HSC 7 flowsheet can be opened simulated and edited albeit with some restrictions in HSC 8 The steps for handling HSC 7 flowsheet models are described briefly in the following section 45 6 1 Conversion from HSC 7 to HSC 8 format When a HSC Sim 7 flowsheet model fls file is opened HSC Sim 8 will convert it into the new format Fig 51 For a large flowsheet this may take several minutes For more details about importing see Chapter 40 section 40 4 Importing HSC7 flowsheet Read units Unit SAGmill Fig 51 Importing an HSC 7 flowsheet When the importing is ready save the model in a new separate folder 45 6 2 Simulating the flowsheet The HSC 7 imported models are simu
77. List In this example two variable lists can be used You can add the lists to the model by double clicking the unit and clicking Variable List Editor or in Excel editor Tools menu and Variable List Editor and by pressing Import Flowsheet_Hydro Hydro_example3 For the Leaching unit we choose Leaching xlsx and for the Cooler unit Cooler xlsx see Fig 2 and Fig 3 It is also possible to use Leaching xlsx list for the Cooler unit but not vice versa B Fill Variable List Manually You can also fill in the variable lists manually see Fig 2 and Fig 3 or Chapter 43 Use Nm3 h unit for the Gas Phase You need to give the mass fractions of the water phase otherwise density cannot be calculated see rows 33 34 in Fig 2 Since H2SO concentration in g l is not in the list you need to create a User Formula U in the Variable List Editor Choose User formula and give it a name H2SO concentration and measure unit g l Make the formula in column D see Fig 2 In the example above the formula in cell D35 is D19 MW H 2 MW H2S04 D30 1000 which means that mass of H2SO is calculated from the amount of H a ions in moles see equation in Fig 4 divided by the water phase volume The result is multiplied by 1000 to obtain the unit grams of HSO per liter of solution The User formula is copied automatically to all the Input and Output streams of each unit when Activate is clicked NB The equation is changed in the Variable
78. List Editor to SAFEDIV SAFEDIV D19 MW H 2 MW H2S04 D30 1000 with equation SAFEDIV HSC8 Sim sets 0 0 0 When modifying the variable list remember that columns A to D are automatically synchronized which means that any changes are automatically copied to all the streams Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta HSC 8 Sim Reactions Example November 25 2014 14022 ORC J E Variable List Editor o O 3 Fig 3 Variable list of the Cooler unit Copyright Outotec Oyj 2014 Activate Exitand Import Database Help Cancel Temperature p Name Measurement Unit e moy Phase Temperature aC v Concentration J Mass Fraction Other pe J Zi a 1 mor Pelis al SC TU VERUS Ea Amount Volume Enthalpy Density HeatCapacity Exergy Ia Ad lTemperature 4 Pr Pressure i 5 A Amount t h 6 H Enthalpy kWh 7 v Volume m3 h 8 Ex Exergy kWh 9 Cp Heat Capacity kWh 10 Pig Gas Phase Nm3 h vi v rj A E E 11 H20 g Nm3 h 12 O2 g Nm3 h 13 N2 g Nm3 h 14 lt Enter Species gt Nm3 h 15 P2a Water Phase t h v iV A v E o 16 u20 t h 17 H2S04 t h l5 18 Fe 2a t h 19 H a t h 20 SO4 2a t h 21 Enter Species t h 22 P3s Pure Phase t h v v E 7 23 F
79. Mass Fraction J A B C D E F G H Type geen d BS Phase Level Variables Amount Volume Enthalpy Density HeatCapacity Exergy Ia T C Temperature Other User Formula 1 2 3 4 Pr Pressure bar 5 A Amount t h 6 H Enthalpy kWh 7 V Volume m3 h 8 Ex Exergy kWh 9 Cp j HeatCapacity kWh 10 Pig Gas Phase t h 11 Enter Species t h 12 P2a Water Phase t h d 13 H20 t h 14 Enter Species t h 15 P3s Pure Phase t h 16 Enter Species t h 17 A2 Amount Phase 2 t h 4 4 gt M Variable List Fig 1 Variable List Editor where user specifies the variables needed in the simulation 43 2 1 Filling Variable List Manually Specify the Species First you need to specify the species you are using in your calculation The species can be any combination of elements like Fe Ag O etc solid species CaCOs Na CuS etc Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 3 15 Kotiranta gases CO g O2 g Ne g etc or liquids H2SO a CuSO a etc or Cu 2a SO 2a H a etc Special case species that are not found in HSC database If the compound is not found from the HSC database To use the compound you need to add it to the own database Here are instructions what you need to take into account when you add the compound The compound needs to have a chemical formula Molecular wei
80. Name Y Target Name Process Unit Measurement Unit Set Point Measured Tolerance X Variable Name Process Unit Measurement Unit Value X Min Limit X Max Limit X Max Step Control Method Active Iterations max limit Iterations min limit Operation Description Name of Y optional Unit name optional Name of the unit of measure optional Set point of Y obligatory Y cell reference obligatory Y tolerance obligatory Name of X optional Unit name optional Name of the unit of measure optional X cell reference obligatory Min limit of the X range obligatory Max limit of the X range obligatory Maximum X Step optional default empty Iteration method optional default Auto Set control ON OFF optional default empty ON Max number of iterations optional default 10 Min number of iterations optional default empty Control calculation operation optional default Light Auto Solves the control with information on rows 20 23 Auto Smart Same as Auto except changes X Max Step and Iterations max limit when needed PID not in use will be added to HSC8 version Light Solves the control with modified tangent method fast Robust Solves the control with modified Newton method slow Simple direct Increases X value when Measured value is too small The step used can be specified in X max step Simple reverse Decreases X value when Measured value is too small The step used
81. Nm h 595 76 Nm h Hide Non essential Columns 9 22 91 kmol 513 50 Nm h 86 19 vol 96 Insert Custom Sheet 10 0 00 kmol 0 00 Nm h 0 00 vol 11 3 67 kmol 82 26 Nm h 13 81 vol 12 0 00 kmol 0 00 Nm h 0 00 vol Add New Control 13 0 00 kmol 0 00 Nm h 0 00 vol 6 14 0 00 kmol 0 00 Nm h 0 00 vol eod icai es eet 15 0 00 kmol 0 00 Nm h 0 00 vol 96 a ast E 17 3 32 kmol 793 76 kg h 67 00 wt Insert Heat Loss 18 0 03 kmol 5 82 kg h 0 49 wt 96 insert Energy Feed 19 0 90 kmol 87 58 kg h 7 39 wt 20 1 15 kmol 93 88 kg h 7 92 wt 21 0 00 kmol 0 01 kg h 0 00 wt 22 0 00 kmol 0 03 kg h 0 00 wt 23 0 03 kmol 1 99 kg h 0 17 wt 24 1 26 kmol 201 67 kg h 17 02 wt 25 26 27 28 29 30 31 32 33 34 4 4 N Input Output Dist Controls Model Gibbs lt m r Fig 15 Distributing elements with the Equilibrium wizard Copyright Outotec Oyj 2014 Qutotec Research Center Pori Lauri M enp Antti Roine 41 5 Set Controls E Distribution Pyro Unit File Edit Insert Calculation Mode Normal Distributions sheet TA Convert to Equilibrium Mode Al Convert to Mixer Dist Sheet Rows Visible L gt Show Distribution Sheet Hide Non essential Columns 83 Insert Custom Sheet G3 Add New Control e Remove Control L gt Show Controls Sheet Heat How 89 Insert Heat Loss 89 Insert Energy Feed HSC 8 Sim Distribution Units November 25 2014 v Liquid water output
82. Not defined X Add new input stream fimi LCA Evaluation EM EA i L X A 1 gt gm P ge CH v FT M M UI qu Tr e H Sa Input Output Manual Manual Indicator Mapping Normalize Help ToGabi To Excel Input Output Manual Input Streams Stream Name Amount Unit Lca Equivalent Lca Group Delete Z Power for buildings 0 f v No Mapping Not defined X i kwh Add new input stream Fig 6 LCA Manual Streams sheet for defining additional flows that do not appear in the simulation The key indicator sheet offers the possibility to examine how much of the compounds are released into the environment in the offgas or flue dust etc This is a valuable part of the evaluation as a transparent analysis can be made of all the compounds that flow into the environment Fig 7 shows all the indicator values and adds them together once they have been mapped as entering the environment You can use the wildcard Table 1 to capture more than a single compound e g CO will collect all CO and CO etc species as defined in the model Table 1 Possible wildcard for compound definition Wildcard Description Zero or more characters Any single character Any single digit 0 9 You can type any compound in the sheet after having clicked on the Add new input stream bar at the bottom of the window Some defaults are given The compound definition may contain wildcards as presented in Table 1 The LCA tool will automatically check if there are double
83. Popup list tool can be used in the specification procedure This tool is automatically opened when you click a cell where the operation is possible The options are Fixed The distribution is fixed with a constant value or an Excel type formula Only a constant value cell may be used as a variable on the Controls sheet Rest When all the specifications have been made for a certain element then the remaining fraction of the element must go to one species and one phase Float This option means that the current cell has been automatically specified by the other elements like metals It is usually wise to specify oxygen sulfur etc as floating elements Copyright Outotec Oyj 2014 Outotec un dM Research Center Pori Lauri Maenpaa Antti 14022 ORC J 9 22 Roine 42 7 1 Step 7 a Distribution to Output Streams ES shaft Furnace _ 5 x File Edit Insert D Normal Distributions sheet Al Convert to Equilibrium Mode A Convert to Mixer Distributions s mess Balance W 980 00 137483 73 0 99 57852 87 ap 1 296465 6 In 980 00 13748373 0 99 57852 87 gt Show Distribution Sheet F L o 0 00 0 00 0 00 0 00 Tos i Stream Dist Hide Non essential Columns Dist Type o Dist Sheet Rows Hidden Amount pecies Total Hematite Pellets Stream Dist Add New Control Dist Type Amount 3 Show Controls Sheet Seege Total Insert Heat Loss Insert Energy Feed Fig 9 Di
84. T column Fig 21 Then you can add a name and measurement unit for this variable but most importantly you should specify whether the variable will be a regulated SET or a calculated variable GET Fig 22 E Scenario editor gt E Run chosen Run all scenario scenarios Wao an uni UIN ike p fpa pa ee ItkAIth It ony naw SL Win KF 19 20 21 22 23 24 25 26 27 28 lt Insertreference gt A B Scenario 1 Unit Name Variable Name Measure Unit Cell Reference Roundsperrun 5 IM 4 b b Scenario 1 Me a m L E Cae L 96 os we el Clone Delete selected Create new SET GET Delete selected Create anew Create a scenario scenario sheet data column data column chart tab new chart Charts li X Copy cell reference Paste cell reference 4 j Fig 21 Add variables to the Scenario Editor by pasting the cell reference of the variable cell Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools Uutotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 15 26 Maenpaa Matti Hietala Jussi Pekka Kentala Scenario editor a x E Q p Sec ER gt Ka en d E o eg Ee p e KN NT NT L3 UH La ed Run chosen Bun al z t New scenario Clone Delete selected Create new SET GET Delete selected Create anew Createa E scenario scenarios sheet scenario scenario sheet data column data column chart tab new chart C5 SET A B E 2 D E 4 1 Scenar
85. Tot H Chem Ex Phy Ex Tot Exergy 5 kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kWh kWh e Dist Sheet Rows Visible 6 3 Show Distribution Sheet 7 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 8 SRC Stream 4 0 00 Nm h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 9 DST Temperature 100 00 zc kg Nm kmol kwh kWh kWh kmol KkWh kmol kWh kWh kWh _ Hide Non essential Columns 10 Pressure 1 00 bar 0 00 0 00 11 Fix Total 0 00 vol 0 00 0 00 0 00 0 00 0 00 0 00 0 00 K Q9 Insert Custom Sheet 12 N2 g 0 00 0 00 0 00 0 61 0 61 13 O2 g 0 00 0 00 0 00 0 62 0 62 0 00 0 00 S 14 H20 g 0 00 0 00 0 00 0 70 66 47 0 00 0 00 3 Add New Control 15 Show Controls Sheet 16 SRC Stream 5 0 00 kg h 17 DST Temperature 100 00 C 18 Pressure 1 00 bar e Insert Heat Loss 19 Fix Total 0 00 wt 20 H20 0 00 0 00 0 00 0 00 0 00 0 00 77 82 0 00 0 00 0 00 89 Insert Energy Feed 21 m M 4 H Input Output Dist Controls Model 7 Fig 8 The user needs to specify the measurement unit for the amounts temperature pressure and the species for the output streams Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Units utotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 6 12 Roine 41 4 Specify Distribution 41 4 1 The distribution of the elements from the Input sheet to the Output sheets can be done by using the Dist sheet or by using the Mixer or Equili
86. Total solids t h e Liquid t h e Pulp flow rate t h e Pulp volumetric flow rate m h e Solids SG g cm e Pulp SG g cm e Solids e Solids recovery 96 e Element wt e Elements recovery 96 e Mineral wt e Mineral recovery 9o e Passing sizes P50 and P80 m e Size fraction percentages Copyright Outotec Oyj 2014 Outotec ee Research Center Pori Antti Remes Pertti 14022 ORC J 32 35 Lamberg Stream Visualization Al Solids Liquids Gas Partides M Total solids t h 135 00 Liquid t h 4 18 Pulp Flowrate t h 139 18 Pulp Volumetric Flowrate m3 h 48 82 Solids SG g cm3 3 02 Pulp SG g cm3 2 85 926 Solids 926 97 00 Solids Recovery t h 100 00 Cu e wt 2 13 Fe e wt 11 73 O e wt 38 70 S e wt 96 13 47 Si e wt 96 33 97 Cu e Rec 100 00 Fe e Rec 100 00 O e Rec 100 00 S e Rec 100 00 Si e Rec 100 00 P80 um 2000 00 Fig 46 Stream Viewer for inspecting the stream content Values that are shown on the flowsheet stream value labels are selected from the HSC Sim main window dropdown menu see Fig 47 The same values are also used for the Sankey diagram presenting the value with the flowsheet stream line width ulp Flowrate t h E IP50 um ation and pap um 20 Pulp Flowrate t h KR D n Diagrai Pulp SG g cm3 Solids SG g cm3 Total amount t h em Devisen Ro m bo Ro ein mo iom cem Fig 47 Stream Visualization to set the values to be
87. al Distributions sheet A c D E F G H I J K L U V W FA Convert to Equilibrium Mode B Input TR Convert to Mixer 4 Flags Input streams Value Units Amounts Heat Content H Total H Heat Cont H TotH Chem Ex Phy Ex Tot Exergy 5 kg Nm kmol kWh kWh kWh mol kWh mol kWh kWh kWh L gt Show Distribution Sheet 6 Nm h 7 t h 201001 29 42 04 1069 00 0 01 296465 61 36421 71 0 00 36421 71 8 SRC Magnetite Ore 200 00 t h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy Hide Non essential Columns 9 DST Temperature 25 00 C Nm kmol kWh kWh kWh mol kWh mol kWh kWh kWh Dist Sheet Rows Visible 10 Pressure 1 00 bar 0 01 296381 39 11 Fix Total 100 00 wt 200000 00 40 60 987 03 0 01 296381 39 27123 15 0 00 27123 15 12 Fe304 95 00 190000 00 36 75 820 60 0 01 254271 26 0 00 309 86 27010 90 Add New Control 13 SiO2 5 00 10000 00 3 85 166 43 0 00 42110 13 0 00 253 0 112 25 0 00 14 Wi Show Controls Sheet 15 SRC Coal 1 00 t h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy nset o O 16 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh mol kWh mol kWh kWh kWh 17 Pressure 1 00 bar 0 00 84 22 Insert Heat Loss 18 Fix Total 100 00 wt 1000 00 044 81 92 0 00 84 22 9298 54 0 00 9298 54 insert Energy Feed 19 C 98 00 980 00 0 43 81 59 0 00 0 00 9298 31 om 20 SiO2 2 00 20 00 0 01 0 33 0 00 253 02 0 22 0 00 21 22 SRC Air 1 00 Nm h Amounts Heat Content H Total H Heat Cont H T
88. all unit and stream Name Labels on the flowsheet 8 Select all unit and stream Value Labels on the flowsheet 9 Select all Other Text Labels on the flowsheet 10 Select All Labels on the flowsheet 11 Select all not including stream tables Tables on the flowsheet 12 Select all Other Drawing Objects on the flowsheet 13 Select All Items on the flowsheet El HSC Sim B rx uae Ele View ca Drawing Tools Window Help O Cp Unis TAISE D P T Unit Mame Labels TET Streams En 7 Be Stream Mame Labels mi Stream Value Labels Stream Tables Mame Labels Value Labels D s E Other Text Labels gt E Units by Type 7 GR All Labels 1 3 Tables t Pad Process ree Log viewer Unit Icons Other Drawing Objects Outotec All Items Ctrl A i A kd y Persist Tool v Snap to Grid Di 1 Fig 15 Select menu Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 11 26 Maenpaa Matti Hietala Jussi Pekka Kentala Tools menu The Tools menu includes many advanced options that may be needed in flowsheet simulation The user needs detailed instructions on how to use those tools Some tools are explained here and others in different Chapters see the list below The Tools menu includes see Fig 17 1 Process information E Process Information c j x Process Process Name Technol
89. als 869 41 0 85 kg Input Air FromNature Material resources Renewable resources 128 67 0 13 kg Input Energy unspecific Electricity Heat Energy resources 5300 47 5 20 kwh Output Slag WasteToTreatment Waste to Hazardous waste 4279 05 4 20 kg Output Pig iron Fe carrier WasteToTreatment Waste to Materials Metals 1019 28 1 00 kg Output Flue gas ToNature Other emissions to air 1710 51 1 68 kg Output Dust containing heavy metals WasteToTreatment Waste to Hazardous waste 45 89 0 05 kg Output Energy unspecific ToNature Energy resources 200 00 0 20 kwh Output Carbon monoxide WasteToTreatment Waste to Inorganic emissions to air 474 18 0 47 kg Output Carbon dioxide ToNature Inorganic emissions to air 261 21 0 26 kg Fig 10 A complete normalized data set defining as a black box the complete process flowsheet or system 49 3 5 Exporting as an Ecospold File to GaBi and as an Excel File The To GaBi exporting menu button writes an Ecospold version 1 0 XML file The exported file contains metadata which provides general process information as required by the LCA methodology Metadata information is entered in the Process Information window and needs to be completed before exporting Fig 11 Stream details are taken from the normalization sheet E Process Information e x Process Process Name Nickel Pig Iron Smelting Technology Electric Furnace General Comment Production of low grade Ni containing pig iron Location Location
90. ange the angle of the stream and c remove the corners of the stream d change the input and output units of the stream e check the connection of the streams Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 3 26 Maenpaa Matti Hietala Jussi Pekka Kentala a Choose the Select icon and by holding down the shift left mouse button the user can make corners on the streams by moving the mouse b Choose the Select icon and click the stream to see the nodes blue squares Hold down the mouse button on a node and move the mouse to change the angle of the stream c Choose the Select icon select the stream then select one stream node blue square move one node on top of another node to remove a stream corner d Choose the Select icon and move the beginning or end of the stream to a new unit or out of the unit HSC8 Sim will suggest a new connection to the stream that the user can accept OK or Cancel e When the flowsheet is ready check that the streams are connected to the correct units The user can check connections visually see Fig 4 A white circle or arrow means that the stream source or destination is unknown a gray arrow means it is known Blue stream means input black stream is between two units and red stream means output It is also possible to click the Tools menu to show the process tree The most time consuming task is sel
91. are presented on the Gibbs sheet which is linked to the Output sheet You need to specify the Input sheet as well as the Output sheet for the wizard The streams on the Output sheet are assumed to be separate phases in the equilibrium calculations Fig 15 Phases can be set either as a mixture or as pure phases E Equilibrium Unit TS E File Edit Insert M Calculation Mode M T Normal Distributions sheet A B C D E F G H l J K L U V W nor TR Convert to Mixer i 1 z 4 Flags Input streams Value Units Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 5 kg Nm kmol kwh kwh kWh kmol kWh kmol kWh kWh kWh e Dist Sheet Rows Visible 6 b gt Show Distribution Sheet 7 2061 67 650 20 36 95 0 00 289 15 1756 51 0 00 1756 51 8 8 SRC Input 1 650 00 Nm h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy Tools A 9 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kWh kWh Hide Non essential Columns 10 Pressure 1 00 bar 0 00 0 00 11 Fix Total 100 00 vol 836 67 650 00 29 00 0 00 0 00 11 30 QJ Insert Custom Sheet 12 N2 g 79 00 641 79 513 50 22 91 0 00 0 00 0 00 0 00 4 58 Controis 13 O2 g 21 00 194 87 136 50 6 09 0 00 0 00 0 00 0 00 6 72 0 00 6 72 d 14 S Add New Control 15 SRC Input 2 1 00t h Amounts Heat Content H TotalH Heat ContH TotH Chem Ex Phy Ex Tot Exergy 3 Show Controls Sheet 16 DST Temperature 25 00 C
92. as given in Properties Fig 29 and the second parameter is solved by HSC Sim by pressing Enter or clicking Calculate Distribution from the Set Passing Size button menu shown in Fig 31 Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Outotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 23 35 Lamberg Set Passing menti Solids Size T Target Rosin Rammler Slope b 1 Gaudin Schuhmann Passing 80 Wd M M M M m amp i t KM Passing Size 74 Size Unit i m mmus Calculate Distribution Top Size zz TIT Fig 31 Automatic calculation of the size distribution to match the given passing size value Finally the cumulative size distribution curve can be seen graphically Fig 32 The figure includes both data points for each given sieve size and the quadratic spline interpolation curve between them Graphs c Cumulative Size Distribution l 100 0 1000 0 10000 0 pm Fig 32 Logarithmic presentation of the cumulative passing size both the given sieve size data points and quadratic spline interpolation between them 45 3 1 5 Mineral and elemental composition The mineral compositions and resulting elemental compositions are edited from the tables shown in Fig 33 The tables consist of Mineral Composition e 100 one of the minerals is always calculated as 100 the sum of all the other minerals e Mineral list o
93. ast Light fast 38 Jw EI hb H Input Output Det Controls Model EIT Fig 26 Variable limits and target tolerance The Heat Balance control can be made by following the same steps First copy the cell reference for the Total H balance Dist J4 Fig 27 B Shaft Furnace o x File Edit Insert Y vro Calculation Mode E vy J6 J5 Normal Distributions sheet al e Ir x v a s c co pe EY Convert to Equilibrium Mode 3k Distributions Elements E Fe N o Si 2 44 Convert to Mixer 3 Total H Shift 4 Flags Balance kWh 2575 91 Cut 0 00 0 00 0 00 0 00 e 5 Input kWh 29646561 oy 137483 73 0 99 57852 87 4683 70 EET CIN UNDE Ea Output kWh 29904152 137483 73 0 99 57852 87 4683 70 im 1o00 10000 ie 100 90 d Process Gas geed 100 00 1123 Dist Sheet Rows Visible 10 Paste cell reference 6498 59 Species Insert new species to this stream trol N2 g E Add New Control 13 O2 g nd age 14 CO g Delete Column s gt Show Controls Sheet us CO2g Insert Conizol 16 117 Hematite Pellets Stream Dist 0 10 100 00 111 23 100 00 Insert Heat Loss 18 Dist Type Fixed b Float Fixed insert Energy Feed 19 Amount 0 98 137483 73 64351 46 4683 70 20 Species Total 21 Fe203 22 Fe304 23 SiO2 8 29 10000 24 C Fixed C 100 00 25 LN lt gt mt Input Output Dist
94. avigation tool e Right side Properties of selected component e Right side Graphs of selected component e Middle area for setting up the feed properties DS m TM em e O B ues T a W 9 w Pr Liquid tph PE Gg Update Discard Element to Solids and Close and Close E Gas tph Mineral Target Al v Analyzed D s Hn Solids 2 A B C D E F G H 5 Total Phases OB 100 Mineral Bulk Unit 20 um 20 75 um 75 125 um 125 250 es em Total Flow Rate Liquid 4 18 TEER 2 Cep 6 137089 3 4656 3 4656409 3 46564091 3 465640914 NS EE COPS 3 H Ei 21 18953 19 997 19 996666 19 996666 19 99666601 Tem Size Distribution 4 F Qtz 72 67338 96 76 538 76 537693 76 5376931 76 5376930 Ces t h Composition 5 Liquid t h beration Distribut 6 Solids t h 7 Liquid g N Total Flow Rate 4 4 gt H Mineral Composition 4 n ciiin 1 DI Unit 20 20 75 um 75 125 um 125 250 Qi Gas 2 UN Cu 2 125006 12 1 2000001 1 20000011 1 200000112 3 Fe 11 73045 96 10 362 10 362307 10 3623071 10 36230707_ Total Flow Rate 4 I o 38 7033 40 761 40 761303 40 7613025 40 76130254 EE s P 13472117 us 11 9 11 8999997 11 89999974 SR 6 EI Si 33 97007 35 776 35 776391 35 7763905 35 77639054 7 4 8 i 9 4 10 11 12 3 IM 4 gt M Elemental Composition d m 2014 Outotec Fig 12 Stream Setup tool dialog for defining a minerals processing feed stream The Solids Composition view is shown her
95. brium wizards Dist Sheet You can create the distribution manually by filling the Dist sheet which is synchronized with the Output sheet The elements need to be distributed to the streams and the species within those streams Therefore the common approach is to first distribute the elements to streams and then to species For instance in this example the elements H N and O need to be distributed to two streams The first stream contains gaseous species N2 g O2 g and H2O g and the second stream contains pure water H2O Fig 9 E Distribution Pyro Unit ea x File Edit Insert gt p 4 Pyro Calculation Mode Normal Distributions sheet A B E D J X Y BK CA CH A Convert to Equilibrium Mode l EH Distributions Elements H N o 2 IR Convert to Mixer 3 Total H Shift 4 Flags Balance kWh 18 70 5 Input kWh 18 70 Input kg Dist Sheet Rows Visible 6 Output kWh 0 00 Output kg L gt Show Distribution Sheet 7 wt 8 Stream 4 Stream Dist 9 Dist Type Fixed Fixed Fixed Hide Non essential Columns 10 Amount kg 0 00 0 00 0 00 11 Species Total wt 0 00 0 00 0 00 GJ Insert Custom Sheet 12 N2 g Fixed 13 021g Ge 14 H20 g G3 Add New Control 15 gt Show Controls Sheet 16 Stream 5 Stream Dist wt 17 Dist Type Fixed i Fixed Heat Flow 18 Amount kg 0 00 0 00 Insert Heat Loss 19 Species Total wt 0 00 0 00 20 H20 Se EJ Insert Energy Feed IM 4 M Input Outputs Dist Controls Model 4 t Fig 9 Dist sh
96. by setting the status to Rest Fig 18 Shaft Furnace a x File Edit Insert Y v Rest Normal Distributions sheet A B C D J X Y AO BE CA CH DC EA A Convert to Equilibrium Mode 1 Distributions Elements C Fe N o Si 2 IR Convert to Mixer 3 Total H Shift m 4 Flags Balance kWh 2575 91 Balance 0 00 0 00 0 00 0 00 L Input kWh 296465 61 Input 980 00 137483 73 0 99 57852 87 Mec Sd EE 6 Output kWh 299041 52 Output 980 00 137483 73 0 99 57852 87 Ke al 7 100 00 100 00 100 00 100 00 8 Process Gas Stream Dist 100 00 11 23 Hide Non essential Columns 9 Dist Type Fixed Rest 9 Dist Sheet Rows Visible 10 0 99 6498 59 11 Species E 100 00 100 00 3 12 N2 g 1 E Add New Control 13 O2 g 14 CO g Show Controls Sheet 15 CO2 g 16 17 Hematite Pellets Stream Dist 0 10 100 00 111 23 100 00 Insert Heat Loss 18 Dist Type i Fixed a Float Fixed Insert Energy Feed 19 Amount 0 98 13748373 64351 46 4683 70 20 Species Total 100 00 100 00 100 00 100 00 21 Fe203 Rest Fe 99 00 90 89 22 Fe304 Fixed Fe 1 00 0 82 23 SiO2 Fixed Si 8 29 100 00 24 C Fixed C 100 00 25 x M 4 gt NI Input Output Dist Controls Model H Fig 18 Oxygen distribution in the gas stream Now the distribution of elements in the output streams is ready It is important to notice that for a correctly filled Dist sheet the Balance value for all of the elements is equal to zero Fig 19 This indicates that all the atoms
97. centration g l 1 01 1 00 0 00 M 4 E M Input Output Dist Controls Model Mi l J Fig 12 Output stream temperatures of both Solution and Offgas streams are put at 70 C 44 2 7 Saving the Process Chapter 40 sections 40 2 and 40 3 1 Processes should always be saved in their own folder Changing the process name is not enough since every unit is an Excel file that is saved in the same folder as the flowsheet The name of these files is the same as the name of the units Therefore you also have to save different scenarios in different folders 44 2 8 Running the Simulation and Checking the Results sections 40 3 1 and 40 3 2 When you have finished the model you can run the simulation First you have to set the number of rounds you wish to calculate the process and then press the Simulate button to start the simulation You should check if the values change during different runs to find out if the process is in balance The value of the selected variable is presented in the value labels see Fig 13 User can add Stream Tables and Header Chapter 40 sections 40 1 4 and 40 3 1 to visualize the calculation results see Fig 14 and Fig 15 Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Example utotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J Kotiranta usc Sim 8 Las File View Select Tools Drawing Tools Window Help T i Select
98. ch Center Pori Markus Reuter Matti 14022 ORC J 1 15 Peltomaki 49 Environmental Impact Environmental impact assessment in HSC Sim 8 combines the simulation functionality of Sim with the functionality of GaBi environmental impact assessment software This provides a rigorous mass and energy balance as well as a techno economic basis for LCA and thus links the environmental impact analysis to technology Hence it can be used to suggest change and innovation Outotec HSC Sim rraem re o y e Rase 43 a dus mmm dam Cm dan do oca d a zamonam e EC eg EE fe EE EE AE gt lt po E ab o EN E m_m m M P Se 4 w 4 a R d ei m on pe Ax d BAT Flow Sheets amp Recycling System Maximizing Environmental Indicators based on BAT Resource Efficiency Benchmarks Driving Benchmarks of Industry US t Product CAPEX amp OPEX ReCiPe and similar Endpoint estimation Recyclability Index based on system simulation of whole cycle Global Warming Potential GWP Energy GJ amp MWh t Product source specific Acidification Potential AP Exergy GJ amp MWh t Eutrification Potential EP kg CO t Product Human Toxicity Potential HTP kg SO t Product Ozone Layer Depletion Potential ODP g NO t Product Photochemical Ozone Creation Potential POCP m Water t Product including ions in solution Aquatic Ecotoxicity Potential AETP kg Residue t Product including
99. ching c j x File Edit Insert View Tools Help os oat arin de Variable List Editor P IA Chemical Reactions Wizard 6 Variables 7 m Temperature 25 00 25 00 8 Pr Pressure i 1 00 1 00 Insert Custom Sheet 9 A Amount t h 84 16 60 00 10 10 10 H Enthalpy kWh 246798 99 223520 49 23278 49 11 V Volume m3 h 60 11 50 15 10 13 ES 12 Ex Exergy kWh 33512 47 28640 61 4681 93 amp 9 Add New Control 13 Cp Heat Capacity kWh 3 Show Controls Sheet 14 P1g Gas Phase Nm3 h 10927 08 0 00 0 00 TS 15 H20 g Nm3 h 0 00 16 O2 g Nm3 h 2294 69 2294 69 17 N2 g Nm3 h 8632 40 8632 40 18 P2a Water Phase t h 60 10 50 00 10 10 0 00 19 H20 t h 50 00 50 00 20 H2504 t h 10 10 10 10 21 Fe 2a t h 0 00 E 22 H a t h 0 00 23 SOA 2a t h 0 00 24 P3s Pure Phase t h 10 00 10 00 0 00 0 00 25 FeS t h 10 00 10 00 26 M t h 0 00 27 A1 Amount Phase 1 t h 14 06 0 00 0 00 14 06 28 A2 Amount Phase 2 t h 60 10 50 00 10 10 0 00 29 A3 Amount Phase 3 t h 10 00 10 00 0 00 0 00 30 V1 Volume Phase 1 m3 h 31 V2 Volume Phase 2 m3 h 60 11 50 15 10 13 0 00 32 V3 Volume Phase 3 m3 h 33 D2 Density Phase 2 kg m3 999 80 996 95 996 95 996 95 34 F2 FeSO4 Fe 2a 0 00 0 00 0 00 0 00 35 F2 H2S04 H a 0 00 0 00 0 00 0 00 36 U H2S04 concentration g l 0 00 0 00 0 00 0 00 M 4 gt HI Input Output Dist Controls Model 4 V Fig 11 Feed stream amounts of the Leaching unit Copyright Outotec Oyj 2014 Qutotec HSC 8 Sim Reactions Example
100. ciency curve Separation in hydrocyclone according to the Plitt model Supports separation by mineral Indicates if underflow discharge is roping Conditioning of particles by setting the flotation kinetic parameters based on the selected calculation model Recycle stream is directed through without changes in the kinetics Recovery of minerals based on flotation kinetics Feed stream particles and liquid are separated to concentrate and tails Launder water inlet and gas inlet outlet streams are optional General thickening model Produces given underflow solids percentage and overflow water clarity General filtering model Produces given cake moisture and filtrate clarity supports optional inlet outlet streams for technical waters HSC 8 Sim Species Converter Units utotec November 19 2014 Research Center Pori Lauri M enp Matti 14022 ORC J 1 5 Hietala 47 Sim Species Converter Units CS Gea le File View Select Tools Drawing Tools Window Help O B Select visualization Bi D gt i15 P Main Process X Gl Species Converter Unit Em wmm jj Properties o g x s y tks Be J E s n RE Au K u ebe 724 Pul 1 J gt Process Drawings de NEER e ew lail on bh S wa 0 S Ko s E Model Help Parameters Input Output Controls Stream Enable Multiple bject Type Jn
101. composition Abiotic Depletion ADP kg Fugitive Emissions t Product Ele kg Particulate Emissions t Product Etc I All analyses are performed on this basis linked to technology and can therefore be used to innovate the technology and or the system and understand its resource efficiency as shown in Fig 1 MINE Primary Resource Geological minerals Market amp Stocks Collection amp Dismantling Functional Metal amp Material Combinations Secondary Resources Unaccounted _ nn MM Losses amp Theft URBAN MINE Secondary Resource Designed mineral GREENPRINT OF THE SYSTEM MAXIMIZE RE RCE EFFICIENCY Maximize Handprint Minimise Footprint Losses Physics complex linkages economics Losses Manufacture Losses amp Stocks Sampling data integrity Le resolution detail statistics mineralogy Stocks Infrastructure Losses Thermodynamics system technology economics metal price feed morphology analysis complexity dilution of alloying metals etc Copyright Outotec Oyj 2014 HSC 8 Sim LCA utotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 2 15 Peltom ki Table of Contents 49 1 Introduction to Life Cycle Assessment CA 3 E EOAR SS e EE 5 49 9 Using the LGA Toolin ASG Sw beet dcutut edv s qaducq cuta uduuess uci nemis iae 6 49 3 1 Automatic Import of All Input and Output StreaMs cc
102. counts of elements compounds species A message box informs the user of double counting and will not add the compound to the list Copyright Outotec Oyj 2014 Outotec d Research Center Pori Markus Reuter Matti 14022 ORC J 9 15 Peltomaki 49 3 3 All the indicators which have some amount will be automatically added to the Manual Output streams list If these emissions are to be excluded from the LCA analysis the streams can be deleted manually by clicking the red cross Sim LCA Evaluation a ee Ea EH Ak ep nma P Ge cm Avant S DN 2 a Save Input Output Manual Manual Indicator Mapping Normalize Help To Gabi To Excel Input Output Indicator 5treams Stream Name Measured Property Amount Unit Lca Group Lca Equivalent Delete CO g CO g 0 00 kg Not defined No Mapping AX CO2 g cOig 0 00 kg Mot defined No Mapping E H200 H200 0 00 kg Mot defined No Mapping X GO GO 0 00 kg Not defined No Mapping x NO NO 0 00 kg Mot defined No Mapping AX ETSEEE E pom TEE TR SE x Add new indicator stream Fig 7 Key Indicator sheet showing the entry of a new compound that has to be tracked for environmental impact Mapping of Process Simulation Flows with GaBi Flow Definitions In order to perform LCA calculations all HSC streams have to be mapped to GaBi equivalents All automatically included input and output streams have to be mapped but mapping of predefined manual streams are not mandatory Non map
103. culated 8096 passing size P80 Properties e Classes Automatic Class Labels True Top Size 10000 Distribution Distribution Type Assay Data Gaudin Schuhmann k 0 00 Gaudin Schuhmann m 0 00 Rosin Rammler a 0 00 Rosi Rammler b 0 00 Size Unit Unit of the sieve sizing Fig 29 The size class and size distribution properties 45 3 1 4 Size distribution The size distribution is given as wt retained values for each size the last size class is automatically calculated to total 100 Fig 30 Also the cumulative passing values are calculated automatically Negative values are not allowed and are indicated by red color which must be corrected before proceeding further If instead of Assay Data user given values the Rosin Rammler or Gaudin Schuhmann distribution calculation is selected Fig 29 the wt values in Fig 30 will also be generated automatically Sieve No Sieve Size Weight Retained Cumulative Passing 5 Size Class Label 11 1 20 0 2000 3000 J4 7 323 3 1000 2000 Um 22 2 33 1 500 1000 um aa 14 9 18 2 250 500 um B 7 9 6 1245 250 um 7 fo 3 7 2S 75 L25 um 20 4 3 LD 20 75 um 1 6 20 im Fig 30 Defining the size distribution The size distribution either Rosin Rammler or Gaudin Schuhmann can be calculated in two ways 1 By the equation based on the two parameters given in Properties Fig 29 2 Bygiving the known passing size value e g for P80 the slope parameter is
104. dic table on the Elements button menu shown in Fig 23 Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 19 35 Lamberg m mem mm mr m ee e e s s Em gm m emn e em s a mmm mer pe e qe m m m pem e en i Ei AA FPE 39 3 5 a EE EJE EJE FN ni FR D iin int nil DURER ni ani m aaa all Fig 23 Editing of elements and selecting them from the periodic table The selected mineral Fig 21 properties are presented on the properties panel on the right Fig 22 and its element composition is presented visually in a pie chart Fig 25 Mineral A Code Ccp DB Ref Mie lCONTONTUNERNTERITVION TR Formula gares EO euam nucon cr iesus Chalcopyrite Misc E 4 35 DB Ref Database reference Fig 24 Mineral properties Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Outotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 20 35 Lamberg Graphs n Chalcopyrite 3 45 3 1 3 94 30 43 Fig 25 Graphical presentation of the elemental composition of a mineral Size classes The sieve size classes can be set up and edited as follows Fig 26 v Top Size can be given or left empty this affects the way the mean size of the topmost class is calculated Y Sieve Size is given and accepted by pres
105. dicator Input Output bag en H t Mapping Normalize Help To Gabi To Excel Input Streams Unit Name Stream Name Amount Unit Lca Equivalent Lca Group p ENPgiontt Lem 5700 00 kg No Mapping Not defined Input Streams amp Value Class Name Value Unit Text Unit Enum r Summary Amount ka 5700 kg Masskg Summary Amount Nm3 2 38597352766815 Nm3 VolumeNm3 Summary Extra energy kWh 0 kWh EnergykWh Summary Total Exergy 666 2412048528 kWh EnergykWh Species NiO 119 7 kg Masskg Species Fe203 1254 kg Masskg Species CoO 4 56 kg Masskg Species CuO 0 684 kg Masskg Species Cr203 39 9 kg Masskg Species SiO2 2223 kg Masskg Species CaO 228 ka Masskg Species Al203 282 15 kg Masskg Species H20 855 ka Masskg Species MgO 693 006 kg Masskg Cnacian lee ecl NiPigIronEF Coke 356 65 kg No Mapping Not defined NiPigIronEF Limestone 869 41 kg No Mapping Not defined NiPigIronEF Infilitrate Air 128 67 kg No Mapping Not defined NiPigIronEF Power kWh 5300 47 kwh No Mapping Not defined Fig 4 Input streams info sheet extracted from flowsheet showing the laterite details The LCA streams sheets contain the HSC Sim stream names as defined by the design engineer and amounts which must be mapped to the GaBi LCA equivalents on the GaBi database The default is No Mapping which unless changed will exclude that stream from the evaluation Fig 4 shows the details of the laterite input stream while Fig 5 shows the output and more specificall
106. e All the required data is entered in the middle part of the dialog by navigating the steps on the left side Phases navigation panel Fig 13 The data can be entered in any order but the easiest way is to follow the links from top to bottom starting from the Solids Total Flow Rate Copyright Outotec Oyj 2014 Qutotec Research Center Pori Antti Hemes Pertti Lamberg HSC 8 Sim Minerals Processing November 20 2014 14022 ORC J 14 85 Phases m is Solids Total Flow Rate Minerals Size Classes Size Distribution Composition H La r bat va Ee JET o UO poy Liquid Total Flow Rate J omponernts iM Gas Total Flow Rate l mrnmeecitmrsi Fig 13 Phases navigator to set the stream data step by step When the desired stream data have been entered the stream and its particle content are saved and updated to the simulation model by clicking Update and Close on the upper bar Fig 14 Alternatively the changes can be cancelled using the Discard and Close button The cell references for the total t h flow rates of the Solids Liquid and Gas phases can be copied by clicking the respective upper bar buttons The cell reference can then be pasted and used elsewhere for example in controls that adjust the flow rates of the feed streams kB o P eh Solids toh per Liquid tph Update Discard and Close andClose di Gas tph Fig 14 Buttons to apply changes and to copy cell references for the total
107. e H20 t h d Air H2504 t h lz Fe 2a t h E Ke Ha t h Cha A f SOA 2a t h J n drei Rage pem Egg wes i Outotec C bar kWh 100 ES j Fig 50 Stream Content awek In this mm bar the user can see a 3 tabulated summary y of e stream properties E HSC Sim 8 Jm lx File View Select Tools Drawing Tools Window Help O amp HR e Amount Did sl BS E QD gt E Le Hydro example3 X Stream Visualization Settings q x u ES bw J J jw Pe eo NE jso en be Ian a MESSER EECH KENE Options CO Visualize stream value labels only eh V Use max line width mm 1 C Use visualization color C We Fes Max line width mm 2 Q O 60 00 Positive color Cp 0 255 QJ Negative color r 255 0 0 X aacht Solution a Reset Options to Default O B 71 74 H2504 Abe us Points within range 10 10 S le V Use absolute values KW E EA Air I A i lo 4 m Min 8 10 Max 200 00 I dre Fagz Pages Outotec C bar kWh 100 2 3 ES M Persist Tool z Snap to Grid Ja 90 Fig 51 Stream Visualization Settings In this docking bar the user can change the settings of the Sankey diagram thickness of the stream shows where most of the material goes Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools Qutotec December 10 2014 Research Center Pori Petri Kobylin Lauri
108. e a 2017 34 40177 01 12 10 240 92 11248 101220 112467 ac Insert Control d d 24 0 00 0 25 0 25 3 12 312 930 0 13 9 43 25 d eegen Bl Convert this stream to an Inert stream P X ils 4 H Input Output Dist Controls Model Delete this output stream n SCH or Fig 21 Copy the cell reference of O2 96 in the gas stream Then set this cell reference as the control by selecting Paste cell reference for the Measured value of the O2 96 control cell D12 Fig 22 Shaft Furnace File Edit Insert EINIGE OutputiD13 Normal Distributions sheet B Th Convert to Equilibrium Mode 1 2 TR Convert to Mixer 3 Distributions 4 5 L Show Distribution Sheet ei D Y TARGET NAME D Hide Non essential Columns i 9 Process unit Dist Sheet Rows Visible 10 Measurement Unit 11 Set Point Cotrls 1 11 12 Measured 3 Add New Control oe Tolerance 4 gt Show Controls Sheet 5 X VARIABLE NAME Process Unit Measurement Unit Insert Heat Loss perum Wes Insert Energy Feed 42 X Min Limit X Max Limit X Max Step CONTROL METHOD Active Iterations Max Limit Operation 02 in Output 140 16 Cut Copy Paste Format Cell s Copy cell reference Insert row s Delete rows Delete Control Auto Smart Insert Control ON Light fast ON Light fast Fig 22 Set cell reference for the target parameter
109. e example in Fig 4 shows a distribution where all the gas species enter the Offgas stream type 100 in cell F14 and all the water and pure species go to the solution phase type 100 in cells E18 and E24 EJ Leaching l EL JL Ele Edt Insert View Tools Help EIF25 F24 Variable List Editor s E F S 1 d 3 4 5 Type Dist Total L 6 Variables 5um Solution E Insert Custom Sheet 14 Pig Gas Phase Nm3 h 100 00 15 H20 g Nm3 h 100 00 SS 16 O2 g Nm3 h 100 00 Go Add New Control ME 17 N2 g Nm3 h 100 00 gt Show Controls Sheet 18 P2a Water Phase t h 100 00 TET 19 H20 t h 100 00 20 H2504 t h 100 00 21 Fe 2a t h 100 00 22 H a t h 100 00 23 SOA 2a t h 100 00 24 Pis PurePhase t h 100 00 25 Fes t h 100 00 26 5 t h 100 00 M a Mj Input Output Dist Contri mn Fig 4 Dist sheet is usually filled with given distribution percentages Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 9 15 Kotiranta 43 5 Creating Controls Controls can be added removed and seen using quick links on the left column see Fig 5 Bim Leaching o H File Edt Inset View Tools Help hi C14 Input F20 Variable List Editor p A B C E l 2 IA Chemical Reactions Wizard 4 Y TARGET NAME Acid conc 5 Process unit 6 Measurement Unit G2 Insert Cu
110. eS is the raw material in reaction 1 You must keep in mind that more than 100 of the raw materials cannot be consumed The sum of Progress cannot be more than 100 for the same raw material although it may be less than 10096 The other species in the reaction equations will automatically be taken into account when a model is created based on the reaction stoichiometry However it is still recommended to check whether there are negative amounts on the Model sheet and remove them for example by decreasing the Progress 9 6 The second step is to test the balances by pressing the Balance button This gives an OK in the Balance column showing that everything is acceptable The balance test will also give enthalpy H and equilibrium constant K for the reaction at 25 C if all the species are found in the active HSC databases Negative H values mean that heat is released in the reaction whereas positive values mean that more heat is needed Large K values 1 mean that the reaction tends to go to the right and small values 1 mean that the reaction tends to go to the left in the equilibrium state The third step is to Activate the reaction equations After that the reactions can be seen on the model sheet This sheet contains a list of the reactions with progress percentages The user may change the Progress cells H7 and H11 manually or by using a control see Fig 3 NB The species name is red if it is not found in the variable list This wil
111. eS t h 24 S t h 28 Enter Species t h 26 Al Amount Phase 1 t h 27 A2 Amount Phase 2 t h 28 A3 Amount Phase 3 t h 29 V1 Volume Phase 1 m3 h 30 V2 Volume Phase 2 m3 h 21 M Volume Phase 3 m3 h 32 D2 Density Phase 2 kg m3 33 F2 Feso4 Fe 2a Ki 34 F2 m2s04 H a 35 uU H2S04 concentration E SAFEDI m DES H Variable List l MTM Fig 2 Variable list of the Leaching unit EL Variable List Editor Jm x o OG e Activate Exitand Import Database Help Cancel Temperature Name Measurement Unit G Phase Ar fe Temperature Concentration g D Mass Fraction Other F G H J a ij eese ssp T Phase Level Variables T5998 Amount Volume Enthalpy Density HeatCapacity Exergy l E T Temperature C 4 Pr Pressure bar zs A Amount t h 6 H Enthalpy kWh 7 V Volume m3 h E 8 Ex Exergy kWh 9 Cp HeatCapacity kWh 10 Pig Gas Phase t h A E E I A T 11 Enter Species t h 12 Pia WaterPhase t h v E E E E E 13 H20 t h ER Enter Species t h 15 P3s Pure Phase t h A w A A A A 16 Enter Species t h 17 A2 Amount Phase 2 t h n lt gt onh Variable List i S Te m d H HSC 8 Sim Reactions Example Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 5 15 Kotiranta 44 2 3 Add Reaction Equations to the Unit Chapter 43 section 43 3 The following leaching reaction equations FeS H a Os g
112. ec Oyj 2014 HSC 8 Sim Distribution November 25 2014 Qutotec 17 Hematite Pellets Stream Dist Research Center Pori Lauri M enp Antti 14022 ORC J 8 22 Roine 42 7 Step 7 Create A Model Eu Shaft Furnace A x File Edit Insert Pyro Calculation Mode Hai Normal Distributions sheet A C D X Y AO BE CA CH DC EA R Convert to Equilibrium Mode 1 l Distributions Elements c Fe N o Si IR Convert to Mixer Total H Shift Distributions 4 Flags Balance kWh 296465 61 Balance 137483 73 57852 87 5 Input kWh 296465 61 Input 137483 73 57852 87 WP Show Distribution Sheet 6 Output kWh 0 00 Output j 0 00 Z 8 Process Gas Stream Dist Hide Non essential Columns o Dist Type Dist Sheet Rows Visible 10 Amount 11 Species Total d 12 N2 g Fixed EJ Add New Control 13 O2 g Fixed 14 CO g L gt Show Controls Sheet 15 CO2 g Seen v Gd Insert Heat Loss 83 Insert Energy Feed 18 19 20 21 22 23 24 Species Fe203 Fe304 SiO2 C Dist Type Amount Total MJ Fixed C 25 M 4 gt H Input Output Dist Controls Model Fig 8 Element distributions need to be specified on the Dist sheet The Sim Distribution mode automatically calculates the total input amounts for the input streams and converts these into elements The user must specify on the Dist sheet how these elements will be distributed a into output streams b into species within one stream The
113. ecting streams one by one and looking at the properties process sheet to see the source and destination of the stream E HSC Sim 8 Jm jx File View Select Tools Drawing Tools Window Help amp A RM e Select visualization X ys it lig et V 4 Main Process X cs x cC 10 n an n z cn 70 2n On 1 1 10 120 120 140 125 EZ 17 125 4 mm E Ut CL m LE ak St SE i 1 L1 Di iri Ei e F F1 Process a it Unit 1 Unit 2 Stream 1 Stream 2 Stream 3 gt Value Value Value L E H x gt FB Units by Type v Search for units og b 7 CH n s Page Page2 Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 100 v Persist Tool v Snap to Grid 113 56 Fig 3 Drawing streams E HSC Sim 8 Jm jx File View Select Tools Drawing Tools Window Help ES A RM e seectvisualization B l gi ET amp gt i 4 MainProcess X ca x a om a nm A e ae Sage BE un rre per geg 3 et ann ei DEI mH t s T 3 Eu ge 7 P i e P ui a e i m i Process c Unit 1 Unit 2 gt A IZ Stream 1 Stream 2 Stream 3 gt Value e Rer BE Bas CJ CL Ce 4 b i t r Paget Page2 Page Process Tree Log viewer Unit Icons Outotec C bar kWh 100 V Persist Tool V Snap to Grid 152 3 Fig 4 Visualizing stream connections Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 4 26
114. ed e Select visualization sl Fe e E Ind gt i 5 mm 10 20 30 40 50 60 70 80 0 100 110 24 10 Ian ben be hb garde ibi e s Stream 1 Stream 2 pen S Value Value R Unit 1 Is oO i Stream 4 cF Value 5 I O G Stream 5 Value t Main Process Stream 3 Value 4 p Page Page2 Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 100 P Persist Tool Snap to Grid 124 89 Fig 2 Draw streams on the flowsheet The second step is to draw streams Fig 2 which must be done using the Stream tool on the left toolbar The shapes and colors at the end points of the streams indicate their connections You can also check the Source and Destination units for each stream from the Process tab If a stream is not connected from either end then this value is shown as a question mark for the missing Source or Destination value Process raw material streams do not have specified Sources whereas the Destination units are missing for the process output streams Intermediate streams should have both Source and Destination values specified Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Qutotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 4 22 Roine 42 3 Step 3 Rename the Units and Streams EN HSC Sim 8 LI File View Select Tools Drawing Tools Window Help amp HR e selectvisualization sl BI RS Hm b E r
115. eet The types of distribution of elements to streams can be Fixed Rest and Float Fixed Constant or function value is used Rest All the rest of the element goes into this stream Float Automatically fixed by other elements In this example all the nitrogen is distributed to the first stream and hydrogen and oxygen are distributed to both streams For instance it can be initially set that 60 of hydrogen is distributed to the first stream and the rest to the second stream For oxygen the distribution type in the second stream will be set as Float and Rest in the first stream Fig 10 Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Units Outotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 7 12 Roine E Distribution Pyro Unit es a x File Edit Insert SE Normal Distributions sheet A B C D J A Y BK CA CH c R Convert to Equilibrium Mode 1 Distributions Elements H N Oo 2 IR Convert to Mixer 3 Total H Shift 4 Flags Balance kWh 18 70 Balance 5 Input kWh 18 70 Input Dist Sheet Rows Visible 6 Output kWh 0 00 Output L gt Show Distribution Sheet 7 8 Stream 4 Stream Dist 9 Dist Type Hide Non essential Columns 10 Amount 11 Species Total EJ Insert Custom Sheet 12 N2 g B 021g 14 H20 g G3 Add New Control 15 gt Show Controls Sheet 16 Stream 5 Stream Dist 17 Dist Type 18 Amount gt Insert Heat Loss 19 Species Total 20 H20 Se 83
116. eet is ready you should check that all the stream connections are going to the correct units The visual notation for the streams is as follows otarting point 2 no shape stream is an output of a unit Starting point white circle stream is a feed input to the simulation Ending point filled arrow stream goes to an input of a unit Ending point white arrow stream is an output of the simulation that does not go to any unit NNS S Fig 11 Example of a flowsheet with units and the streams connecting them NB There is no need to define the stream type as solids slurry or liquid water as required in HSC 7 HSC 8 handles all of the streams in the same manner regardless of the stream composition When the flowsheet is ready and you have checked it is correct the feed stream s can be defined Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 13 35 Lamberg 45 3 Stream Setup Defining the feed composition Feed Streams for HSC Sim minerals processing models are defined by using the Stream Setup tool To open Stream Setup v Right click a feed stream and select Define this stream with Stream Setup v When the stream content is already defined it can be modified at any time Open otream Setup by double clicking the stream The Stream Setup dialog Fig 12 consists of e Upper bar buttons e eft side Phases n
117. ents distributed to species NB When all the elements have been correctly distributed to the species the element balance on row 4 should show zero values for all the elements This ensures that all the atoms are conserved in the distribution unit Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Units utotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 8 12 Roine 41 4 2 Mixer Wizard If the unit operation does not include any reactions between the species then the species can be distributed directly to the output streams with the Mixer wizard For the Mixer wizard you do not need to specify the species for the Output sheet but you need to specify the measurement unit for the amounts Please also note that the Mixer wizard requires that the same measurement unit is used for all the streams both input and output The Mixer wizard option is found on the left hand panel Fig 12 Distribution in the wizard is specified using percentages for each of the output streams Fig 13 E Mixer Unit ERUNT File Edit Insert im Normal Distributions sheet A B C D E F G H I J K L U LV Ww A Convert to Equilibrium Mode 1 Input Wemewme g 4 Flags Input streams Value Units Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 5 kg Nm kmol kWh kwh kWh kmol kWh kmol kWh kWh kWh Dist Sheet Rows Visible 6 DD Show Distribution Sheet 7 300 00 0 06 2 81 0 00 104 99 62
118. es to contain 100 of the stream s silicon content fimi Shaft Furnace File Edit Insert Calculation Mode Normal Distributions sheet IA Convert to Equilibrium Mode 1 Convert to Mixer L gt Show Distribution Sheet e Hide Non essential Columns Dist Sheet Rows Visible Vi amp 3 Add New Control L gt Show Controls Sheet Insert Heat Loss 83 Insert Energy Feed mg Fig 14 DC23 v 100 A B C D J X Y AO BE CA CH DC 1 Distributions Elements C Fe N o Si 2 3 Total H Shift 4 Flags Balance kWh 256288 85 Balance 979 02 137483 73 0 99 52516 57 5 Input kWh 296465 61 Input 137483 73 0 99 57852 87 6 Output kWh 40176 76 Output 0 00 5336 30 7 K L V a 8 Process Gas Stream Dist 100 00 9 Dist Type i Rest 10 Amount 0 99 52516 57 11 Species Total 0 00 0 00 12 N2 g 13 O2 g 14 CO g 15 CO2 g 16 17 Hematite Pellets Stream Dist 100 00 9 22 18 Dist Type i Fixed Float i 19 Amount 137483 73 5336 30 20 Species Total 0 00 100 00 21 Fe203 22 Fe304 23 SiO2 Fixed Si 100 00 100 001 24 C Fixed C 100 00 25 ld 4 EH Input Output Dist Controls Model Fig 14 Carbon and silicon distribution in the pellets stream Copyright Outotec Oyj 2014 EA HSC 8 Sim Distribution Qutotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 12 22 Roine Iron is distributed between magnetite Fe3O4 and hematite Fe203
119. ess tree Fig 14 lists all the flows and amounts and if this summary is OK the final import can be started by clicking the green play button At the end of this import a log file popup appears in GaBi that informs the user whether the import was successful or not The log file can be closed without saving in GaBi i Import EcoSpold file rm EM No mapping scheme loaded Preview IOs Object list Mapping scheme 1 Inputs Flow Amount Unit Tracke Standard dexComment unit Nickel ore 1 5 Material resources Non renewable resources 5 59216200362 kg X Coke metallurgic Materials Intermediate products 0 34989767681kg X Limestone Materials Minerals 0 85296445228 kg X Air Material resources Renewable resources 0 12623534541kg Energy unspecific Energy resources 5 200188 10444kwh X 4 Outputs Flow Amount Unit TrackeStandard de Comment units Slag Hazardous waste 4 1980906238 ikg x Pig iron Fe carrier Materials Metals 1 kg D Flue gas Other emissions to air 1 6781503806 kg Dust containing heavy metals Hazardous waste 0 0450186566 1kg Energy unspecific Energy resources 0 1962162106tkwh Carbon monoxide Inorganic emissions to air 0 4652124642 kg Carbon dioxide Inorganic emissions to air 0 2562684662Skg Cancel Fig 15 Process summary presented during import as a check before clicking on the play button to complete the import The new pr
120. f minerals Codes e Bulk bulk composition cannot be edited when sized data is then calculated automatically e Unit e Size fractions mineral composition of the fractions Elemental Composition e Analyzed indicates if the value is analyzed thus it will not be updated based on the minerals Instead this is then the initial data for element to mineral conversion Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Hemes Pertti 14022 ORC J Lamberg 24 35 e Element list of all elements e Bulk bulk composition cannot be edited when sized data is then calculated automatically editable for Analyzed elements in the case of unsized data e Unit e Size fractions elemental composition of the fractions These are automatically calculated based on the minerals except if the element is marked Analyzed will be the initial data for element to mineral conversion 12 6753408131342 SSC EECHER EC SCC EC DEELT EE Unit 20 um 20 75 um 75 125 um 125 250 um Eie omn s 1 0686 2 8302731 3 78332431 1 992743339 3 0 py 2611407 21 564 25 276068 43 547916 21 89495501 HEEL ee ees aal else Te 11030068 5 rs N 4 k HI Mineral Composition Ta 8 c E orm 6 iH 1 analyzed Element Bulk Unit 20 um 20 75 um 75 125 um 125 250 um 2 Jo 078852 037 ag 131 ail pe 1284813 10 362 12 626341 21 4212403 10
121. fficiency Curve DLL Authors Antti Remes Rodrigo Grau Tails Thickener Thickener General Filter General DLL Outotec Finland Bin Description Flotation Cell DLL Select Model Recovery of minerals based on flotation kinetics Karra Screen Efficiency Curve DLL E ee Feed stream particles and liquid are separated to Mass Distributor DLL concentrate and tails Launder water inlet and gas Mineral Splitter DLL inlet outlet streams are optional MinPro To Hydro Converter DLL Perfect Mixer DLL Thickener General DLL Whiten Screen Efficiency Curve DLL Cancel Fig 43 Select Unit Models Once the models have been applied to the units the model parameters are next edited and viewed with the model editor as shown in Fig 44 The model input and output streams can be viewed their connection to the model inputs and outputs can be configured and controls for the models can be defined Setting up the Controls and Cell References between the units is described in sections 43 5 and 44 2 5 Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Outotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 30 35 Ball mill o x mn A e 1 P Gi w Li 6 Le A ria BS Model Help Parameters Input Output Controls Stream Enable Multiple Info Connections Windows Model parameters v Show all B LEX j D E F a Rosin Rammler EA GENERAL EA 3 y Name Value Value
122. fy the output streams Create a model a Distribution to output streams b Distribution to species within streams Create the controls Run the process model NOOR WD CO CO Copyright Outotec Oyj 2014 Qutotec Research Center Pori Lauri M enp Antti Hoine 42 1 Step 1 Draw the flowsheet EN HSC Sim 8 File View Select Tools Drawing Tools Window Help LJ BS H bed Select visualization v Re Main Process X a o ve 10 20 30 40 56 iD e Unit 1 ES EH 8 L1 l C3 S G a O b D 8 z a L s1 gi e R Page Page2 Pages Outotec C bar kWh HSC 8 Sim Distribution November 25 2014 Me x Bit BD gt E E om x Process Drawings General NameID Unit 1 Number Alias General o R x JCT Main Process Process Tree Log viewer Unit Icons 100 fl P Persist Tool P Snap to Grid 149 0 Fig 1 Draw unit distribution on the flowsheet First draw the flowsheet for the process Usually it is easiest to start with the units of the process Fig 1 You can draw a generic unit and select its model from the Unit Model Editor or simply draw a distribution unit by using the red unit icon Copyright Outotec Oyj 2014 Outotec un dM Research Center Pori Lauri M enp Antti 14022 ORC J 3 22 Hoine 42 2 Step 2 Draw the Streams on the Flowsheet E HSC Sim 8 Jo mJ x File View Select Tools Drawing Tools Window Help Lj amp cl b
123. ge briefly described in Fig 32 Fig 42 Many drawing options can be later edited from docking toolbar Properties after they have been drawn section 40 3 2 Hei Ia u Fig 32 Units and streams Select or Draw Units or Draw Streams see also section 40 1 b Fig 33 Calculations Simulate and give iteration rounds for calculations Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 21 26 Maenpaa Matti Hietala Jussi Pekka Kentala amp Select visualization iB B 2 18 1 8 Fig 34 Visualization Select or unselect visualization mode and select the stream property that is visualized The user can also change measurement units open the Stream Table Editor visualize stream connections add a header and copy the flowsheet picture to the clipboard using this toolbar CDI OO OG Spe Fig 35 Drawing tool With this toolbar the user can add shapes like an ellipse rectangle rounded rectangle pie and chord It is also possible to add a textbox E sep oma 2 Tz t fel RN Fig 36 Height and Width With this toolbar the user can make the size of the selected units or streams equal p Si d at ug Fig 37 Align With this toolbar the user can align selected units in many ways thus making it easier to draw professional looking flowsheets US E y gp gg Fig 38 Layers With this toolbar the user can edit pages and layers Fig 27 or
124. ght fast Light fast 28 M 4 H Input Output Diet Controls Model ak r Fig 28 Set the Total H balance as the target parameter The variable to regulate the heat balance can be set as the amount of coal fed into the furnace Copy the cell reference of the Coal stream s total amount Input D15 Fig 29 and paste it to the Value cell of the Heat Balance control Fig 30 EL Shaft Furnace oO X File Edit Insert Normal Distributions sheet B A B C DM E F eo H J A Convert to Equilibrium Mode E 1 Input SI TR Convert to Mixer 3 Distributions 1 A Flags Input streams Value Units Amounts Heat Content H Total 5 kWh kWt L gt Show Distribution Sheet 6 Nm h ee 8 ISRC Magnetite Ore 200 00 t h Heat Content H Total H Hide Non essential Columns 9 DST Temperature 25 00 C kg kWh kWh Dist Sheet Rows Visible 10 10 Pressure 1 00 bar 0 01 296381 3 11 Fix Total 100 00 wt 200000 00 40 60 987 03 0 01 296381 3 Controls SSS 12 Fe304 95 00 190000 00 36 75 820 60 0 01 254271 2t Add New Control 13 43 SiO2 5 00 10000 00 3 85 166 43 0 00 42110 1 14 b gt Show Controls Sheet SCH SRC Coal 100 dii at Content H Total H een e 057 EC i E Pressure 1 00 D 0 00 84 2 Insert Heat Loss 18 Fix Total 100 00 inni 0 00 84 2 3 Insert Energy Feed 19 C 98 00 Format Cell s 0 00
125. ght is calculated from the formula For mixtures use formula that gives average molecular weight and if you do not know the exact formula use formula that has correct molecular weight For example organic compound with average molecular weight of 350 g mol can be put to the database as C29 MPEG350 Note that the last character in brackets defines the phase so it cannot be any of the following characters a g s or You can add properties to the compound manually for example enthalpy kJ mol entropy J mol K heat capacity J mol K and density kg l For heat capacity you can fit data for different temperature ranges If you know the chemical formula for the compound the enthalpy entropy and heat capacity values can be estimated with H S and Cp estimates module Example Organic compound In copper solvent extraction you have unloaded reagent loaded reagent and diluent that are not found from the HSC database You know the density and molecular weight of the compounds This is one way how you add the compounds to the database Type the compound name to the variable list editor It will open the database editor automatically and copy the compound name to editor if compound is not found from the database Type the data for the compound name and density in units kg l C42H2 unloaded reagent 0 96 C42Cu loaded reagent 1 00 C14 diluent 0 79 If you know enthalpy entropy or heat capacity values you can add t
126. hem for the compounds After adding compounds to the database and the densities you can use these organic compounds in your model The density for the organic phase is calculated automatically from the fed data The compounds can be used in chemical reactions just like other compounds Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 4 15 Kotiranta 43 2 2 Divide the Species into Phases Divide the species into meaningful phases because only this will enable you to calculate phase properties like densities and compositions Fig 1 Species can be typed manually or they can be imported from the database A Type species formulae manually into enter species cells B Go to cell enter species click database button select species and click Import items button in Database Browser Specify the Variables Phase Measurement units of different phases e Gas Nm h t h kg h e Water Particles Organic Solid t h kg h Default phases are Gas Phase Water Phase and Pure Phase The user can change phase names and add new phases as well using the Modify button or delete phases using Remove Concentrate Concentration Measurement units of different phases e Gas Wt vol or ppm e Water wt 96 g l or ppm e Pure wt or ppm Mass Fraction To calculate mass fractions of the Water phase the user has to give
127. i Petri Kobylin Tuukka Kotiranta HSC 8 Sim Reactions Unit November 25 2014 14022 ORC J 10 15 4 Go to Control sheet cell C8 and right mouse click Paste cell reference 5 Give the tolerance of the calculation in cell C9 When the difference between the Set Point and the Measured value is smaller than the Tolerance the control is in balance and will not be calculated further 6 Type the name and the unit of measure in cells C12 and C13 optional T Locate the Variable cell from your active unit and select Copy cell reference 8 Go to Control sheet cell C14 and right mouse click Paste cell reference 9 Type Limit Min and Max in cells C15 and C16 a narrow numerical range speeds up the calculations The default Tolerance is A small tolerance increases the calculation time and a large tolerance increases errors Some 2 of the target value may be a good compromise The control will not be taken into account if the value is within the tolerance oim Controls have exactly the same limitations as real process controls for example If the target cell does not depend on the variable cell value the iterations will fail If an external variable cell is used there may be a long delay before the effect on the target value becomes visible In these cases a lot of iteration rounds might be needed to reach the set point This increases the calculation time Table 1 Information on the Control sheet Row 23
128. ial support for using old Sim 7 minpro Excel Wizard models and the user should be able to run calculations for the imported Sim 7 minpro Excel Wizards However the user cannot currently edit or make the Excel Wizards for the old minpro models If users want to edit their old mineral process models they should replace the old minpro Excel Wizards with the new DLL models Minor points oim 8 uses different Stream Tables than Sim 7 Because of this users cannot edit oim 7 Stream Tables in Sim 8 but they can make new ones using Sim 8 tools The visibility of the connected streams is forced on for input and output streams in oim 8 If there are any such streams hidden in the imported Sim 7 model they will appear in Sim 8 A few drawing objects like a B zier curve are not supported in the first version of Sim 8 In some rare cases Sim 8 does not recognize Sim 7 stream connections correctly Information about this will be given in the import log Afterwards the user should manually confirm the notified stream connections In Sim 7 the user had the possibility to encrypt some units This function is no longer supported in Sim 8 which means those units will not be loaded during the import External workbook references work differently in Sim 7 and Sim 8 When you import a Sim 7 model all external references are changed and will include REF at the beginning of the reference oim 7 used automatically safe division for all division operations i
129. imulation is started If the flowsheet contains more than one unit and the units are connected intermediate stream properties cannot be edited since these values are calculated see Fig 7 Sim Leaching x File Edit Insert View Tools Help hi 16 0 21 0 79 Variable List Editor A 6 Variables Sum i 8 H 1X Chemical Reactions Wizard 7 T Temperature 25 00 25 00 8 Pr Pressure S 1 00 1 00 E Insert Custom Sheet i ampum t h 416 60 00 10 49 10 H Enthalpy kWh 246798 99 223520 49 23278 49 LIN Volume m3 h 60 11 50 15 10 13 Q Adi New Contra 12 Ex Exergy l kWh 33512 47 28640 61 4681 93 13 Cp Heat Capacity kWh L3 Show Controls Sheet 14 Pig Gas Phase Nm3 h 10927 08 0 00 0 00 Bi eat Eas 15 H2O0 g Nm3 h 0 00 16 O2 g Nm3 h 2294 69 17 N2 g Nm3 h 8632 40 8632 40 18 Pia Water Phase t h 60 10 50 00 10 10 0 00 19 H20 t h 50 00 50 00 20 H2504 t h 10 10 10 10 21 Fe 2a t h 0 00 E 22 H a t h 0 00 23 SO4 2a t h 0 00 24 Pis Pure Phase t h 10 00 10 00 0 00 0 00 25 FeS t h 10 00 10 00 26 5 t h 0 00 27 Al Amount Phase 1 t h 14 06 0 00 0 00 14 06 28 A2 Amount Phase 2 t h 60 10 50 00 10 10 0 00 29 A3 Amount Phase 3 t h 10 00 10 00 0 00 0 00 30 V1 Volume Phase 1 m3 h 21 vi Volume Phase 2 m3 h 60 11 50 15 10 13 0 00 32 V3 Volume Phase 3 m3 h 33 D2 Density Phase 2 kg m3 999 80 996 95 996 95 996 95 34 F2 FesO4 Fe 2a 0 00 0 00 0 00 0 00 35 H H250
130. ineral model Each mineral is treated Copyright Outotec Oyj 2014 Typically 5 25 particles Typically 3 8 particles Typically 9 150 particles Typically 15 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 9 35 Lamberg separately by size This approach enables the simulation 300 particles of a full mineral processing circuit including crushing grinding classification and different kind of separation techniques like flotation gravity separation magnetic separation and dewatering e True particles model This is the highest level of modeling Typically 200 where particles treated in the process have been 15 000 measured with e g MLA and all of them or groups formed particles from them are treated in the process Hemember that if you go to a higher level approach you will need more data and better models 3 List the minerals present in the circuit Find their chemical composition and specific gravity If you do not know please ask a geologist or mineralogist or look for a mineralogical report 4 Find the chemical composition or mineral composition of the feed streams If you have only the chemical composition do the element to mineral conversion with HSC Geo together with the Sim Stream Setup tool 5 Find the flowsheet of the process or if it is a greenfield process consider possible alternatives and decide where to sta
131. inerals Processing Outotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 16 35 Lamberg Phase Total Amount d Solids flow rate 135 00 ith Fig 16 Setting the total solids flow rate and its measure unit In addition the total phase flows can be entered and the measure units changed in the properties panel on the right Fig 17 Properties zc Total Phases as 0 00 Liquid 4 18 Solids 135 00 Units Gas t h Liquid t h EE UR E d Bu kg h el it kg Je Solids Solids measurement unit Fig 17 Properties of total phase flows in the panel on the right The total flow rates are visualized in a bar graph indicating the amounts of solids liquid and gas flow rates Fig 18 Graphs Total Flow Kates Solids Fig 18 Total flow rate graph Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 17 35 Lamberg 45 3 1 2 Minerals Minerals can be added by selecting them from the HSC Geo mineral database or a new mineral can be created from scratch In both cases the element composition as well as the specific gravity can be edited freely The upper bar buttons for setting up the minerals are shown in Fig 19 Add Mineral Remove Create Elements from DB Mineral Mineral 7 Fig 19 Buttons for adding minerals from the database removing minerals creating new custom minerals
132. io 1 Chartsi X 2 Unit Name Unit 1 3 Variable Name Ore Feed 4 Measure Unit t h Teas are va ir 5 SETZ GET SET You can use s or 6 Cell Reference BE ET CH as shortcuts 8 Rounds per run 5 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 M 4 bl Scenario 1 d Fig 22 Specify the SET GET value for the variable After adding enough variables specify the parameter values for the SET columns add some charts and finally run the scenario Fig 23 Scenario editor J X H uy c nm ka r1 Pli e Le Lj E ER S a W Run chosen Run all New scenario Clone Delete selected Create new SET GET Delete selected Createanew Createa Editchart scenario scenarios sheet scenario scenario sheet data column data column chart tab new chart data 1 10 A B G D E F a t q 1 Scenario 1 Chatsi X 2 Unit Name Unit 1 Unit 1 Unit 2 Unit 2 3 Variable Name Ca Ore Feed Heat Loss 1 Heat Loss 2 Offgas 4 Measure Unit t h kWh kWh Nm3 h S SET GET See SET GET GET GET 6 Cell Reference 8 6828 019906 389 0789221 24031 02967 8 Rounds per rmn 5 i Heat Loss 1 9 Run 1 5 0 0 0 10 Run 2 e 0 0 0 11 Run 3 6 0 0 0 12 Run A 6 5 0 0 0 13 Run 5 7 0 0 0 14 Run 6 7 5 0 0 0 15 Run 7 8 0 0 0 Ore Feed t h 16 Run 8 8 5 0 0 0 17 Run 9 9 0 0 0 18 Run 10 9 5 0 0 0 19 Run 11 10 0 0 0 20 21 22 23 24 25 26 27 28 29 af ts Feed Wi M 4 gt H Scenario 1
133. ions Partides Others Import Cooling Tower Nm3 v Unit 1 Model Type Mode Hydro Empty Reactions Hydro unit DLL Type Code Cooling Tower Nm3 t Excel Technology Cooling Tower tph Excel Sub Technology Filter Excel Authors Tuukka Kotiranta Thickener aL Excel Outotec Finland d E Thickener wt Excel Description Thickener gL with OF solids Excel Select Model thickener wt with OF solids Excel WIZARD FILE Cooling Tower xls WIZARD SHEET Cooling Tower Nm3 VERSION 19 October 2012 for HSC Sim 7 1 This calculates needed air feed to the Cooling Tower according to the given temperatures and relative humidity NOTE You need following rows in the variable list T Pig O2 a N2 g H20 a Pia H20 and enthalpy rows P3 is for solids Cancel Fig 20 Select Unit Models window Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Lauri 14022 ORC J 14 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 2 3 Scenario Editor HSC 8 Sim Common Tools December 10 2014 The Scenario Editor lets you run your process model with different operating parameters and see how they affect process variables The calculated results can then be collected in the charts To use the Scenario Editor first select the processing parameter that you want to regulate and copy its cell reference from the appropriate cell Next open the Scenario Editor and paste the cell reference in the first SET GE
134. iption Converter for MinPro to Hydro unit Cancel HSC 8 Sim Species Converter Units Qutotec November 19 2014 Research Center Pori Lauri M enp Matti 14022 ORC J 3 5 Hietala 47 2 Setting the conversion parameters The conversion from the element distribution of the minerals to chemical species requires a list of species These species are entered on the Parameters page in the unit under the Species heading Fig 2 Fig 2 Enter the species that can be formed Users can also set optional parameters for the conversion to adjust the conversion by target values and weighting coefficients These optional parameters are entered in the mineral species matrix Fig 3 If a species does not have any specific target values then 1 is used as a default parameter Mineral to species conversion targets and weights 5 GO d d 0 1 1 4 1 E 1 15 0 100 0 1 1 E 1 1 0 0 0 100 1 1 E 1 E 1 1 E 1 A 6 1 1 A A A Fig 3 Set target and weight coefficient values to adjust the conversion Finally when all the necessary parameters are set run the model to get the conversion results Copyright Outotec Oyj 2014 HSC 8 Sim Species Converter Units utotec November 19 2014 Research Center Pori Lauri M enp Matti 14022 ORC J 4 5 Hietala 47 3 Conversion results After the model is run the conversion results can be checked from the Output page to see the ac
135. ist Editor LA B C D E F t 1 Wizards id 1X Chemical Reactions Wizard p Ed d e RI insert Custom Sheet 6 Variables sum Solution Offgas 14 Pig Gas Phase Nm3 h 100 00 15 H20 g Nm3 h 100 00 E 16 Zl 100 amp 9 Add New Control e 8 Nm3 h 199 09 17 N2 g Nm3 h 100 00 L3 Show Controls Sheet 18 Pia Water Phase t h 100 00 ER ERE 19 H20 t h 100 00 20 H2504 t h 100 00 21 Fe 2a t h 100 00 22 H a t h 100 00 23 SOA 2a t h 100 00 24 Pis Pure Phase t h 100 00 25 Fes t h 100 00 26 5 t h 100 00 37 38 33 Se l M 4 Ek HI Input Output Dist Contri m Fig 5 Dist sheet of the Leaching unit Setting Controls for the Process Chapter 43 section 43 5 Controls can be added removed and seen using quick links on the left column see Fig 6 In the first control sheet the HSO concentration after leaching is set at 1 g l of solution by calculating the input amount of H25O see Fig 6 and Table 1 In the second control sheet the cooling requirements heat balance of the highly exothermic leaching process are set to 0 by calculating the cooling water amount NB Insert an extra sheet in the Cooler unit see Fig 7 to Fig 10 and Table 2 Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta Bim Leaching File Edit Inset View Tools Help Z Variable List Editor Wiards oooO O Al Chemical Reactions Wizard Tools Ga I
136. it I 3 3 Info Connections Windows NameID Species Converter Unit s 2 Species Converter Unit aaen meum CSS P Ton EE ES o 3 Mineral Stream cvm E lodel parameters X O a e egen C WS Show all SubTechnolog 5 e 3 Value Value in use Unit Limits Description IS x O f j D Run time parameters 4 Output temperature 298 15 298 15 Kelvins gt 0 Temperature of H Page Pagel Ahe m Variables that can be set by user 5 Species list Layer Layer 0 Default E Variables that can be read 6 Visibility 2 fil All variables Name Label True TIE To Distribution Unit User defined calculations Y Distribution Unit im E i d r d og viewer Ds x a les 1 1 1 1 1 g ef Output Stream 1 4 A 1 EI TAA E 1 1 1 1 1 Connecting Stream 1 as a source to tH t g z x S Connecting Unit 1 as a target of the re fal 1 4 a d d E d Flowsheetunit PrepareCalculations 1 1 E a 1 amp Calculating static round 1 ga E 1 1 d 1 1 4 44 Process unit CleanUpCalculations M D 1 E 1 1 1 S 1 E 1 1 1 2 19 3306133 0 01849528 F 8 67165054 1 63E 07 E 25 4948515 0 01305635 x 21 4755405 0 00390283 0 0149447 5 0102E 07 S 0 02988941 3 8129E 07 11 6309528 0 02887314 S 0 0026475 0 02254084 13 3321972 0 0253424 0 0092325 0 0092325 T m j i 0 00747998 0 3 Jo uu m Hide all V warnings D Finderrors IS Pagel X Page Page lt unl m Process Tree Log viewer Unit Icons 2012 Ou
137. it for the total amount is set next to the total amount value Fig 3 Please note that the selected measurement unit t h kg h or Nm h will determine the composition percentage unit wt or vol Stream 1 Temperature Pressure Total Stream 1 Temperature 25 00 un Ed Pressure 1 00 YS Total 0 00 vol 96 Fig 3 Measurement unit for the total amount The temperature and pressure values can be changed from the cells below the total amount Fig 4 Stream 1 50 00 Nm h Temperature 75 oo c Pressure 1 00 bar Total 0 00 vol Fig 4 Temperature and pressure of the stream Species and Composition The species of the stream are entered in the white cells below the stream s header rows Fig 5 Stream 1 50 00 Nm h Temperature 75 00 C Pressure 1 00 bar Total 0 00 vol N2 g 072 H20 g Fig 5 Enter species in the streams Once all the species have been entered then the composition can be specified Fig 6 Please pay attention to the composition percentage units Copyright Outotec Oyj 2014 Qutotec Research Center Pori Lauri M enp Antti Roine HSC 8 Sim Distribution Units November 25 2014 14022 ORC J 4 12 Stream 1 50 00 Nm h Temperature 75 00 C Pressure 1 00 bar Total 100 00 vol 3 N2lg 75 00 O2 g 20 00 H2O0 g 5 001 Fig 6 Composition of a stream The above steps need to be repeated for all of the input streams which act as raw materia
138. kWh kWh kmol kWh kmol kWh kWh e Dist Sheet Rows Visible 6 3 Show Distribution Sheet 7 acd 0 00 0 00 0 00 0 00 0 00 0 00 O 8 SRC Stream 1 f Amounts Heat Content H Total H Heat Cont H TotH Chem Ex Phy 9 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh kmol KkWh kmol kWh kWh Hide Non essential Columns 10 Pressure 1 00 bar 0 00 0 00 11 Fix Total 0 00 vol 0 00 0 00 0 00 0 00 0 00 0 00 0 89 Insert Custom Sheet 12 E se 13 SRC Stream 2 Amounts Heat Content H Total H Heat Cont H TOt H Chem Ex Phy 14 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kWh ZS Add New Control 15 Pressure 1 00 bar 0 00 0 00 L2 Show Controls Sheet 16 Fix Total 0 00 vol 0 00 0 00 0 00 0 00 0 00 0 00 0 17 na 18 SRC Stream 3 Amounts Heat Content H Total H Heat ContH Tot H Chem Ex Phy Insert Heat Loss 19 DST Temperature 25 00 C kg Nm kmol kWwh kWh kWh kmol kWh kmol kWh kWh 20 Pressure 1 00 bar 0 00 0 00 deel e 21 Fix Total 0 00 vol 96 0 00 0 00 0 00 0 00 0 00 0 00 o 22 M 4 gt gt I Input Output Dist Controls Model 4 j Fig 1 Distribution unit editor Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Units Qutotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 3 12 Roine 41 2 1 Total Amount Temperature and Pressure 41 2 2 The total amount of the input stream is specified in the cell next to the stream name Fig 2 The measurement un
139. kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kWh kWh 17 Pressure 1 00 bar 0 00 209 00 Heat How 18 Fix Total 100 00 wt 1000 00 0 16 5 40 0 00 209 00 1136 92 0 00 Insert Heat Loss 19 PbS 80 00 800 00 0 11 3 34 0 00 93 26 0 00 27 89 706 03 om 20 ZnS 20 00 200 00 0 05 2 05 0 00 115 73 0 00 56 39 430 89 0 00 430 89 Sai Insert Energy Feed 21 22 SRC Input 3 225 00 kg h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 23 DST Temperature 25 00 C kg Nm kWh kWh kmol kWh kmol kWh kWh kWh 24 Pressure 1 00 bar 0 00 80 16 25 Fix Total 100 00 wt 225 00 0 00 80 16 608 30 0 00 608 30 26 FeS2 5 00 11 25 0 00 0 09 0 00 4 64 0 00 49 51 37 16 0 00 37 16 27 FeS 90 00 202 50 0 04 2 30 0 00 63 98 0 00 27 78 565 39 0 00 565 39 28 FeO 5 00 11 25 0 00 0 16 0 00 11 53 0 00 73 63 5 75 0 00 5 75 29 4 4 gt H Input Output Dist Controls Model d m Fig 14 Using the Equilibrium wizard fimi Equilibrium Unit mmn File Edit Insert v CalculationMode P zi Gibbs Equilibrium mode using Gibbs A B C D E E G H J z IR Convert to Normal Mode B 2 EQUILIBRIUM MODEL Sim uses this model if flag Input A5 Gibbs exists j Convert to Mixer 3 Assumption Phases Output Sheet Streams 4 Temperature 5oo oo c 5 Pressure 1 00 bar L Show Gibbs Sheet 6 7 OUTPUT SPECIES AC Equilibrium Amounts Equilibrium Amounts Equilibrium Composition 8 Mixed OutputGas 5 89576
140. l Chemical Composition Bulk Material Sized Particles Flotation Flotation Physical Physical Separation Separation Ele Comminution EIC MLA Based Particles Modeling Fig 5 Levels of modeling detail examples of modeling application areas 45 1 3 Minerals processing flowsheet structure in HSC Sim The HSC Sim process flowsheet consists of Units and Streams Fig 6 When the modeling is based on particles a Stream consists of Solids and Liquid and Gas phases although the gas phase is rarely set for a mineral slurry feed stream The liquid may have soluble components but in minerals processing these species are often ignored i e the liquid water only has density as a parameter Solids consist of particles which are composed of minerals Minerals have properties such as chemical composition In HSC oim all the properties of solids are calculated from particle flow rates particle compositions and mineral properties For example copper does not behave independently in the process but is always bound to a mineral or minerals that occur in particles which vary in size and composition
141. l inputs If an input stream is not a raw material input but a stream from another unit then the properties of this stream cannot be edited on the Input sheet of the destination unit The energy feeds or heat losses can be entered in the streams using the buttons in the left hand panel Fig 7 E Distribution Pyro Unit Jm x File Edit Insert v ENERGY FEED Normal Distributions sheet A B c DB f ie lH 3 Xx amp o wb A Convert to Equilibrium Mode 5 kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kWh kWh 6 1A Convert to Mixer 7 68 15 50 01 2 51 0 83 18 70 0 93 289 43 290 Stream 1 50 00 Nm h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exe N 9 DST Temperature 75 00 C kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kWh kWh Dist Sheet Rows Visible 10 Pressure 1 00 bar 0 91 6 58 3 Show Distribution Sheet 11 Fix Total 100 00 vol 63 15 50 00 2 23 0 91 6 58 0 86 287 49 288 12 N2 g 75 00 46 87 37 50 1 67 0 68 0 68 0 40 0 40 0 33 44 01 44 E 13 O2 g 20 00 14 28 10 00 0 45 0 18 0 18 0 AT 0 AT 0 49 11 90 12 Hide Non essential Columns 14 H20 g 5 00 2 01 2 50 0 11 0 05 7 44 0 47 66 71 0 03 23158 231 15 Q Insert Custom Sheet 16 SRC Stream 2 5 00 kg h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exe 17 DST Temperature 10 00 C kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kWh kWh 18 Pressure 1 00 bar 0 09 22 12 K Add New Cont
142. l kWh kWh kWh L gt Show Distribution Sheet 6 Nm h 7 Wh 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 8 SRC Magnetite Ore s Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 9 Hide Non essential Columns 9 DST Temperature 25 00 C kg Nm kmol kWh kwh kWh mol kWh mol kWh kwh kWh e Dist Sheet Rows Visible 10 Pressure 1 00 bar 0 00 0 00 E 11 Fix Total 0 00 vol 96 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 12 Pack WE DEE ET Add New Control 13 SRC Coal Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exergy 14 DST Temperature 25 00 C kg Nm kmol kwh kWh kWh mol kWh mol kWh kWh kWh en renee 15 Pressure 1 00 bar 0 00 0 00 Insert 16 Fix Total 0 00 vol 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 17 BE EEN Insert Heat Loss 18 SRC Air Amounts Heat Content H Total H Heat ContH Tot H Chem Ex Phy Ex Tot Exergy Insert Energy Feed 19 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh mol kWh mol kWh kWh kWh 20 Pressure 1 00 bar 0 00 0 00 21 Fix Total 0 00 vol 96 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 22 M 4 gt MM Input Output Dist Controls Model d Fig 5 Raw materials on the Input sheet You can open Unit Editor by double clicking the unit icon on the flowsheet The raw material streams can be found on the Input sheet At the beginning these streams are empty opecies can be typed into streams manually Shaft Furnace o File Edit Insert D8 Y 200 Norm
143. l lead to material balance errors since the missing species will not be copied to the output sheet Copyright Outotec Oyj 2014 Outotec HE Mm Research Center Pori Petri Kobylin Tuukka 14022 ORC J 7 15 Kotiranta 43 3 1 EU Leaching ell ee File Edit Insert View Tools Help _Signal_1 v ModellE10 Model D 10 5 variable List Editor A B C D E F G H l J K DE DF DG DH 1 MODEL 2 Al Chemical Reactions Wizard WIZARD Chemical Reactions CHEMICAL REACTIONS insert Custom Sheet 6 Phases Species Total Total Total 7 IE Temperature GE 0 00 0 00 H a O2 g Fe 2a S 8 Pr Pressure bar 0 00 0 00 2 00 4 00 1 00 2 00 9 JA Amount t h 84 16 84 16 102 38 204 75 51 19 102 38 102 38 102 38 G3 Add New Control 10 H Enthalpy kWh 246798 99 254763 42 7964 431 9 00 0 21 1 64 5 72 3 28 1 84 gt Show Controls Sheet 11V Volume m3 h 60 11 55 62 H a SO4 23 b gt Unit format 12 Ex Exergy kWh 33512 47 25999 19 S 2 00 1 00 13 Cp Heat Capacity kWh 0 00 0 00 205 91 102 95 14 Pig Gas Phase Nm3 h 10927 08 9779 74 0 21 9 89 15 H20 g Nm3 h 0 00 0 00 16 O2 g Nm3 h 2294 69 1147 34 1147 34 17 N2 g Nm3 h 8632 40 8632 40 18 P2a Water Phase t h 60 10 67 45 19 H20 t h 50 00 51 84 1 84 20 H2504 t h 10 10 0 00 10 10 21 Fe 2a t h 0 00 5 72 5 72 22 H a t h 0 00 0 00 0 00 23 SO4 2a t h 0 00 9 89 9 89 24 P3s Pure Phase t h 10 00 4 28 25 FeS t h 10 00 1 00 9 00 26 S t h 0 00 3 28 3 28 27 A1 Amount Phase 1 t h 14 06
144. lance H j Fig 19 Unit balance sheet of the report file Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools Qutotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 13 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 2 2 Select Unit Models The user can choose different models for the units The Select Unit Models window can be opened from the Tools menu or by right clicking if the cursor is on top of one of the units see Fig 20 On the left side of the window is the list of units on the flowsheet In the middle part the user can select a unit model from the Reactions Distribution Particle and Others sheet and in the HSC8 update also Import own unit models Double click the unit to select it and then click OK Most of the units are dll type but there are still some Excel Wizards available for the Reactions units If Excel Wizards are chosen the user needs to check the stream names Information about the units can be found on the right side of the selector window Empty Reactions or Distributions units are the same as R and D unit Icons on the main flowsheet DrawBar see Fig 1 In the HSC8 update that comes later there will be instructions on how users can make their own dll units Chapter 50 User made units can be imported using the import sheet E Select Unit Models x Select unit Select model Double Click to Select Model Properties v Unit Active Model Reactions Distribut
145. lated in a similar way by setting the number of calculation rounds and clicking Simulate Fig 45 If some errors or warning occur please refer to Chapter 40 section 40 4 for how to solve them 45 6 3 Modifying feed composition The feed composition can be edited by selecting from the HSC Sim menu bar Tools gt Old Mineral Setup visible only for imported models In Mineral Setup Fig 52 you can Change the element wt in each mineral Change the mineral SG Change the water SG Change the feed rate t h Change the particle size distribution wt Change the mineral composition by size Change the fraction amounts of floatability classes SON SS ON AUN But you cannot e Add remove or rename minerals e Add or remove elements e Change the number of size classes e Change the number of floatability classes since they affect the variable list content which can be edited only in HSC 7 for the old file format models Copyright Outotec Oyj 2014 Qutotec HSC 8 Sim Minerals Processing November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 35 35 Lamberg E Mineral Setup e x Update Discard Minerals Feed and Close and Close Al v E S E BE 5 5 TS F G H I J K L ai 1 IHsc Sim Mineral Based Model Set up File Global Mineral Set up EA Liquid name Water Ider ification is done Ba Liquid SG 0 9982
146. ll refe Insert Insert Delete Delete II Equal width Format T Paste Mo ree row column row column uj Equal wi Cells Al T EE B B LZ a Fig 7 Table editor remember to uncheck Size lock when inserting rows and columns E Stream Table Editor es O X Available variables Amount Phase 2 t h Amount Phase 3 t h Amount t h Density Phase 2 kg m3 Enthalpy kWh Exergy kWh FeS5O4 Fe 2a Gas Phase Mm3 h Gas Phase t h H2504 concentration g l H2504 HI teil Heat Capacity kWh Pressure bar Pure Phase t h Temperature C Water Phase t h d P mA X Amount Phase 1 123 45 vi Check all the stream tables visible View mode Column 1 Color Mame value and unit Name and value jMame value and unit Compact in 1 column Compact in 2 columns OK s sei C0 0 255 255 255 Visible variables Amount Phase 1 t h dh Column 2 color 70 255 255 255 Number Format 0 00 Cancel Fig 8 Stream tables editor for adding stream tables to the flowsheet Add and remove variables by double clicking Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools Qutotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 6 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 1 5 Editing a flowsheet sometimes the user wants to edit a flowsheet later and add new units Adding a new unit Unit 3 in the middle of a stream Stream 1 connected to two u
147. ls Processing Outotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 26 35 Lamberg A B C D F T Analyzed Element Bulk 5 Ed Cu 0 78852 2 26 Fe 12 84813 9 6 10 362 jelementto mineral p o 38 13627 96 41 203 5 s 147547 9 ug 145 Si 33 47239 36 164 33 605607 24 6192 k Elemental Composition Fig 36 Analyzed elements not calculated from minerals but updated after element to mineral conversion B Setting element composition minerals are calculated Firstly select the analyzed elements Fig 36 these are the initial values for element to mineral conversion The conversion is done using HSC Geo in its Modal Calculations tool To open HSC Geo for modal Element to calculation click the Element to Mineral button The Modal Mineral Calculations dialog shown in Fig 37 will open Compos The Modal Calculations tool indicates the selected elements in the periodic table and lists the minerals included in the Stream Setup The calculation procedure is described in Chapter 84 in brief the steps are Select the mineral s for calculation round 1 Select the elements s for calculation round 1 Add new calculation round s using the Add Round button The last round is practically always marked Sum 100 thus that mineral is to be the remaining gangue material All the calculation rounds are then performed sequentially with the selected meth
148. m has a Feed 2 HSCStream separate file to describe the Feed N HSCStream particle feed composition 45 1 1 Before starting to create a simulation model Before starting to build a process for simulation you should collect all the relevant data of the process According to the data and your aims you should 1 Decide the level of detail you want to have in the drawing and simulation els it necessary to draw all the existing units e g pump sumps or could the circuit be simplified without losing any essential information e t is a good idea to draw a draft of the flowsheet on a piece of paper That will help you to position the units correctly 2 Decide the level in terms of particles The possible levels from the lowest least information to the highest are a Sized model without composition Typically grinding circuits are modeled like this The chemical and mineral composition of the input e g ROM is identical to the output e g flotation feed and the main interests are in flow rates and the required energy b Unsized mineral model Each mineral is treated separately but all the size classes are treated together Typically a simple flotation model is like this C Unsized floatability components model Each mineral is divided into 2 3 floatability classes i e fast floating slow floating and non floating or several 20 different classes of floatability distribution e g Klimpel model d Size by m
149. n November 25 2014 14022 ORC J Step 7 b Distribution to Species within Streams Eu Shaft Furnace File Edit Insert Pyro Calculation Mode Normal Distributions sheet A Convert to Equilibrium Mode IR Convert to Mixer L gt Show Distribution Sheet e Hide Non essential Columns Dist Sheet Rows Visible GJ Add New Control L gt Show Controls Sheet amp 9 Insert Heat Loss Insert Energy Feed Al X A B C D J X Y AO BE CA CH DC 1 l Distributions Elements C Fe N o Si 2 d Total H Shift 4 Flags Balance kWh 296465 61 Balance 980 00 137483 73 57852 87 5 Input kWh 296465 61 Input 980 00 137483 73 57852 87 6 Output kWh 0 00 Output 7 a 8 Process Gas Stream Dist wt 100 00 100 00 9 Dist Type 4 Rest 1 10 Amount kg 0 99 57852 87 11 Species Total 12 N2 g 13 O2 g 14 CO g 15 CO2 g 16 17 Hematite Pellets Stream Dist 18 Dist Type 19 Amount 20 Species Total 21 Fe203 22 Fe304 23 SiO2 24 c Fixed C 25 M 4 H Input Output Dist Controls Model Fig 13 Distribution of elements to species 11 22 EA In the Hematite Pellets stream it is easiest to start with carbon C and silica SiO2 For carbon atoms there is only one species C so this species can be assigned to contain 100 of the streame carbon content Similarly you can fix the silica amount by assigning the species to the element Si and setting the speci
150. n RNENSE SEESE 45 1 2 Levels of modeling detail 45 1 3 Minerals processing flowsheet structure in HSC Sim 45 14 ASC SIM MME SITUCIFO rtt tege 45 1 1 Before starting to create a simulation model 45 2 Drawing a flowsheet nennen nnns 45 2 1 Unts dnd UhlL CONS siesta tuii e he Roper e proe aa erae Sax urs eror n eek Ernte es 45 2 2 Connecting streams esssessssssssssseeee nennen nennen nnn nnn 45 2 3 Checking the flowsheet 0annnnnnannnennennnennnnnnnnnnnnnnnnnnnnnnrnnnnresnrennenne 45 3 Stream Setup Defining the feed Gomposton 45 3 1 Solids feed 43 Di TOA SONAS RNC Em ae NS e E 45 9 E 45 9 NEE al Ed de E e ucosc edt eret ee ee ne ener neal eee er eee eee 45 3 1 5 Mineral and elemental COMPOSITION cccccceeeeseeeseeeeeeeeneeeseeeeaeeeeees Ase COUTO E E AS FOC a E a 45 4 Selecting unit models essssessssessssessseeeee nennen nennen 45 5 Run simulation and view the results cccccccceccceeceeeseeeseeeseeeeeeeeeeseeeeaees 25 5 EE 45 5 2 Visualization tables graphs ocenanosg 45 6 Opening an HSC 7 flowsheet in HSC 8 45 6 1 Conversion from HSC 7 to HSC Giormat eese 45 6 2 Simulating the floweheet 45 6 3 Modifying feed composition nnannnannannnnnnnnnoennsernnnnnnnrrrrrnnresnrrnnenni 45 6 4 Editing model parameters and reloading the unit models
151. n the workbook This meant that for example 0 0 did not give an error as the answer Sim 8 adds the safediv function to division operations oim 8 will change the sheet names of the workbook if the sheet contains illegal characters like Copyright Outotec Oyj 2014 Qutotec HSC 8 Sim Distribution Units November 25 2014 Research Center Pori Lauri Maenpaa Antti 14022 ORC J 1 12 Roine 8 8 B 8 H 41 Sim Distribution Pyro Units E HSC Sim 8 JE JC x File View Select Tools Drawing Tools Window Help amp i iei Select visualization H e ET i gt il 4 Main Process X O ff x o mu 30 wi 70 80 30 Process Drawings u General CH me istribut f NameID Distribution Pyro U iS 3 Number Alias E E m t c Stream 1 Senat I Value L1 etri P SS General e Distribution Pyro Unit Ce Stream 5 Stream 2 F 5 2 Value D fp x oO Value ee i He E a i E te Main Process I Bl Distribution Pyro Unit wl Stream 1 og Stream 2 Stream 3 wll Stream 3 f Stream 4 Value f Stream 5 2b je z e D P 8 m m emm p erh L u z Page Page2 Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 100 V Persist Tool P Snap to Grid 163 24 The Distribution unit also known as the Pyro unit is a basic unit type in which output species are formed based on the element distribution This distribution can be defined
152. nces in this table copy cell reference from the unit sheets and paste cell reference in the table see Fig 6 and Fig 7 The user can also insert stream tables by clicking the Stream Table Editor icon which will open the editor where the user can add variables by double clicking A visible variable list can be sorted by dragging the variables up and down in the list see Fig 8 The user can check which stream tables can be visible or invisible in the editor or does that later from View Menu stream tables show hide all EL HSC Sim 8 Ip ji File View Select Tools DrawingTools Window Help amp A RM Select visualization zi Fig gt i MainProcess X 0O 4 X Du n n T saan vam 2 am um me ech in e mm A T T xt T ae L1 E i hin 1 ii i Process e Unit 1 Unit 2 ES Input stredm Stream 3 O Value Value 4 e q x gt B Unitsby Type Search for units 9 C n 3 Page Page2 Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 100 H W Persist Tool W Snap to Grid 163 34 Fig 6 Table added to the flowsheet Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Lauri HSC 8 Sim Common Tools December 10 2014 14022 ORC J 5 26 Maenpaa Matti Hietala Jussi Pekka Kentala Bim Table 1 Itm ix d Cut gl Copy cell reference pore TT Equal height ES CU Copy Sg Wi Size lock 25 Paste ce
153. nits Unit 1 and Unit 2 is explained here First draw a new unit Unit 3 and connect Stream 1 from Unit 1 to Unit 3 Then add a new stream Stream 2 which starts from Unit 3 and ends at Unit 2 see Fig 9 Fig 11 Information in Unit 1 and Unit 2 is automatically updated so the user only needs to make changes in Unit 3 and Stream 3 to run the simulation EL HSC Sim 8 DCH BE Ele View Select Tools Drawing Tools Window Help L ES HR Select visualization BSI ZI EID gt 7 Main Process X ES 2 4 3 40 E Co K WE Unit 1 Unit 2 s F 2 stream 1 c value b Ld z T o d II Sie 7 Outotec C bar kWh 100 A Si v Persist Tool V Snap to Grid 139 37 Fig 9 Adding a unit to a stream between two units starting situation Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J Maenpaa Matti Hietala Jussi Pekka Kentala Drawing Tools Window Help Select visualization 7 26 JL m JLx J File View Select Tools Drawing Tools Window Help O ES H ki E Select visualization stream 1 stream 2 Value Value Fig 11 Adding a unit to a stream between two units final situation Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Lauri Maenpaa Matti Hietala Jussi Pekka Kentala December 10 2014
154. nsert Custom Sheet Controls 1 amp 9 Add New Control Remove Control L2 Show Controls Sheet gt Unit format X Min Limit C15 X Max Limit C16 GA jak j a C14 kA E i ja pu de a RJ B Ba E l kA Oe Whe O u i 24 M 4 MI Output Dist Controls 1 Fig 6 Controls sheet of the Leaching unit 1 100 A e 14022 ORC J InputlF20 B TARGET NAME Process unit Measurement Unit Set Point Measured Tolerance X VARIABLE NAME Process Unit Measurement Unit Value X Min Limit X Max Limit X Max Step CONTROL METHOD Active Iterations Max Limit Operation Table 1 Data for controlling the HSO concentration after leaching Row name Cell Filled value or formula Set point C7 HSC 8 Sim Reactions Example November 25 2014 Acid conc g l 1 00 1 00 m Acid feed Static OWN 10 Robust slow Po Desired H SO concentration g l Measured C8 Output E36 Measured H2SO concentration g l Tolerance C9 Tolerance for concentration Value C14 Input F20 H2SO input to the process t h H Minimum amount for H SO input Maximum amount for H SO input Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta Ele Edit Insert View Tools Help E3 Add New Control 2 Show Controls Sheet Lex Unit format pum Cooler File Edit In
155. ocess is available in GaBi Processes under the HSC folder This HSC Sim generated process can now be used in the new LCA plans together with all other Gab processes functionality and an impact assessment performed as shown in Fig 17 Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J Peltomaki A ossi 6 14 15 Database Edit Extras View Help EA E kb Object hierarchy Naton Name Type Sm QA D Source Group Last change 1D Nickel Pig Iron Smelting Electric Furnace DB Process EP Deposal Object Edit View Help Szeen Jhi p Gis aea E gt T eens Name ID Nickel Pig Iron Smelting d Den Parameter P OFLA Parameter Pormda P Outotec PSF FO model pyrometalurgy emir P Perce ne amp tn amp tco eur iewe Documentation d Industry data Completeness No statement emm Inputs IP Recovery Mow BO Repairing 2 Coke metallurgic Intermediate products WO Transport 4 Energy unspecific Energy resources FO Utireton A Limestone Minerals WP version 2005 2 N ckel ore 1 5 Won renewable resources d Verson 2011 BP Ae Renenable resources d Version 2012 i Fows A Quenttes W Units User Contacts teuer 2 Carbon dioxide Inorganic emissions to air X Glabs parameter alf Energy unspectfc Energy resources Reference Citation alf Fue gas Other emissions to a D Caper example 2012 C ProgramData PE Intemationa Ga8
156. od when you click Calculate v When mineral composition calculation results are satisfactory they are brought to Stream Setup by clicking Update and Close NN NON S Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 2 35 Lamberg Modal Calculations a x l Modal Calculations l ie ES Export Eo E view equations e O STi E BR mee Ipde Discard Data Source Rules Result Calculate A import Define o Reset Copy mineral ose and Close Dry minerals matrix Calculation Error Estimation MM MEN lt j Data Source CS Element SHIFT SS p Phase Element ger D EE T Modal Calculations We WG e eer Ce E pe pe Ee Se GELEET 2 Export Minerals Phases and Elements per Rounds A E Define Be Round 1 s E Add Round 6 Remove Round p Phases Elements Chalcopyrite D un Pyrite O e Quartz H 9 4 C Sum 100 K gi Method l o Least Squares LS weighed Least Squares WLS LA Non negative Least Squares NNLS Weighed non negative Least Squares WNNLS 45 3 2 Fig 37 HSC Geo Modal Calculations When the element to mineral calculation with HSC Geo is ready the results are seen in the otream Setup Composition view Fig 38 Now the tooltip of the Analyzed values shows the original assay value
157. of modeling detail Before starting to build up HSC Sim minerals processing models it is worth considering how much detail is required what background data are available and what type of unit models are available with what level of detail Fig 4 illustrates how the feed material can be defined and thus how the unit models should be capable of handling stream compositions In addition to increasing the level of detail the number of particles transferred between the units increases With large simulation models this might have impact on the simulation calculation speed especially in the case of dynamic simulation Also quite often increasing the modeling details means increasing the time needed to build up and parameterize the simulation model Fig 5 lists some of the minerals processing application areas where different details of modeling are typically applied REESEN No Composition Bulk Sieved Chemical Composition Bulk Assays Sized by Assay Liberated Particles Bulk Assays Non Liberated Particles M O R E D E T A Mineral Composition MORE DETAILS Fig 4 Levels of modeling detail required background data Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing utotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 7 35 Lamberg sized LL ae No Composition Simple Material th Crushing Balance Grinding Screening Cyclones Etc Minera
158. ogy General Comment Location Location v Location Comment Developer Author Date 26 9 2014 v Version Number Cancel OK Fig 16 The user can add Process Information to this sheet LCA Evaluation see Chapter 49 Mass Balancing see Chapters 51 and 52 Reports see section 40 2 1 Select Unit Models see section 40 2 2 Scenario Editor see section 40 2 3 Show the process tree see section 40 2 4 Errors in flowsheet shows possible errors in the flowsheet po c QU oe eh EL HSC Sim 8 mJ x File View Select Tools Drawing Tools Window Help au ll Process Information zB m P E C Main Process LCA Evaluation on x Igel Bas Mass Balancing Mass Balancing D Reports Reset Mass Balancing We Select Unit Models Pap Scenario Editor rna x Show process tree gt EB Units by Type v Search for units 4 4 m TE Errors in flowsheet Lu LI Ej Page Pages Pages Process Tree Log viewer Unit Icons 4 Outotec C bar kWh 100 j vl Persist Tool v Snap to Grid 58 3 Fig 17 Tools menu options Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools utotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 12 26 Maenpaa Matti Hietala Jussi Pekka Kentala 40 2 1 Reports A summary of flowsheet results can be saved and printed here There are two pages in this report sheet
159. on method slow Simple direct Increases X value when Measured value is too small The step used can be specified in X max step Simple reverse Decreases X value when Measured value is too small The step used can be specified in X max step Internal and External Controls 1 Internal control in which the target and variable cells exist in the same process unit FAST 2 External control in which the target and variable cells exist in different process units SLOW Calculation of an internal control is fast because only one unit is calculated Usually you can create a large number of internal controls in a process without a dramatic drop in calculation speed because they do not increase the number of calculation rounds of the process Calculation of an external control might take more time because material must be recirculated within the whole process several times to reach a stable target value Usually only a few external controls can be used in one process without a considerable decrease in the calculation speed because external controls might multiply the calculation rounds of the process Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Units Qutotec November 25 2014 Research Center Pori Lauri Maenpaa Antti 14022 ORC J 12 12 Hoine 41 5 2 Advice When Using Controls Itis recommended to moderate large changes of the variable with the use of X Max Step when using external controls with slow responses
160. one for units and one for streams This report uses Hydro example3 Sim8 Flowsheet report JD US am o DS Save Print Add custom Cells sheet A B C D E F G H I J K 1 Reactions Variable List 1 streams 2 streams INTERMEDIATE 4 Destination Leaching Leaching Leaching 5 Temperature C 75 00 25 00 25 00 25 00 140 00 70 00 70 00 6 Pressure bar E 3 00 1 00 1 00 1 00 2 00 1 00 1 00 7 Amount t h 84 16 60 00 10 10 14 06 84 17 71 74 12 43 8 Enthalpy kWh 246798 98 223520 49 23278 49 0 00 254763 42 254922 58 159 16 9 Volume m3 h 60 28 50 15 10 13 0 00 56 60 56 60 0 00 10 Exergy kWh 7513 33512 47 28640 61 4681 93 189 93 25999 19 25854 79 144 40 11 Heat Capacity kWh 0 00 12 Gas Phase Nm3 h 0 00 0 00 10927 08 9779 74 0 00 9779 74 13 H20 g Nm3 h 0 00 0 00 0 00 14 02 g Nm3 h 1147 35 2294 691 2294 69 1147 34 0 00 1147 34 15 N2 g Nm3 h 0 00 8632 40 8632 40 8632 40 0 00 8632 40 16 water Phase t h 7 35 60 10 50 00 10 10 0 00 67 45 67 45 0 00 E 17 H20 t h 1 84 50 00 50 00 51 84 51 84 0 00 18 H2504 t h 10 10 10 10 10 10 0 00 0 00 0 00 19 Fe 2a t h 5 72 0 00 5 72 5 72 0 00 20 H a t h 0 00 0 00 0 00 0 00 0 00 21 so4 2a t h 9 89 0 00 9 89 9 89 0 00 22 Pure Phase t h 5 72 10 00 10 00 0 00 0 00 4 28 4 28 0 00 23 Fes t h 9 00 10 00 10 00 1 00 1 00 0 00 24 5 t h 3 28 0 00 3 28 3 28 0 00 25 Amount Phase 1 t h 1 63 14 06 0 00 0 00 14 06 12 43 0 00 12 43 26 Amount Phase 2 t h 7 35 60 10 50 00
161. only species N2 g which contains nitrogen Fig 16 fimi Shaft Furnace Em m mu File Edit Insert Pyro Calculation Mode CA12 v 100 Normal Distributions sheet A B C D J X Y AO BE CA CH DC EA A Convert to Equilibrium Mode 1 Distributions Elements c Fe N o Si 2 1 Convert to Mixer 3 Total H Shift 4 Flags Balance kWh 7331 46 Balance 979 02 0 00 0 00 6498 59 5 Input kWh 296465 61 Input 980 00 137483 73 0 99 57852 87 WP Show Distribution Sheet 6 Output kWh 289134 15 Output 0 98 137483 73 0 99 64351 46 2 e 8 Process Gas Stream Dist 100 00 Hide Non essential Columns o Dist Type 5 Dist Sheet Rows Visible 10 Amount x 0 99 11 Species Total S 12 N2 g E Add New Control 13 O2 g 14 CO g L gt Show Controls Sheet 15 CO2 g Es 17 Hematite Pellets Stream Dist f 111 23 Insert Heat Loss 18 Dist Type i e s Float 83 Insert Energy Feed 19 Amount 20 Species Total 21 Fe203 Rest 22 Fe304 Fixed Fe 1 00 0 82 23 si02 Fixed Si 8 29 100 00 24 C Fixed C 100 00 25 7 M 4 gt NI Input Output Dist Controls Model H r Fig 16 Nitrogen distribution in the gas stream For the carbon containing species CO g and CO2 g it can be assumed that enough oxygen is provided for all of the carbon in the gas stream to be oxidized into carbon dioxide Thus carbon C can be assigned to both species and the CO g will be fixed at 0 00 and for CO2 g the status can be set as Rest Fig 17 Copyright O
162. ont Bold False Font Italic False Font Color EN 0 0 0 General Save Save As Load Load From Restore Default Fig 13 Flowsheet settings x 2 Show and hide the flowsheet Name labels Value labels and Stream tables 3 Check and uncheck all Toolbars which are explained in section 40 3 EJ HSC Sim 8 Ele View Select Tools Drawing Tools el Je Flowsheet Settings Neualization Name Labels Value Labels Stream Tables k y E Toolbars ey k wl e me es SS R CN T n W s Paget Pagez i lc LE 1 Outotec C bar kWh Fig 14 View menu F Er 40 d j i ai 100 Window Help Process O D x gt B Units by Type Search for units Gop Process Tree Log viewer Unit Icons F M Persist Tool Y Snap to Grid D 17 eo Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools Qutotec December 10 2014 Research Center Pori Petri Kobylin Lauri 14022 ORC J 10 26 Maenpaa Matti Hietala Jussi Pekka Kentala Select menu The Select menu is typically used to edit or move many properties at once Here the user can see Fig 15 below 1 Select all Units on the flowsheet 2 Select all Unit Name Labels on the flowsheet 3 Select all Streams on the flowsheet 4 Select all Stream Name Labels on the flowsheet 5 Select all Stream Value Labels on the flowsheet 6 Select all Stream Tables on the flowsheet 7 Select
163. originally made for hydrometallurgical process calculations but can be used for almost any process especially those that can be modeled with chemical reactions Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 2 15 Kotiranta 43 1 Steps to Successful Sim Reactions Simulation It is important to add the necessary information before the simulation can be started It is good to follow this list while making your Sim Reactions models Steps 3 to 9 are explained in more detail below Draw units and streams see Chapter 40 section 40 1 oave Process see step 8 Create variable list Add reaction equations opecify distributions oet controls opecify raw material amounts Save Process and Save Backup Run process O w A ODIUM a VC kam 43 2 Creating a Variable List A variable list editor is shown in Fig 1 The user should at least add some species to phases in this editor In this simple cooler example only H2O has been added to the water phase row 13 and just the amount has been checked cell E12 which automatically creates row 17 Default system variables are also shown in rows 3 9 and default phases in rows 10 12 and 15 E Variable List Editor EA A E O OG 8 e Activate Exitand Import Database Help Cancel Variables Temperature Phase Modi Name Measuremen t Unit Wal ify Temperature R Concentration
164. ot H Chem Ex Phy Ex Tot Exergy 23 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh mol kWh mol kWh kWh kWh 24 Pressure 1 00 bar 0 00 0 00 25 Fix Total 100 00 vol 1 29 1 00 0 04 0 00 0 00 0 02 0 00 0 02 26 N2 g 79 00 0 99 0 79 0 04 0 00 0 00 0 00 0 00 0 01 0 00 0 01 27 O2 g 21 00 0 30 021 0 01 0 00 0 00 0 00 0 00 0 01 0 00 0 01 28 M 4 gt I Input Output Dist Controls Model d m Fig 6 Specify stream species compositions raw material amounts and measure units T You need to specify the raw material stream species as well as their compositions and temperatures It is also important to specify the measure units for the streams Valid selections are t h kg h Nm3 h only for gases Please note that the stream composition is given in wt if mass units are used and in vol 2e if normal cubic meters are used If the feed amount is not yet available then it is good to specify an initial value such as 1 t h especially if this raw material will be used within some control Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Qutotec November 25 2014 Research Center Pori Lauri Maenpaa Antti 14022 ORC J 7 22 Roine 42 6 Step 6 Specify the Output Streams E Shaft Furnace oO x File Edit Insert D18 zjm Normal Distributions sheet A B C D E F G H l J K L U V W SX Convert to Equilibrium Mode 1 Output 2 TR Convert to Mixer 3 4 Amounts Heat Content H Total H Heat
165. parameter In this example you can use the total input of the Air stream To set this cell reference go to the Input sheet and copy the correct cell reference Input D22 Fig 24 and paste the cell reference on the Controls sheet to the Value cell Controls D18 Also fill in the process and measurement unit information for the variable parameter Fig 25 Copyright Outotec Oyj 2014 Outotec Vrae diria Research Center Pori Lauri Maenpaa Antti 14022 ORC J 17 22 Roine EL Shaft Furnace o j x File Edit Insert Pyro Calculation Mode Normal Distributions sheet A Convert to Equilibrium Mode Al Convert to Mixer Distributions a Input streams Value Units Amounts Total H kg Nm kWh kWh 3 Show Distribution Sheet 6 i Nm h fob 7 bre 1 201001 29 42 04 1069 00 0 01 296465 61 8 ISRC Magnetite Ore 200 00 t h Amounts Heat Content H Total H Hide Non essential Columns 9 DST Temperature 25 00 C kg Nm kmol kWh kWh Dist Sheet Rows Visible 10 Pressure 1 00 bar 0 01 296381 39 11 Fix Total 100 00 wt 200000 00 40 60 987 03 0 01 296381 39 Controls 1 Fe304 95 00 190000 00 36 75 820 60 0 01 254271 26 Add New Control 13 SiO2 5 00 10000 00 3 85 166 43 0 00 42110 13 BE Coal 1 00t h Amounts Heat Content H Total H insert SN 16 DST Temperature 25 00 C kg Nm kmol kWh kWh
166. ped streams are discarded automatically The mapping dialog is started by clicking the mapping button on the button menu On the left side of the dialog window all the HSC Sim process streams are given and the search tool for the GaBi database is on the right side Stream mapping and selection is done by drag and drop from the GaBi side to the HSC side see Fig 8 The right side will be updated automatically if changes are made to that stream fim LCA Evaluation o x is Ps A T GF HIR HS La T E v 9 w amp d B Save Input Output Manual Manual Indicator Mapping Normalize Help To Gabi To Excel Input Output Inputs Outputs Manual Inputs Manual Outputs Indicators t Flows Keyword Search Coke Input Streams Deposited goods Coke Breeze Unit Name Stream Name Amount Unit Lca Equivalent Lca Group Emissions to agricultural soil US Dummy Metallurgical coke combusted in ind Emissions to air NiPigIronEF Laterite 5700 00 kg No Mapping Not defined i inb do celsi US Dummy Petroleum coke combusted in indus UL RST eee Emissions to fresh water E M Petrol coke El NiPigIronEF Coke 356 65 kg Coke metallurgic Not defined RH Fmissinns to industrial soil NiPigIronEF Limestone 869 41 kg No Mapping Group Bios eder Hard coal coke I m ee fi S NiPigIronEF Infilitrate Air 128 67 kg No Mapping Not defined trie oven quan Ce Materials Fuels f SC Hard coal coke NiPigIronEF Power kWh 5300
167. phase flow rates Good to know v You can always relocate or detach the dialog components as you like v Just drag and drop them to undock amp dock elsewhere v You can leave the dialog components floating on the display and resize them freely The figures have tools that appear when you place the cursor over them you can copy print clone etc Copyright Outotec Oyj 2014 Outotec ee Research Center Pori Antti Remes Pertti 14022 ORC J 15 35 Lamberg j by K l n 135 00 th ss 45 3 1 45 3 1 1 Legeg 4 18 Solids Liquid Gas Fig 15 Relocate and resize the dialog components by undocking and docking them with the left mouse button held down Solids feed Solids feed is based on particles in the HSC Sim minerals processing models see Fig 6 In the simplest form no size classes bulk flow and no minerals are defined thus the default is bulk Ore mineral To set up the solids feed composition and mineralogy the following data need to be defined e Total Flow Rate e Minerals e Size Classes e Size Distribution e Composition of minerals and elements Total solids The total solids are entered in the Amount field the unit can be changed from the dropdown menu and the amount is then automatically recalculated Fig 16 NB The unit in this selection does not affect the unit shown in the flowsheet simulation There the flow rates are shown in t h Copyright Outotec Oyj 2014 HSC 8 Sim M
168. places where it can flow to as selected as shown in Fig 9 Input Streams Unit Name Stream Name Amount Unit Lea Equivalent Lca Group fom i Material resources i i Arseni jeLanthanides Fig 9 LCA equivalent search from the GaBi database structure selection of LCA Group When i navigating away you are asked to apply mapping The stream description field shows the stream name category and reference quantity as shown at the bottom of Fig 9 If changes are required simply drag and drop a new Gab equivalent or if something is to be omitted select Not defined from the pulldown menu When navigating away from the page you will be prompted to apply the changes as shown in Fig 9 All changes must always be saved to be effective Main Product Selection and Normalization of Data Selection of the Main product is needed in order for normalization of the data to be performed The Main product is always one of the output streams No matter how many by products there are only one main product can be selected as all flows are normalized relative to this This selection is made by checking the box as shown in Fig 5 Normalize calculates how much of each flow is needed to obtain 1 kg of the main product The Normalize button in the button menu executes normalization and the results are written in a new LCA normalized data sheet which appears after the calculation as shown in Fig 10 The normalization sheet summari
169. processing unit model library Copyright Outotec Oyj 2014 Qutotec Research Center Pori Antti Remes 14022 ORC J Table 1 HSC Sim minerals processing unit models Technology Concentrator General Separation General Comminution General Screens Hydrocyclones Flotation Thickeners Filters Type Code MU 110 10 MU 120 10 MU 120 11 MU 120 12 MU 130 10 MU 230 10 MU 230 1 1 MU 230 12 MU 240 10 MU 310 10 MU 310 1 1 MU 510 10 MU 520 10 Model Perfect Mixer Efficiency Curve Whiten Mass Distributor Mineral Splitter Fixed PSD Rosin Rammler Whiten Efficiency Curve Karra Efficiency Curve Batterham Efficiency Curve Plitt Conditioner Flotation Cell Thickener General Filter General Copyright Outotec Oyj 2014 HSC 8 Sim MinPro Unit Models November 19 2014 Description Mixes all input material from one or several streams and passes it equally to one or several outputs Whiten efficiency curve Supports separation by mineral and inclusion of the fish hook effect Distributes solids and water to several outputs with given ratios Mineral by size split of the feed into the concentrate and tails streams and optionally into a middlings stream Fixed Particle Size Distribution calculated by using Rosin Rammler or Gaudin Schuhmann equations Whiten screen efficiency curve Karra screen efficiency curve Batterham screen effi
170. r the stream source destination should also be changed Fig 9 In addition the source and destination can be set from the stream properties panel on the right Fig 10 Copyright Outotec Oyj 2014 Outotec asd i a Research Center Pori Antti Remes Pertti 14022 ORC J 11 35 Lamberg L Fig 8 Drawing the streams Bim Change Stream Source And Destination X Stream CUF Source Unit Old Cydone en Ek E Destination Unit Old Ball mill New d T Cancel OK Fig 9 Setting stream source and destination after redirecting the stream on the flow sheet drawing Properties D ff X Process Drawings General Ad MameID Flotation Feed Number Alias Source Conditioner Destination Flotation Cell Location Page Pagel Layer Layer 0 Default Visibility A Name Label True Value Label True I Fig 10 Stream properties where the Source and Destination can be set The streams are renamed by double clicking the stream name label or from the stream properties panel The value labels showing the simulated values of the selected variable in the visualization mode are inserted automatically The stream names and value labels can be modified in terms of font color etc from the properties panel Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Qutotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 12 35 Lamberg 45 2 3 Checking the flowsheet When the flowsh
171. reams where the first icon is Select U Generic Units R Reactions Units D Distributions Units and the last icon is Streams 40 1 1 Drawing units Select the unit by left clicking the unit icon The cursor shows the user which icon is active Move the cursor to somewhere on the flowsheet and draw a unit by a holding down the left mouse button b moving the mouse to increase the size of the unit c releasing the button to stop drawing see Fig 2 The user can change the size of the units later EL HSC Sim 8 mJ x File View Select Tools Drawing Tools Window Help amp HR selctviualzation BS SS 0 E E la Main Process X Dm X m 10 20 3c 40 50 50 70 SC 30 100 110 120 Bocess ma US Unit 1 Unit 2 fie oO g x b gt E Unitsby Type Search for units ss E p i d leri S _ Paget Page2 Page3 Process Tree Log viewer Unit Icons Outotec C bar kWh 100 i VY Persist Tool V Snap to Grid 54 41 Fig 2 Drawing two Reactions Hydro units The Reactions unit is the active icon in this figure see the mouse cursor 40 1 2 Drawing streams Select the stream icon with the mouse left button Move the cursor to somewhere on the flowsheet and click the mouse left button to start the stream The user can add a corner to the stream with another click and double click left button to end the drawing of the stream see Fig 3 Editing Streams How to a make a corner on the stream b ch
172. ri Kobylin Tuukka 14022 ORC J 1 15 Kotiranta 44 Sim Reactions Example 44 1 General This example contains instructions on how to create a simple leaching reactor model where 10 t h of FeS is leached with acid H2SO and air at 70 C The water feed is 50 t h and the FeS leaching efficiency is 90 oxygen efficiency is 50 and the acid concentration in the product is 1 g l The reactor is cooled with cooling coils The cooling water input temperature is 25 C and output temperature 60 C You should keep in mind that streams are put into the input and output sheets in the same order as you have drawn them This means that when you make a new model the streams might be in a different column than explained here The example files can be found from the HSC Chemistry installation folder Flowsheet Hydro Hydro example3 Hydro example3 Sim8 This example describes the creation of the flowsheet in detail with references to the Sim Flowsheet manual E HSC Sim 8 Jm Jj x File View Select Tools Drawing Tools Window Help LJ K 1 bed e Select visualization sl A e e ET rw gt Sp K Hydro_example3 X D g x IR 16 ze 2n So 35 a an ann 110 12n Ap san aen 5 e ep eg Si 30 EM de 80 s u e an CH a Process Drawings General Offgas NameID Leaching Number Alias uum Value imm B L B iz FeS O Value I O W 3 Solution b g Leaching Location alue age age O Value P Pagel H2504 Layer Layer 0
173. rmula The user may change the measurement units only in the variable list editor Columns E Streams Each stream has a column of its own Copyright Outotec Oyj 2014 HSC 8 Sim Reactions Unit Qutotec November 25 2014 Research Center Pori Petri Kobylin Tuukka 14022 ORC J 6 15 Kotiranta 43 3 Adding Reaction Equations to Create Calculation Model In the reactions unit the mathematical connection model between the Input and Output streams is created using Chemical Reactions Wizard This model transforms the raw materials into products by using chemical reactions given by the user see Fig 3 EL Hydro Reactions Editor x o Q ii Activate Exitand Balance Cancel A B C D E F G H l j l Progress Reactant Reactants Products Product Balance H K E SolidPhase Separated with Separated with Solid Phase kcal e ES 90 2FeS 4H a O2 g 2Fe 42a 25 2H20 OK 131 4208359 3 93824E 75 4 100 H2504 2H a SO4 2a OK 22 852 3462533170 H z 4 z IM 4 HI Reactions Dynamic 4 Fig 2 In Chemical Reactions Wizard the user specifies reaction equations and their progress The first step is to enter the reactions that happen in the process unit in the Chemical Reactions Wizard Fig 2 The species used in the reactions must exist in the variable list The first species of each reaction is assumed to be the raw material which is consumed in this reaction according to the progress 96 For example F
174. rol 19 Fix Total 100 00 wt 5 00 0 01 0 28 0 09 22 12 0 07 1 95 2 j 0 09 22 12 0 31 79 71 0 07 1 95 2 21 22 SRC Stream 3 0 00 kg h Amounts Heat Content H Total H Heat Cont H Tot H Chem Ex Phy Ex Tot Exe Insert Heat Loss 23 DST Temperature 25 00 C kg Nm kmol kWh kWh kWh kmol kWh kmol kWh kWh kWh 24 Pressure 1 00 bar 0 00 0 00 25 Fix Total 0 00 wt 96 0 00 0 00 0 00 0 00 10 00 0 00 0 00 0 26 HF ENERGY FEED 10 00 M 4 gt NI Input Output Dist Controls Model 4 Fig 7 Inserting an energy feed into a stream Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Units utotec November 25 2014 Research Center Pori Lauri M enp Antti 14022 ORC J 5 12 Roine 41 3 Specify Output Streams On the Output sheet the same steps need to be carried out as those done for the Input sheet with the exception of specifying the total amounts and the stream compositions Fig The amounts and compositions of the output streams are usually specified on the Dist sheet but there are also wizards which can be used to specify these properties Specifying the distribution is introduced in section 41 4 CO Distribution Pyro Unit D x File Edit Insert ro Calculation Mode Normal Distributions sheet A B C D F G H J K L D y Ww TA Convert to Equilibrium Mode 1 Output 2 1 amp Convert to Mixer 3 4 Flags Output streams Value Units Amounts Heat Content H Total H Heat Cont H
175. rt 6 Find data for unit models and their parameters To create models you will need some experimental data These are elemental assays from a laboratory test pilot test or survey If you have data you can organize the data in HSC using the Mass Balance module to mass balance and reconcile data see Chapter 51 Mass Balance Some of the simplest models do not have operational parameters like size length gap size volume or area but if you want to use more comprehensive models you should gather this information as well After obtaining the background data the building of a simulation model comprises the following main steps l Draw the flowsheet place the units there rename them draw the streams and rename them ll Check that all the streams are connected correctly Il If not yet done next save the flowsheet to a separate folder Please take backups every now and then IV Define the feed streams feed rate select minerals size classes size and mineral elemental composition liquid and gas phases V Select and load the unit models and set the parameters and possible controls for them VI Simulate and fine tune the model View visualize and report the results These steps are described in more detail in the following sections Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Qutotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 10 35 Lamberg 45 2 Drawing a flowsheet
176. s presented in the lower part of the display in the Mineral Matrix Fig 22 Mineral Code SG Formula DB Ref k Chalcopyrite Ccp 4 35 CuFe52 M Ccp 40 Pyrite Py 5 01 Fes2 M Py 54 Quartz Otz 2 65 SiO2 M Ote 41 Fig 21 List of selected minerals The Mineral Matrix allows you to edit the list of included elements new elements can be added simply by typing them on the list and or editing the existing elements In the same way the element wt in each mineral can be edited Copyright Outotec Oyj 2014 HSC 8 Sim Minerals Processing Qutotec November 20 2014 Research Center Pori Antti Remes Pertti 14022 ORC J 18 35 Lamberg Note the element wt in each mineral is typically approximately 100 However this is not necessary the chemical composition of a mineral can present just the measured elements for example Note Il the editing of the mineral properties element wt S G etc does not affect them on the HSC Geo database The edited minerals properties are only applied in the current HSC Sim simulation feed stream B2 se 34 6256332397461 A B C D Fe 3043 46 55 o I 53 26 5 34 94 5345 5i 46 74 Woo pS ED IL Dm um H L IM 4 k NI Mineral Matrix Fig 22 Mineral matrix for presenting and editing the element compositions of selected minerals Alternatively to edit the Mineral Matrix element list in the lower part of the dialog elements can be added removed or selected from the perio
177. s visible In these cases a lot of iteration rounds might be needed to reach the Set Point This increases the calculation time Table 1 Information on the Controls sheet How Name Description 8 Y Target Name Name of Y optional 9 Process Unit Unit name optional 10 Measurement Unit Name of the unit of measure optional 11 Set Point Set point of Y obligatory 12 Measured Y cell reference obligatory 13 Tolerance Y tolerance obligatory 15 X Variable Name Name of X optional 16 Process Unit Unit name optional 17 Measurement Unit Name of the unit of measure optional 18 Value X cell reference obligatory 19 X Min Limit Min limit of the X range obligatory 20 X Max Limit Max limit of the X range obligatory 21 X Max Step Maximum X Step optional default empty 23 Control Method Iteration method optional default Auto 24 Active Set control ON OFF optional default empty ON 25 Iterations max limit Max number of iterations optional default 10 26 Iterations min limit Mm number of iterations optional default empty 27 Operation Control calculation operation optional default Light Auto Solves the control with information on rows 24 27 Auto Smart Same as Auto except changes X Max Step and Iterations max limit when needed PID not in use will be added to the HSC8 version Light Solves the control with modified tangent method fast Robust Solves the control with modified Newt
178. sert View Tooli Help E Variable List Editor Hk Chemical Reactions Wizard T Insert Custom Sheet E3 Add New Control E Show Controls Sheet gt Unit format HSC 8 Sim Reactions Example November 25 2014 14022 ORC J ul ER ILC Variables Temperature Pressure Amount Enthalpy Volume Exergy Heat Capacity Gas Phase Water Phase H20 t h Pure Phase t h Amount Phase 2 t h il A 5um Cold Water C bar t h 195 83 kWh 863052 94 m3 h kWh kWh t h t h Leaching unit Enthalpy Cooler Enthalpy Heat Balance Dist Controls Model Extra sheet Fig 7 Insert Custom Sheet and text added to this new sheet renamed to Extra sheet Copyright Outotec Oyj 2014 8 15 Qutotec Research Center Pori Petri Kobylin Tuukka Kotiranta Leaching HSC 8 Sim Reactions Example November 25 2014 14022 ORC J File Edit Insert View Tools Variable List Editor CH Chemical Reactions Wizard Insert Custom Sheet e Add New Control gt Show Controls Sheet gt Unit format Cim E Cooler 4 I sg 2 3 5 6 7 8 9 10 11 v Model E10 Model D 10 B MODEL WIZARD Chemical Reactions eee Pressure Amount Phases Sp at Ja 254763 42 Cut 55 62 25999 19 0 00 9779 74 0 00 1147 34 8632 40 67 45 51 84 0 00 5 72 0 00 Copy Paste Format Cell s Paste cell reference
179. shown on the stream value labels and stream Sankey diagram line width In addition the variables can be shown on the flowsheet in tables The variables can be inserted and edited with the Stream Table Editor Fig 48 see section 40 1 4 Tables can also be inserted from Tables button on the left Fig 49 and by editing the content manually with cell reference and text Copyright Outotec Oyj 2014 Outotec iaa ie Research Center Pori Antti Remes Pertti 14022 ORC J 33 35 Lamberg Ha 5tream Table Editor Available variables Visible variables Total Solids t h zi EE Cu t F EN amount EE Fe th H t h t h 5 um Si th Ore wt 9 Py wt 95 Otz wt 3 amp Pulp 5G g cm3 Total amount 234 56 View mode Column 1 Color Column 2 color Number Format Name and value C 0 255 255 255 10 255 255 e 110 00 OK Cancel Fig 48 Stream Table Editor for adding tables that present the stream variable details Grindi Table mn Fig 49 Inserting tables from the left bar button Table selection L EHI LE Jericho 10 zii It is also possible to repeat a sequence of simulations with different model parameterization and or feed composition and record the simulation results Fig 50 This can be done by selecting v HSC Sim menu bar Tools gt Run Scenarios This will open the Scenario Editor described in section 40 2 3 E Scenario editor ES e x
180. sing Enter or the Add Sieve button Fig 26 alternatively there is a right mouse button tool for this Fig 27 v The selected sieve can be removed by clicking Remove Sieve or by right clicking Fig 27 v Create Sieve Series offers a way to create standard sieve series up to the given Top Size by using Fig 28 e ISO 565 Test Sieves e American Standard ASTM E11 e British Standard BS 410 e Square root of 2 series down to gt 1 m e OR to create a given number of square root 2 series classes up from 1 m In this case Top Size is not needed B m vi A Top Size 10000 e p KLS Sieve Size 0 Add Sieve Remove Create Seve Sieve Serie T Fig 26 Tool for creating and editing sieve size classes Copyright Outotec Oyj 2014 Outotec cma Research Center Pori Antti Remes Pertti 14022 ORC J 21 35 Lamberg sieve No Sieve Size Lower Size Tum oize Fraction Average Size Class Label 3000 3000 10000 5477 2 3000 10000 um 2000 2000 3000 2449 5 2000 3000 um 1000 1000 2000 1414 2 1000 2000 um s reus 500 L000 707 1 500 1000 um Pide sue 250 500 353 6 250 500 um Remove Sieve 125 250 176 8 125 250 um 7 75 75 125 96 8 75 125 um 20 20 75 38 7 20 75 um 20 20 14 1 20 um Fig 27 Size classes view for editing sieves and size class labels Create Sieve Serie Is SIZE ISO 565 Test Steves American Standard ASTM E11 i Britis Standard BS 410 zl SORT 2 Serie E No
181. st Light fast 4 4 OK Input Output Dist Controls Model ak Fig 30 Set Coal feed as the variable Cut Copy Paste Format Cell s Copy cell reference Paste cell reference Insert row s Delete row s Delete Control Insert Control 20 22 To complete the process controls add a tolerance value for the heat balance and adjust the minimum and maximum limits for the coal feed Fig 31 ey Shaft Furnace File Edit Insert Normal Distributions sheet TA Convert to Equilibrium Mode EH Convert to Mixer gt Show Distribution Sheet Q Hide Non essential Columns 7 Dist Sheet Rows Visible Add New Control gt Show Controls Sheet Insert Heat Loss Insert Energy Feed Y TARGET NAME 02 in Output Heat Balance Process unit Shaft Furnace Shaft Furnace Measurement Unit vol kWh Set Point 5 00 0 00 Measured 140 16 2575 91 Tolerance 0 01 0 1 X VARIABLE NAME Air Feed Coal Feed Process Unit Shaft Furnace Shaft Furnace Measurement Unit Nm3 h t h Value 1 00 1 00 X Min Limit 10000 U X Max Limit 100000 X Max Step CONTROL METHOD Auto Smart Auto Smart Active ON ON Iterations Max Limit Operation Light fast Light fast Fig 31 Completed controls M gt H Input Output Diet Controls Model lal Copyright Outotec Oyj 2014 HSC 8 Sim Distribution Qutotec November 25 201
182. stom Sheet i S gi 7 Set Point 1 00 E Measured 1 00 g Tolerance amp 2 Add New Control i 10 Remove Control 11 X VARIABLE NAME Acid feed La Show Controls Sheet l Process Unit 13 Measurement Unit t h L2 Unit format 14 Value 10 10 15 X Min Limit o 16 X Max Limit 100 EF X Max 5tep 18 19 CONTROL METHOD Static 20 Active ON 21 Iterations Max Limit 10 22 23 Operation Robust slow IM 4 k H Output Dist Controls 4 t Fig 5 The calculation model Controls sheet with one control The HSC Sim Controls sheet makes it possible to create controls that regulate the target parameter cell value using another variable cell value see Fig 5 In principle Sim Control works exactly like a real process control For example in a real process unit you can assign a set point to the process unit temperature and regulate the temperature by changing the fuel oil feed To create a control on the Controls sheet you have to set at least the set point the Target cell reference the Variable cell reference the limits for the variable and the tolerance You can type this information on the Controls sheet using the following procedure 1 Type the name and the unit of measure in Control sheet cells C4 to C6 optional 2 Type Target set value in cell C7 3 Locate the Target cell from your active unit and right mouse click Copy cell reference Copyright Outotec Oyj 2014 Qutotec Research Center Por
183. stribution to output streams When distributing the elements to output streams it might be helpful to hide the species rows with the Dist Sheet Rows button in the left hand panel Fig 9 An easy way to start is to fix the elements which are present only in one stream In this example this applies to nitrogen N iron Fe and silicon Si Nitrogen is present only in the Process Gas stream whereas iron and silicon are only found in the Hematite Pellets stream To distribute these elements set their status to Fixed in the correct streams and give their wt value as 100 Fig 10 Note that you can also use the Rest status for the elements that are found only in one stream E shaft Furnace aves File Edit Insert Pyro Calculation Mode Normal Distributions sheet amp Convert to Equilibrium Mode Elements CH Convert to Mixer Shift Distributions kWh 296465 61 Balance kg 980 00 137483 73 0 99 57852 87 kWh 296465 61 Input kg 980 00 137483 73 0 99 57852 87 Mc kWh 0 00 Output kg 0 00 0 00 0 00 0 00 wt 96 0 00 100 00 100 00 0 00 Mos Geet Hide Non essential Columns Dist Type Q Dist Sheet Rows Hidden Amount Species Total Hematite Pellets Stream Dist 100 00 Add New Control Dist Type i Fixed Fixed Amount 0 00 137483 73 0 00 4683 70 Ub Show Controls Sheet Species Total E 0 00 0 00 0 00 0 00 3 Insert Heat Loss Insert Energy Feed
184. t button in the Variable list editor and choose the xls or xlsx file that includes your variable list Some example files can be found in the HSC Chemistry installation folder XFlowsheet Hydro 43 2 3 Activating Variable List After filling the variable list manually or importing it the next thing is to click Activate 43 2 4 Summary of Columns The meaning of the Input Output and Dist sheet columns can be summarized as follows Column A Type Specifies the row type T Temperature Pr Pressure A Amount H Enthalpy MV Volume Ex Exergy Cp Heat Capacity P Phase Species D Density mass fractions also need to be specified for water phase species Concentration concentrate F Mass Fraction base species must be specified O Other U User formula The number section in the row type parameter refers to the phase number For example A2 Amount of phase 2 H3 enthalpy of phase 3 etc Column B Variable Specifies the variable name Column C Unit Specifies the measurement unit Use the same measurement units within all the process unit models Column D Formula Specifies the Excel type cell formula which will automatically be added into model Input and Output sheets in Column D and in all the stream columns HSC Addin functions can also be used e g MW H20 The HSC Addin function Units C MJ will check whether the temperature and energy units are as specified in the fo
185. the Target set value Set Point into cell D11 3 Locate the Target cell in your active unit and right click Copy cell reference 4 Go to Controls sheet cell D12 and right click Paste cell reference 5 Give the tolerance of the calculation in cell D13 When the difference of Set Point and Measured value is smaller than the Tolerance the control is in balance and will not be calculated further 6 Type the name and the unit of measure in cells D16 and D17 optional 7 Locate the Variable cell in your active unit and select Copy cell reference 8 Go to Controls sheet cell D18 and right click Paste cell reference 9 Type Limit Min and Max in cells D19 and D20 a narrow numerical range speeds up the calculations The default Tolerance is A small tolerance increases the calculation time and a large tolerance increases errors Some 2 of the target value may be a good compromise The control will not be taken into account if the value is within the tolerance Copyright Outotec Oyj 2014 Qutotec Research Center Pori Lauri Maenpaa Antti Roine 41 5 1 HSC 8 Sim Distribution Units November 25 2014 14022 ORC J 11 12 oim Controls have exactly the same limitations as real process controls for example If the target cell does not depend on the variable cell value the iterations will fail If an external variable cell is used there may be a long delay before the effect on the target value become
186. the flowsheet as a process tree Copyright Outotec Oyj 2014 Qutotec Research Center Pori Petri Kobylin Lauri Maenpaa Matti Hietala Jussi Pekka Kentala December 10 2014 14022 ORC J Properties c s x Properties Process Process Drawings General General Object Type Unit Drawing Object MameID Unit 1 Page Number Alias Layer Made Reactions Hydro Image Type DLL Unit Image Model Reactions Hydro Unit Image with Technology Ee SSES Drawing Line subTecnnology Line Color Sequence 1 SS Line Style Page Pagel Line SC Drawing Fi Layer Layer 0 Default E Visibility e Name Label True lis Gor 2 General General Fig 45 Properties Unit Process and Drawings Properties Process Drawings General Process Drawings Genera Object Type MameID Number Alias Source Drawing Object Auto Snap to Unit Stick Stream Ends Page Destination Layer Drawing Line Line Color Line Style Line Width Drawing Arrows Auto Arrow End Update Arrow Calor Start Arrow Head Cs edn Layer 0 Default Visibility Name Label True Value Label True Stream Table General General Fig 46 Properties Stream Process and Drawings Copyright Outotec Oyj 2014 HSC 8 Sim Common Tools Rectangle Pagel Layer 0 Default none none EN 0 0 0 Solid 0 25 CL White 1166 214 255 False Pagel Layer 0 Default EN 0 0 0 Solid 0 25 23 26
187. the gas stream Finally oxygen needs to be distributed to the output streams In the Hematite Pellets stream oxygen is present in iron oxides and silica By letting the iron and silicon content of the pellet stream determine the amount of oxygen the status can be set as Float The rest of the oxygen will be distributed to the Process Gas stream by setting the status as Rest Fig 12 Ei Shaft Furnace PER roo File Edit Insert Normal Distributions sheet E 5 i ER Convert to Equilibrium Mode 1 Elements A Convert to Mixer Shift Distributions kWh 296465 6 Balance 7980 00 13748373 0 99 57852 87 kWh 296465 61 Input d 980 00 137483 73 0 99 57852 87 M heec kWh 0 00 Output 0 00 j 0 00 0 00 fos GR See Stream Dist 7 Hide Non essential Columns Dist Type Dist Sheet Rows Hidden Amount l Total Controls O Stream Dist Add New Control d Dist Type Amount 0 98 137483 73 3 Show Controls Sheet 20 Den 3 0 00 0 00 ES Insert Heat Loss Insert Energy Feed i4 4 H Input Output Dist Controls Model Fig 12 Distribution of oxygen to output streams Please note that after the elemental distribution to the output streams is finished the wt values in row 7 should all be 100 Copyright Outotec Oyj 2014 Qutotec Research Center Pori Lauri M enp Antti Roine 42 7 2 HSC 8 Sim Distributio
188. totec Oyj C bar kWh 120 31 ofM Persist Tool M Snap to Grid 166 146 In Sim 8 it is possible to connect minerals processing DLL units to conventional Reactions Hydro and Distribution Pyro units However this connection requires that the content of the mineral streams is converted to chemical species This conversion is carried out with the Species Converter unit Copyright Outotec Oyj 2014 Qutotec HSC 8 Sim Species Converter Units November 19 2014 Research Center Pori Lauri M enp Matti 14022 ORC J Hietala 47 1 Selecting the Species Converter unit model The Species Converter unit model is selected with the Select Unit Model tool Fig 1 Mineral streams are connected as inputs and the output of a Species Converter unit is connected either to a Reactions or a Distribution unit EL Select Unit Models Select unit IS Unit Distribution Unit i Species Converter Unit Select model Double Click to Select Reactions Distributions Partides Others Import Model Column Flotation Hydraulic Separator Feed Stream Select Model Fig 1 Selecting the Species Converter unit model Copyright Outotec Oyj 2014 Type DLL DLL DLL DLL Model Properties Species Converter Mode Others Type Code OU 000 10 Technology Sub Technology Authors Outotec Finland Descr
189. tual amounts of the species However it is also extremely important to check the element balance on Parameters page after the conversion to ensure that the residuals of the element balance are acceptable Fig 4 If the residual values are too high you can try to obtain a better conversion by adding more species to the list or by changing the target and weighting parameters 18 3306133 0 01834455 8 67165054 2 5977E 07 25 4948515 0 01318637 21 4755405 0 00418113 0 0149447 5 3151E 07 0 02888941 4 089E 07 11 6309528 0 0288 313 0 0026475 0 02254082 13 3321972 0 02534243 0 0082325 0 0092325 0 00747998 Fig 4 Element balance residuals after conversion Copyright Outotec Oyj 2014 HSC 8 Sim Species Converter Units Qutotec November 19 2014 Research Center Pori Lauri M enp Matti 14022 ORC J 5 5 Hietala 47 4 Advices when using Species Converter unit e The species used in the conversion have to be found from the active HSC database main or own e Usually the more species is specified the better conversion is obtained small element balance residuals e H2O amount of the input mineral streams is automatically converted to the output stream e When connecting the output of a Species Converter unit to a Reactions Hydro unit all the converted species have to be found from the variable list including Others Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Resear
190. uct relative to which every flow is normalized Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 8 15 Peltom ki 49 3 2 Adding Manual Streams not Defined in the Process Simulation Model sometimes during the LCI development via HSC Simulation some missing streams may be identified The best and recommended way is to add missing streams directly to the process simulation model This typically would include all fugitive emissions additional power leakages from the system etc In some cases it is also appropriate to add streams for LCA purposes only Adding these is done via the Manual Streams sheet as depicted in Fig 6 For example if general ancillary process electricity usage is not defined with its own stream in the process simulation model then it can be defined via the manual streams dialog sheet This can also be done for the output side As shown in Fig 6 the stream can be added click on Add new input stream button at the bottom of the window adding a name as well as the units and the amount for the flow that matches the data in the flowsheet as it is being simulated E LCA Evaluation eat OH v T M IM UT Wu iW 6 B Save Input Output Manual Manual Indicator Mapping Normalize Help To Gabi To Excel Input Output Manual Input Streams Stream Name Amount Unit Lca Equivalent Lca Group Delete I Power for buildings 0 kwh No Mapping
191. utotec Oyj 2014 HSC 8 Sim Distribution Outotec November 25 2014 Research Center Pori Lauri Maenpaa Antti 14022 ORC J 13 22 Roine Shaft Furnace x File Edit Insert M n v Rest Normal Distributions sheet A B C D J X Y AO BE CA CH DC EA R Convert to Equilibrium Mode 1 Distributions Elements c Fe N o Si 2 1 amp Convert to Mixer 3 Total H Shift 4 Flags Balance kWh 854 73 Balance f 0 00 0 00 9106 82 Be Input kWh 296465 61 Input 137483 73 0 99 57852 87 UE 6 Output kWh 297320 34 Output 137483 73 0 99 66959 69 hooky al 7 100 00 100 00 100 00 8 Process Gas Stream Dist 100 00 11 23 Hide Non essential Columns 9 Dist Type Fixed Rest 27 Dist Sheet Rows Visible 10 Amount 0 99 6498 59 11 Species 100 00 40 14 3 Controis 12 N2 g 1 E Add New Control 13 O2 g 14 CO g L gt Show Controls Sheet 15 CO2 g 16 17 Hematite Pellets Team met 0 10 100 00 111 23 100 00 Insert Heat Loss 18 Dist Type i Fixed Float Fixed Insert Energy Feed 19 Amount 0 98 13748373 64351 46 4683 70 20 Species Total 100 00 100 00 100 00 100 00 21 Fe203 Rest Fe 99 00 90 89 22 Fe304 Fixed Fe 1 00 0 82 23 sio2 Fixed Si 8 29 100 00 24 C Fixed C 100 00 25 m 4 4 gt HI Input Output Dist Controls Model H Fig 17 Carbon distribution in the gas stream The final thing to do is to distribute all excess oxygen atoms O to oxygen gas O2 g This can be done
192. with the simulation to study whether the process reaches steady state After a few simulation rounds the value labels should obtain values which no longer change when further simulation rounds are run It is also recommended to check the controls Fig 35 They are OK if the Set Point has been reached within the tolerance Copyright Outotec Oyj 2014 Outotec Vrae diria Research Center Pori Lauri M enp Antti 14022 ORC J 22 22 Hoine EU HSC Sim 8 ISI File View Select Tools Drawing Tools Window Help Le BB e ocn J E SS EQ gt 002 ls Magnetite X Stream Viewer A x Ri he SG Ss e RS Is BR ra ai a Boies igus i CH cf Magnetite Ore z 57 84 Temperature C E Pressure bar Es E N2 g t h a ey UN O P3 SS CO g t h _4 Hematite Pellets CO2 g t h DH S t E D Outotec C bar kWh 100 34 E M Persist Tool Z Snap to Grid 103 84 Fig 34 Element balances and behavior can be seen when element amounts are selected in the visualization In this screenshot the diagram shows the behavior of oxygen in the process E Shaft Furnace m IS File Edit Insert Help 100000 Normal Distributions sheet B S I Convert to Equilibrium Mode EH Convert to Mixer Gd Dist Sheet Rows Visible Show Distribution Sheet Y TARGET NAME O2 in Output Heat Balance Process unit
193. y the pig iron stream Please note that the exergy value is also given which is very useful additional information for analyzing technology reactors plants and systems E LCA Evaluation F ay amp PAN 1 P gt CH V M amp Sr d Save Input Output Manual Manual Indicator Input Output i H o 9 Mapping Normalize Help Unit Name Stream Name Amount NiPigIronEF Slag I El NiPigironEF Ni Pig Iron a Value Class Name D Summary Amount ka Summary Amount Nm3 Summary Extra energy kWh Summary Total Exergy Species Si l Species Feil Species Cu Species Cr I Species HO Species Cof Species Pi Species C Species Element C Clement Ca NiPigIronEF Offgas NiPigIronEF Fluedust NiPigIronEF Heat Loss 2 EE 1710 51 45 89 200 00 T LB To Gabi To Excel Output Streams Unit 4279 05 1019 28 Output Streams Value 1019 28377545331 0 150249149287767 0 257545 550861513 31 4964345332637 859 537992162226 0 540959117183395 0 27299676690 1068 84 6539423076923 3 55049781132093 0 39 2309527547227 0 39 2309527547227 5407791120002 Lca Equivalent kg No Mapping kg No Mapping Unit Text kg len kg No Mapping kg No Mapping kwh No Mapping Main Product Unit Enum n Masskg VolumeNm3 EnergykWh EnergykWh Masskg Masskg Masskg Masskg Masskg Masskg Masskg Masskg Masskg Masskg saaka Fig 5 LCA Streams sheet for Output also marking the main prod
194. yright Outotec Oyj 2014 HSC 8 Sim MinPro Unit Models Qutotec November 19 2014 Research Center Pori Antti Remes 14022 ORC J 1 3 46 Sim Minerals Processing Unit Models TOC 46 1 Minerals Processing Unit Model Library cccccccccceeeeseeeeseeeseeeeseeeeseeeeseeeeseeeesaeeeeas Copyright Outotec Oyj 2014 HSC 8 Sim MinPro Unit Models Qutotec November 19 2014 Research Center Pori Antti Remes 14022 ORC J 2 3 46 1 Minerals Processing Unit Model Library HSC Sim 8 includes a library of process models covering a wide range of unit operations in mineral processing In HSC Sim the process models for the unit operations are called unit models while the process flowsheet calculation blocks are units All the calculations are performed using solids liquid and gas phases where the solids are always defined as mineral particles for minerals processing applications Thus the model calculations are performed with an HSC Sim Particles type model To define a feed stream for Particles models in HSC Sim the Stream Set up see Chapter 45 Sim Minerals Processing tool is used Mineral processing units can also be connected to other process unit model types e g hydrometallurgical and pyrometallurgical units by using the stream conversion block between them see Chapter 47 To create your own custom unit models programmed as DLL files please refer to Chapter 50 Table 1 summarizes the HSC Sim minerals
195. zes all the process LCA data and also provides a good opportunity to check the data validity All the same mappings are combined in one stream and unmapped streams are not included in the summary If for example more than one stream is mapped with the same GaBi data Air all Air LCA Equivalents will be added to create one stream Copyright Outotec Oyj 2014 HSC 8 Sim LCA Qutotec November 20 2014 Research Center Pori Markus Reuter Matti 14022 ORC J 11 15 Peltom ki This normalization sheet Fig 10 also provides a complete overview of all the flows which thus provides an excellent black box summary of the complete simulation producing a complete and consistent mass and energy balance As only mapped inputs and outputs are considered and no internal flows the black box does not reveal any proprietary process detail making it ideal for benchmarking processes inclusion in environmental databases etc LCA Evaluation ao x is L d i 1 ES Cn gag H ae Su 8 ii EH ei Save Input Output Manual Manual Indicator Mapping Normalize Help To Gabi To Excel Input Output Norma lized Flows Direction Flow Name group Name Category Sub Category Amount Normalized Amount Unit Input Nickel ore 1 5 FromTechnosphere Material resources Non renewable resources 5700 00 5 59 kg Input Coke metallurgic FromTechnosphere Materials Intermediate products 356 65 0 35 kg Input Limestone FromTechnosphere Materials Miner

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