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1. Double clicking on a mechanical bank or flotation unit in the Flotation tab will report the grade and recovery across the unit in a new tab SGS Minerals Services IGS User Manual SGS Minerals Services 29 IGS User Manual 30 Double clicking on other units feed product junction etc or streams lines connecting two units will report the metal and mineral grade flotation kinetics Kay and Rmax stream percent solids and throughput mass water and volume flow For feed junctions and modifier units the output stream is reported ac na ee Me atin ac el Se Si aang aa Mirian Mian a Lau gi panmi Mirian Mian a wie Baa nq rir La ada Baas my sb Er Po Er A LS rs Mra Wi Wrs ieee rn Mra tas Meran EA A a a Pa r E A P a ij p A i val Lr a Br a Fels m l To view the metals and minerals results of specific blocks click on Tools and select Select block s A pop up window will appear with a list of blocks that were in the dataset Click on the block s of interest and click Select To select multiple blocks hold down control Ctrl when clicking on the blocks A maximum of 10 blocks can be selected at once The simulation results can be exported to excel 2003 2007 and 2010 or csv file Click on Export on the report window s menu bar and select Results Browse to the folder where the file is to be saved enter a filename
2. El Open Image El sue sly Export 2 Navigate to the destination folder and enter a filename Click hal Genannte Image Save Ey Modify VANCED SYSTEMS SGS Minerals Services IGS User Manual 14 k GO di gt Computer MEW VOLUME Ej User manual Flowsheets Organize New folder Documents Name q Music Destination Pictures H Videos folder wy IHomegroup Computer Local Disk C E ca Local Disk D ca Backup 1 E ca Backup I Fi Enter flowsheet in filename ee NEW VOLUME E ca Local Disk 1 File name Flotation circuit Save as type Png Files eng a Hide Folders 7 7 MODIFY FLOWSHEETS Each flowsheet is assigned a name and description upon saving The flowsheet name and description can be modified through the Manage Flowsheets window Flowsheets can also be deleted from the same window 1 To open the flowsheet management window click on Flowsheet on the menu and select Modify 2 To delete a flowsheet click the Delete button associated to the flowsheet Click Yes on the confirmation pop up to delete 7 File Edit View Flowsheet Data Grinding Flotation Help m Ber lil Open la Save import Sh Export Ti Generate Image Ef Modify SGS Minerals Services IGS User Manual 15 Rename or delete flowsheets Edit flowsheet name and Flowsheet 1 description User Name User Flowsheet User Name User Delete fl
3. INTEGRATED GEOMETALLURGICAL SIMULATOR USER MANUAL SGS Canada Inc 1140 Sheppard Ave West Unit 6 Toronto Ontario Canada M3K 2A2 Tel 416 633 9400 Fax 416 633 2695 www met sgs com www ca sgs com Member of the SGS Group SGS SA Table of Contents Calp AAA A 1 ls ANTOCUCHON atun loto eat 1 2 System Requirements 1 3J a E A en ereraseee 1 A MIS Fall AllO Mi bicis 1 Operating Gulden 2 5 Main WVINdoW OVEIVIEW een 2 0 Pr jeet Flle Management year 5 Gilly Creating New Projet lle iCal 6 6 2 Opening EXisting Pr ll ein 6 9 95 SAVE PROC AA o o a a Ta a EE a mesons 7 6 4 Save Project as New Proje ct cccccccssececcesseecceeseeecsaeeecseseesceaueeessageeecsegeeesseueeesssegeeesageees 7 0 9 COSO PIO Oct aiole 8 7 Flowsheet Management occccoccncconnnccocnccnonoconononnncncnnannnonnnnnnnnnnnnnnnrnnnrnnnnnrnnnnnnnnnnrnnnnnnnnnrnnnnnnanas 9 7 1 Creating a New FIOWSNEGEL ccccccccccssseecceeseeeceesececseseeeceaueessugeeecsaaseesseaseesssageeessegeeesseaes 9 12 Open EIOWSsheet pi ee ee ll 9 7 9 SAVE FlOWsheet un nn icon 10 LA IMDORLFIOWsheet 2 Mn A ne dei 12 1 93 EXDOTL EIOWSHeeL nn Me ae o Ma Bee 12 7 6 Export Flowsheet to Image s02 2000200000000000n0n0nnnnnn neuen nnnnnnnnennnnnnnnnnnnnnnnnnnnennnnnnnennnn 13 Tile MOdI Flo Ws ness zn zen N een nee 14 de lata Mana demente eet meee ae merry Me ene ne ee ee eee 16 AS SO ee a ere ae ee eee 16 A Bs er ee a Ener
4. If you have not received a SGS USB key the install file can be downloaded from hitp www met sgs com Process Access Login Place mouse over Applications and select Integrated CEET Login Geometallurgical Simulator Click on the download link nen MET Online Support and fill out the registration form CEET FLEET and Process Access First Time Users Integrated Geometallurgical 4 UNINSTALLATION Simulator GS To uninstall IGS open Control Panel via the start menu under settings Double click on Add or Remove Programs Scroll down and select IGS Click uninstall and follow the instructions SGS Minerals Services IGS User Manual 2 Operating Guide 5 MAIN WINDOW OVERVIEW Double click on the IGS icon will start the program and the following main window is displayed on the screen _ BDO 2 AE nz u E le Edit View Flowsheet Data Grinding Flotation Help a Benefits of a geometallurgical approac Increased understanding of the ore body and how the Wocessing system responds to natural variability in the ore Plant design services take into consideration the variabili N e JN mine including the difficult production periods in the mine sc Reduced decision making risk at all stages from prefeasibili n Menu bar operation ti Opportunity to change the mining schedule to eliminate problem production periods op IONS Optimization of plant performance takes i
5. l 1 Ms peed Pconc 3 1 2 3 conc total total mass flow rate M w water flow rate Peonc concentrate solids fraction and on a stage basis R jeleR where 3 1 2 4 N number of cells The final water recovery is the most complex of the three and requires the most iteration The water flow is specified by stages where multiple mechanical banks are grouped together The water recovery is calculated similarly to the 2nd method for every cell and summed The final equation for conversion of a cell recovery to a stage recovery is under review and the derivation is as follows By definition R O cone Mn up Muse given that SGw 1 3 1 2 5 Per the above equation M S CONC M S conc AS M conc iz VA x u w feed s cone 3 1 2 6 therefore SGS Minerals Services IGS User Manual R a i ee ee M scons M sone w feed S CONC aal 2 1 M conc M conc w feed SCONE 3 1 2 8 SO M CONC R UM w feed 3 1 2 9 3 1 3 Volumetric recovery As shown above Mie a Q otal gt SG Bl O LJ 2Y 3 1 2 5 And by definition Mere EM 1 5 feed 3 1 2 6 Then R M J feed O ioni Dr u T RO LJ I 3 1 2 7 and we can define recovery on a volumetric basis as R M l X J I J feed ae R gt R 7 56 Q Or feed 3 1 2 8 3 1 4 Water recovery Water recovery is calculated by one of three mechanisms The first a water recovery specified in the input sheet
6. 1 1 R where 3 1 2 4 N number of cells The final equation for conversion of a cell recovery to a stage recovery is under review The derivation of the above is as follows By definition M R PR O sis a up Muse given that SGw 1 3 1 2 5 Per the above equation M S CONC M S conc T M conc ary mo w feed s conc 3 1 2 6 therefore M S CONC M S CONC M w conc M conc ber Teer wi feed s conc 3 1 2 7 M conc M conc w feed 4 s conc 34128 so R zn w conc M y feed 3 1 2 9 SGS Minerals Services IGS User Manual 45 3 1 5 Overall Recovery Each of the three water flow options uses different formula to determine the water flow in the streams which affects the overall recovery Using the two compartment model by Savassi the overall recovery is calculated by HE oF REE IR J ENT Ra att Ps u k is I k g Ro aR O LR is 8 1 2 1 In the terminology of this work this is rephrased as ky y TR 1 R ENT R Ras O 0 0 0 02 rer USRI ENTER 3 1 2 2 where R recovery of mineral in the Jth floatability class k fae rate constant I J R froth recovery defined in the cell input R water recovery based on the last iteration ENT entrainment factor defined in the cell input T residence time and y T Q 3 1 2 3 where T residence time of the cell V volume of the stage where V N enV cen Qa volumetric flow of the feed to the cell as opposed
7. 5 i Flotation circuit 3 construction F frame yl Stage reporting frame 7 Selected dataset name property frame Selected flowsheet name Flotation unit Dataset None Flowsheet None SGS Minerals Services IGS User Manual Clicking on the Grinding tab will change to the grinding main window interface E Demo Project IGS File Flotation Grinding Crusher Index Enable Pebble Crusher G Grind Target Default S G P pc50 g Crusher CSS mer i oo i PC80 Ball Mill Parameters SEEN TER ION Min Ci alae Target P80 Max PCCL Slope Enable Ball Mill R Target TPH Max Feed Parameters PCCL Intercept Design Ball Mill Power F50 Max Mill Power kW Bond Relationship Bond Multiplier Fines Tuning F50 Slope F50 Intercept F80 Slope F80 Intercept Bond Exponent Bond Constant Autogenous Mill Parameters Enable AG SAG Mill Type SAG Mill 7 Steel Load 15 Design Autogenous Mill Power Variable Power El Transfer Size Parameters Mill Power kW Type Efficiency Factor Design Screen Size SAG AG Factor Slope Screen Size mm SAG AG Factor Intercept T80 Slope Design Grate Size T80 Intercept Grate Size mm Dataset Grinding Plant Only Flowsheet Demo Flowsheet The tabs will be automatically selected based on the active dataset The flotation tab is selected when the a
8. and click Save The report file reports the mass water recoveries mineral and metal grade and flotation kinetics of each mineral for each block in the dataset The mechanical bank and flotation column performance are also reported 11 FLOTATION BENCHMARK IGS can automatically benchmark plant survey data with MFT simulation results This functionality is enabled by the dataset provided by SGS Canada When a dataset with benchmark functionality enabled the Benchmark option will appear under Flotation on the menu bar SGS Minerals Services IGS User Manual 31 EEE ing Flotation Help 3 Simulate tg Simulate 4 Benchmark i Order Connections _ Order Connections 11 1 SELECT DATASET AND FLOWSHEET CONSTRUCTION Datasets containing flotation feed and flotation survey must be loaded for simulation To select the dataset follow the instructions outlined in 8 1 Flotation Feed Select dataset q Data Plant Data Construct the plant s flowsheet by following the instructions outlined in 10 2 11 2 BENCHMARK AND REPORTING With the appropriate dataset selected and the flowsheet constructed click on Flotation on the menu bar and select Benchmark If the Benchmark option is not available please contact SGS Canada at IGS sgs com for more information A dialog with objective function error will appear indicating the benchmarking progress A report window will pop up when the mini
9. inputs SGS Minerals Services IGS User Manual Save flowsheet as Name Flowsheet Name Description Flowsheet description Note A name must be given to save the flowsheet If the field is empty a red outline will appear around the name box Save flowsheet as Name Description Flowsheet description E Error indicator SGS Minerals Services 11 IGS User Manual 12 7 4 IMPORT FLOWSHEET FH New el Open A flowsheet can be imported from a file igsflsh This will la swe Import import the saved flowsheet and its inputs Ed Epor By Generate image EY Modify Note Flowsheet files do not contain datasets 1 To import a flowsheet select Import under Flowsheet on the menu bar AMPLE SELECTION 2 Navigate to the destination folder and select the flowsheet file igsflsh Click Open ND Select a flowsheet to open F OW de k Computer NEW VOLUME E Usermarual Flowsheets Organize New folder Name Libraries L Flowsheet export 1 flsh Documents 3 _ Flowsheet export fish a Music t Pictures H Videos el Homegroup Computer llo Local Disk C Select flowsheet ca Local Disk Dr i ca Backup l E file ca Backup I F ca Backup M 6 exe NEW VOLUME E ca Local Disk k File parne Flowsheet Files fish Ga aa Note Imported flowsheet will not be automatically saved into the project file Refer to 7 3 to sa
10. k avg product sai T M kavg mod k avg feed I where a R nax feed kavg mod M kavg mod Maximum recovery of the product from the modifier Maximum recovery of the feed to the modifier kavg constant value in the modifier kavg multiplier value in the modifier SGS Minerals Services IGS User Manual 55 NOTE In the initial design the product rate constant values may not exceed the source values Therefore Ci avg mod M lt kavg mod If it is desirable that this constraint be lifted the modifier and rate constant values will need to be redesigned to allow for higher than source rate constants 5 1 1 Mass fraction adjustment for kavg of the product In order to calculate the mass fraction reallocation between bins it is necessary to determine the kavg of the modifier feed Determining the 50th percentile of the floatable material in the feed By definition the kavg is the 50th percentile median of the rate constant distribution excluding the material in the 1st rate constant bin Defining the nomenclature for this value K yo K i N 50th percentile median of the mass in the J 2 N rate constant classes Consider D the cumulative distribution of the mass fractions in the rate constant bins excluding the first bin D k as k In the unlikely case that there is a value D 0 5 the N value value is the corresponding rate constant Now in the cumulative distribution there are in genera
11. 8 where I F Solid target concentration solid defined in the input If Csotia is less than Csotidthen F Csia Solid When the water addition option selected is Target Solids Dilute Thicken then I Csotia Csotia 5 6 9 When the water addition option selected is Water addition flowrate m3 h and the number of loops is less or equal to 10 then SGS Minerals Services IGS User Manual 65 F M Una x100 o F eF ed M Prin Numboop x01 5 6 10 where I Vw volumetric flow of water added defined in the input NumLoop the number of time the flowsheet has been recalculated When the water addition option selected is Water addition flowrate m3 h and the number of loops is greater than 10 then a M Ca a p A LP M rns 2 5 6 11 y Mx 100 Csorna a Lan C sotia 5 6 12 y im Coona a Solid 5 6 13 SGS Minerals Services
12. X and X exist that are adjacent to The mass fraction of the source bin is linearly gt k redistributed into X and X according to the relative distance to This is also known as a nearest neighbour approach to the redistribution Then for each source rate ky and its mass in the feed 7 Mi M y and k k arg et M pt u 1 yM p Pae z where and k k arg et M pt u 1 yM p ua where Mr target Mass fraction of the rate fraction bin adjacent to and above The deltas for each target bin are calculated for each source rate constant bin and summed Once this is completed there may be too much or too little material allocated to the zero flotation rate constant bin to satisfy the specified Rmax The adjustment to get the appropriate Rmax is described below 5 1 2 Mass fraction adjustment for Rmax of the product The material in the 1st rate constant bin is the material having a flotation rate of zero and is determined from Ap l Rs The adjustment to the rate constant distribution to achieve the correct Rmax after the modifier is performed after the redistribution of material by kavg The mass fraction of material in each of the non zero bins is adjusted on a mass weighted basis to adjust for the mass fraction of material in the 1st Rmax bin So for each of the J 2 N rate constant bins X AX lt a X Xp ro gt pr ad where AX The change in the mass fraction of material in
13. by the destination unit s input node By default the stream nam Rougher Bank 2 tail is identified by the source units output node The stream conn concert Column tail Cinr S5 name can be changed to the destination unit s input node by z Cinr Scav Bank tail Regrind product click on Toggle Rougher Bank 2 concentrate Cinr Junction product Feed product To move a stream select the stream and click on one of the Down Lawn four movement buttons Bottom GE Clicking on Ascending or Descending will automatically Descending order the stream names alphabetically Click Ok when finished or Cancel to discard the changes 10 4 SIMULATION AND REPORTING With the appropriate dataset selected and the flowsheet constructed click on Flotation on the menu bar and select Simulate Once the simulation is complete a report window with two tabs will appear The first Flotation tab displays the flowsheet constructed by the user The unit parameters are unchangeable in this window At the bottom of the Flotation tab each stream s solid and volumetric flows are reported as well as the maximum solid and volumetric flow and maximum percent solids SGS Minerals Services IGS User Manual 28 JUNCTION 7 MECHANICAL BANK 2 MECHANICAL BANK 3 Metal Grade Mineral Grade ae E cu 5 te CuSulph Pyrite NSG Metal Recovery Mineral Recovery
14. holdup Us Particle slip velocity relative to the slurry Then 7 on 60 44 Recovery 4 4 1 Vessel dispersion number The vessel dispersion number is calculated by 0 63 D onmn y SuperficialParticleVelocityH Ny collection 3 Given the vessel dispersion number and particle residence time the Dobby Finch equation is used to determine the a parameter by 4 4 2 a parameter a 1 4k E 7 N Where a a parameter of the Dobby Finch equation ky Flotation rate constant of the Jth rate class T P Particle residence time Na Vessel dispersion number Es 7 Efficiency factor k multiplier E00 gps Then if N Gl 7 4 4 3 Recovery in the collection zone The recovery in the collection zone can then be calculated from ar 4ae Rj ancz ake F i L a e 1 aj e Where Ry ancz I Recovery of the Jth floatability class by attachment a a parameter of the Dobby Finch equation SGS Minerals Services IGS User Manual 53 Na Vessel dispersion number 8 4 4 4 Recovery Then the recovery of the Jth floatability class in the column is given by Ry ancz R 1 R ENT R 1 Io neg LR J att CZ R recovery of the Jth floatability class ky rate constant of the Jth floatability class R froth recovery defined in the cell input R w water recovery ENT entrainment factor SGS Minerals Services IGS User Manual 54 5 0 Modifier Modifiers represent any unit that c
15. instructions outlined in 8 1 If a dataset containing both flotation and grinding feed is selected only the grinding feed will be used in the simulation SGS Minerals Services IGS User Manual 19 9 2 CONFIGURE GRIND CIRCUIT 1 To configure the grinding circuit click on Grinding tab on the left side of the main window A graphical representation of a typical autogenous ball mill circuit will appear File Edit View Flowsheet Data Grinding Flotation Help Pebble Crusher Parameters Crusher Index Enable Pebble Crusher Default S G Set a minimum cap for crusher index PCSO Grind Target Crusher CSS e e i d mm o JL PC8O bk Ball Mill Parameters Target P80 Max Target TPH Max Flotation Grinding Min Ci 10 AN PCCL Slope z Enable Ball Mill Feed Parameters PCCL Intercept Design Ball Mill Power F50 Max 0 45 Mill Power kW Fines Tuning 1 Bond Relationship F50 Slope a Bond Multiplier i Bond Exponent F50 Intercept 0 A ATA F80 Slope Bond Constant F80 Intercept 0 Autogenous Mill Parameters Pe A Enable AG SAG v Mill Type SAG Mill y Steel Load 13 Design Autogenous Mill Power Variable Power Transfer Size Parameters A A Mill Power kW o E Type SPI Range 0 Design Screen Size Efficiency Factor Screen Size mm SAG AG Factor Slope T80 Slope SAG AG Factor Intercept T80 Int
16. name e Simulation status Message display when simulation is complete or failed SGS Minerals Services IGS User Manual 5 6 PROJECT FILE MANAGEMENT The IGS project file is a database containing multiple flowsheets and datasets The database structure is IGS Project File show below Grind Float Grind Feed Float Feed Grind Float Circuit Feed The flowsheets are constructed and configured by the user while the datasets are provided by SGS and are vital for simulation There are two sub categories of datasets flotation and comminution feed The flotation feed contains mineral floatability data and the comminution feed contains ore s grindability data Appropriate datasets need to be loaded for the specific type of simulation SGS Minerals Services IGS User Manual 6 6 1 CREATING NEW PROJECT 1 To create a new project file select File on the menu bar and click New Flowsheet Data Grinding Flotation Help Cien Ctrl O Ctrl S PROCESS DESIGN 2 Enter a project name and select the destination folder Then click Save 7 E p xX h Ce Computer NEW VOLUME Project EEE Organiza New folder Dats Grinding Flotation Help H Videos 2 Name MH Demonstration Project igs ID Flotation Guideigs Destination folder TD Grind Guide iqs 05 12 2000 Ikl 165 Project 916 KE sl Homegroup Computer EL Local Disk C ca Local Disk D 7 ca Backup l E ca Backup
17. rate of the water since SG 1 3 1 2 Water Balance Once the residence time is established the water is balanced IGS gives the user three options to calculate water recovery Percent solid of concentrate stream Fixed water flow per cell Fixed water flow per stage The first water balance option is the simplest of all three The user specifies a desired percent solids target in the input sheet and the water recovery is calculated simply by dividing the mass flow by the specified percent solids and then multiplying by 1 percent solids The second method fixed water flow per cell is calculated using a linear function of the froth recovery The equation for this is simply Be SEP ey 3 1 3 1 SGS Minerals Services IGS User Manual 42 where R w water recovery R froth recovery C the constant parameter specified in the input sheet C N the linear parameter specified in the input sheet Note that the water recovery is a function of a constant parameter and froth recovery Thus the water recovery may change during the simulation runs The water recovery is dependent of froth recovery which is determined by solving the mass recovery until convergence When the mass recovery converges the water recovery iteration begins to solve for the water recovery Therefore by definition M conc I J Rig M redi 9 1 2 2 and M conc total gt M conc J I J Then the water recovery is given by R Mont
18. to save the current active flowsheet Click No to discard the current flowsheet Note The new flowsheet will not be saved when created A save action is required to save the flowsheet to the project file 7 2 OPEN FLOWSHEET Open a flowsheet saved in the project file 1 Click on Flowsheet on the menu and select Open Flowsheet Th File Edit View Flowsheet Data Grinding Flotation Help 2 Select the desired flowsheet to open and click Open z saved flowsheet and all its inputs will be loaded Es Save Import os Export Generate Image 4 IVANCED SYSTEMS New flowsheet Cancel SGS Minerals Services IGS User Manual 10 View Flowsheet Data Grinding Flotation Help El New Open flowsheet Flowsheet 1 User Name User 1 Flowsheet 1 description pla Al Lil a WA WA lode Ll a Er A Flowsheet 3 User Name User 1 Flowsheet 3 description Flowsheet created and last modified Flowsheet time stamp description 3 A prompt window will appear asking to save the current flowsheet before openning Click Yes to save No to discard or Cancel to cancel the open flowsheet action 7 3 SAVE FLOWSHEET Save the flowsheet into the project file 1 Click on Flowsheet on the menu and select Save Flowsheet 2 Enter a flowsheet name and description Then click Ok Both the comminution and flotation circuit flowsheet will be saved as well as the units
19. 0 2 CONFIGURE FLOTATION CIRCUIT 10 2 1 Creating Flowsheet Feed 1 Right click anywhere on the flowsheet construction frame to bring out a list of flotation unit icons 5 Mechanical Bank a i a 2 Column 2 Click on the desired unit will place the unit icon on the construction frame emt Regrind Modifier Note All flotation circuits must begin with a Feed unit odie and end with Product units Water Adder Junction 3 Placing a Feed and Mechanical Bank units on the construction frame looks like the following below The added units are also listed in the stage reporting frame B Mass Splitter P Product SGS Minerals Services 4 gt IGS User Manual TD Alatation Guida 165 File Edit View Flowsheet Data Grinding Flotation Help IE Y Error indicator RA Mechanical Bank 1 MECHANICAL BANK 1 Input output ports List of units DN FORECASTING Note Notice the red dot on the top left corner of the unit This indicates that the unit is not properly configured Right click on the unit and select Show Errors to display the error list associated with the unit MECHANICALBANK 0 Show Errors Route Links Configuration errors Type Source Name Message Error Unit MechanicalBank 0 Missing feed concentrate tail connection s Note The yellow dots indicate the unit s input and output ports Here showing the m
20. 17 8 9 AE ls A ree tr eer ere a oe Se ee Se ae 18 9 1 8101 AC he 018 re A O 18 9 1 Select Dataset a nas 18 9 2 Contigure Sind Bireulteni stats ea eu ee 19 9 83 SImUulat on and Reporingssu asia nenn Cecelia had come 19 10 PFlotallonSimulaloneen za ee ee 21 10 Select Dataset a een eier 21 10 2 Contigure Flotation Eifel ee a 21 10 2 1 Greating FleWwshedt unse alle ur 21 10 2 2 Units Contigua ON ie 23 10 22 5998 SEUD ae E ii aid 24 10 3 SImulation and Repo caida 26 IGS User Manual Appendix A Flotation Model SGS Minerals Services IGS User Manual 1 Getting Started 1 INTRODUCTION Integrated Geometallurgical Simulator IGS is a comminution and flotation simulation tool for production forecasting and circuit design The simulation parameters are extracted from standard tests Minnovex Flotation Test MFT for flotation and SAG Power Index SPI for comminution 2 SYSTEM REQUIREMENTS Operating System Windows XP Service pack 3 Windows Vista Service Pack 1 Windows 7 Software Microsoft NET Framework 4 0 Microsoft SQL Server 3 5 SP2 Compact Edition 3 INSTALLATION Execute the installer file provided in the SGS USB key and follow the instructions All required software Microsoft NET Framework 4 0 and Microsoft SQL Server Compact Database will be downloaded by the installer Note Administrative privileges are required to install Microsoft NET Framework 4 0 and Microsoft SQL Server Compact Edition
21. 5192 200 200 1 12575497 0 050303882 0 008422685 2 468216608 3 1900 lola a a ep ea E 12 2718 Fyi43 i fa fa 5192 os 200 200 jo 10401465492 0 17594563_ 0 012706029 r 6 33722 Fyia4 i fa fa 5192 od 200200 Ja fi fio 1517394073 0 0521596770 0192 os 2 26457 050173725 3 91672 m sl l l js e2 jo 200 200 Ja fi Jo 1243274503 0 021528503 0 012094845 1 001508405 2 33876 ECE EN FW ESS fo fejo o poo E PN PS 2 o 032413425 2896418634 4 33961 Fria i i fa 5192 Joza 200 200 J a fio 1636364902 o 027429265 0 000384757 2 24151747 4 7134 Fyi49 i fa fa 5192 od 200 20 a a Jo o997701278 0 140246688 0 005558943 3 004508674 1 5510 Fyi4i0 i 1 5192 fozg 200 200 a a Jo 1079207254 0 071596694 0 003549414 3 760229395 14081 Fyi4iifi fa fa 5192 jo 200 200 a fi 1160623229 0 0029467 0 001539884 4 515950115 1 2653C FY 1412 1 1 1 5192 hig Ini ese sige setae ae 03254 evaaa fa fa 5192 foz8 200 200 Ji Ji fio 1118371472 0031500404 0 010406682 4 126640706 2 9645 via 18 1 a a 5192 fozg 200 200 Ja Ji fao tos39234 0 065737821 0 017053167 a 449141 5 018170838 2 2334 Fyi4i6 i 1 a 5192 fozg 200200 a fi Jo 1107408231 0 040496259 0 010786489 2 012681441 3 1621 4 542549646 5 7243E m 9 GRINDING SIMULATION 9 1 SELECT DATASET Datasets containing grinding feed must be loaded for simulation To select the dataset follow the
22. 8 HE I Computer NEW VOLUME E Project Search Project Destination folder Organize New folder H Videos Name MH Demonstration Project igs H ze sine ir W Flotation Guideigs 03 12 2010 7 56 mic m Grind Guide igs 05 12 2000 10 41 I Lom er EL Local Disk C ca Local Disk D ca Backup l E ca Backup I F ca Backup M G exe NEW VOLUME E ca Local Disk 2 Enter new IGS project name Gia Network O Save project changes u No Cancel 6 5 CLOSE PROJECT 1 To close the active project select File on the menu bar and click Close 2 A save changes prompt will appear Click Yes to save changes No to discard changes or Cancel to cancel the close action Any changes made on the active flowsheet will be lost SGS Minerals Services IGS User Manual 7 FLOWSHEET MANAGEMENT kan Fite Edit View Flowsheet Data Grinding Flotation Help A flowsheet is defined by a comminution circuit and a flotation A circuit The circuit to be simulated is dictated by the feed data u Multiple flowsheets can be saved in one project file and can be il E Generate Image Hi Modify loaded as needed 7 1 CREATING A NEW FLOWSHEET CESS OPTIMIZATION 1 Click on Flowsheet on the menu and select New flowsheet 2 A prompt window will appear asking to save the current flowsheet 3 Click Yes
23. AM User Name User Modified 11 9 2010 11 10 19 AM Flotation feed example Grinding Example Example Dataset for grinding simulation Grinding Feed Grinding Example No Items 3955 User Name User Grinding feed example 8 2 IMPORT DATA SETS 1 To import a dataset igsdata click on Data and select Import 2 Navigate to the folder where the datasets are located select the desired dataset file and click Open Note Importing additional dataset files will append to the list of datasets in the project file SGS Minerals Services IGS User Manual 18 z 9 Select a dataset to open 1 QU de gt Computer NEW VOLUME i Usermanual Data set Organize v New folder S Name A Libraries TA APO NA Destination _ Grind Export dset 21 11 2010 908 4 eh folder E Pictures Bl Videos 2 Homegroup ME Computer amp Local Disk C Select ca Local Disk D o aii dataset file ca Backup I F a Backup IM G e NEW VOLUME l ca Local Disk Ji File name vw Dataset Files dset z 8 3 VIEW DATA SETS To view the block data of a dataset select a data set and click View A maximum of 100 blocks will be displayed Click Close when finished Flotation Plant Demo Flotation Feed Grinding Feed ID X Y Z Solid Mass Flow Solid Fraction P80 Reference P80 Ore Type Tons en Angle CuSulf_Assay CuOx_Assay Moly_Assay Au_Assay Pyrite_ FY14_1 1 1 1
24. Flowsheet Data Grinding Flotation Help Edit View Flowsheet Data Grinding Flotation Help E gt Feed 0 E gt Feed 0 I Product 1 F IR Product 1 F I Product 8 iI Product 8 P Junction 6 P Junction 7 i Mechanical Bank 2 FA Mechanical Bank 3 Regrind Modifier 9 Column 4 i in H pan E du i 00 IGS User Manual 25 3 To delete a stage right click on the stage name and select delete All units grouped under the deleted stage will be automatically moved out of the stage File Edit View Flowsheet Data Grinding Flotation Help Noris E iP iP OPTIMIZATION Stage Feed 0 Product 1 Product 8 ZZ Regrind Modifier 9 Delete 6 F Junction 7 Mechanical Bank 2 MA Mechanical Bank 3 DN FORECASTING Edit View Flowsheet Data Grinding Flotation Help E gt Feed 0 iI Product 1 i Product 8 E Regrind Modifier 9 7 Column 4 P Junction 6 P Junction 7 Es Mechanical Bank 2 Fl Mechanical Bank 3 4 To name a stage select the stage and enter a name for the stage in the Name field in the unit property frame Repeat for all stages E iP E D UA Lu a un xf J je eL Feed 0 Product 1 Product 8 Enugher P Junction 6 PP Junction 7 FA Mechanical Bank 2 A Mechanical Bank 3 Cleaner Regrind Modifier 9 7 Column 4 Edit View Flo
25. I F ca Backup M 6 E em NEW VOLUME Ga Local Disk 4 Enter project name Alt F4 fia Network VANCED SYSTEMS 6 2 OPENING EXISTING PROJECT 1 To open an existing project file select File on the menu bar and click Open 2 Navigate to the folder where the project file is located 3 Select the project file and click Open or double clicking the project file SGS Minerals Services 6 3 1 To save the active project select File on the menu bar and 6 4 SAVE PROJECT click Save IGS User Manual Destination folds Alt FA om Select project to open CESS OPTIMIZATIO ROCESS DESIGN SAVE PROJECT AS NEW PROJECT 1 To save the active project as a new IGS project file select File on the menu bar and click Save As 2 Navigate to the destination folder Organize New folder al Music Name Pictures H Videos M Demonstration Projectigs M Flotation Guide igs Enter an IGS project name and click Save Date modified Type 04 12 2010 10 12 165 Project 03 122010 7 56 AM 165 Project I Grind Guide igs 05 12 2010 10 21 165 Project el Homegroup Computer EL Local Disk CH ca Local Disk D ca Backup Lie ca Backup I F ca Backup M G aa NEW VOLUME E a Local Disk k Gia Network I File name Grind Guide igs SGS Minerals Services IGS User Manual
26. appear Once complete the standard flotation report window will pop up See section 10 4 for more information SGS Minerals Services IGS User Manual SGS Minerals Services 33 IGS User Manual APPENDIX A FLOTATION MODEL SGS Minerals Services 34 IGS User Manual 35 1 0 IGS Flotation Model 1 1 Flotation Simulation IGS is mathematical simulation software used to simulate a metallurgical operation to forecast the metallurgical production It is also a powerful tool to monitor the operation IGS employs a new mathematical model FLEET used an iterative process where each unit is calculated until convergence before moving to the next unit This method uses multiple nested loops which are very repetitive and time consuming For flowsheets involving recycles convergence will most likely not reached after the set maximum amount of iteration allowed This obstacle was overcome with IGS by using a matrix of simultaneous equations to balance the entire circuit Like the FLEET software the flotation inputs for IGS are gathered from MFT tests 1 2 System of Simultaneous Linear Equations IGS employs the system of linear equations Ax b to solve the flowsheet where A is a matrix representing the flowsheet configuration x is the result vector column matrix and b the constraint vector The constraint vector contains the solid and water going into the system The matrix is solved for each mineral rate The flowsheet co
27. ctive dataset contains both grinding and flotation block data As default the flotation tab will be automatically selected when no active dataset is selected SGS Minerals Services IGS User Manual Menu Bar Options e File New Create new project Open Open existing project Save Save project Save As Save project as a new project file Close Close the project Exit Exit IGS program e Edit Undo Undo last action Redo Redo previous action Delete Delete selection Cut Cut selection to clipboard Copy Copy selection to clipboard Paste Paste clipboard to cursor e View Zoom in Zoom In by 25 Zoom out Zoom Out by 25 Reset Reset zoom to 100 e Flowsheet New Flowsheet Create a new flowsheet Open Flowsheet Open an existing flowsheet Save Flowsheet Save the flowsheet Import Flowsheet Import a flowsheet from file Export Flowsheet Export the flowsheet to file Generate Flowsheet to Image Export flowsheet to picture PNG format Modify Flowsheets Rename and delete saved flowsheets e Data Import Data Import dataset from file Modify Data Edit dataset name and description and delete datasets Select Data Select dataset for simulation e Grinding Configure Configure grinding circuit inputs Simulate Simulate grinding circuit e Flotation Simulate Simulate the flotation circuit Order Connections Set stream reporting order e Help About Software information Status Bar e Dataset Display selected dataset
28. echanical bank s input and output ports These ports are used to connect the units together 22 To move the units around the frame place mouse over the center of the unit icon and the mouse cursor will change Into Click and drag the unit to the desired location in the construction frame To connect the units mouse over the output ports indicated by yellow dots The mouse cursor will turn into a Click and drag to another unit s input port also indicated by yellow dots If the unit SGS Minerals Services IGS User Manual 23 cannot be connected at the cursor s location the cursor shape will turn into 6 The mouse cursor M will indicate that the input port can be connected with D Rotation Guide 165 File Edit View Flowsheet Data Grinding Flotation Help were Mechanical Bank 1 FEED 6 MECHANICAL BANK 1 OPTIMIZATION 6 Repeat steps 2 to 7 until the flowsheet is constructed Edit View Flowsheet Data Grinding Flotation Help FEED 0 FA Mechanical Bank 2 LE il Mechanical Bank 3 JUNCTION 7 MECHANICAL BANK 2 MECHANICAL BANK 1 Column 4 SUNSC TION 16 P Junction 6 P Junction 7 REGRIND MOCIFIER 5 iB Product 8 Regnnd Mad her 5 COLUMN 4 SAMPLE SELECTION 7 Save the flowsheet by clicking on Flowsheet on the menu bar and select Save Enter a name and a description and click Ok 10 2 2 Units Configuration Each unit needs t
29. ercept Design Grate Size nva d n put Grate Size mm Dataset None Flowsheet None 2 Fill out the input paramter form with appropriate values and click Ok Note Invalid inputs are indicated by a red outline around the input field Place mouse over the input field will display an error tooltip All input fields must be clear of errors in order to continue Tips Placing the mouse over the input field will display a tooltip with detail description of the input parameter 9 3 SIMULATION AND REPORTING SGS Minerals Services IGS User Manual 20 With the appropriate dataset selected and the flowsheet configured click on Grinding on the Summary Sine SPEM Throughput Sporte Power menu bar and select Simulate Once the nn wa simulation is complete a report window will appear u E SMG A 1503000 SAGING kh SOLLEN The first tab displays the result summary SS en Line and Ball Wear 2165 17 Sa Agel 140136450 18 2417 48 SALIA Liner 121767654 TE Kira TPH 2111 BM Ball MALE The second to fifth tab display the cumulative BM ne 5705301539 Mine Life distribution plots for feed bond work index BWi Seance zur SAG power index SPI circuit throughput specific power and transfer and product size The limiting throughput plot is also included in the reporting window SFI sel DAN Cumae Deir Dago tim teen 105008 rro beoir ees Speni Pose Derbi
30. hanges the floatability distribution of the feed to the product This is equivalent to moving mass from one floatability particle class or rate constant bin to another Two distinct types of modifiers must be considered Concentrate modifier Second float modifier The models of these two types of modifier are different since they represent significantly different physical processes 5 1 Concentrate modifier The concentrate modifier typically takes rougher concentrate and represents a regrind and or chemical change where the product has significantly lower floatability for the gangue mineral s and slightly reduced floatability for the valuable minerals This type of modifier is typical of a copper concentrate regrind where the particles are further liberated or polished in the regrind to remove attached gangue from the floatable particles and or the chemical conditions are changed to depress floatable gangue such as pyrite In terms of the model the modifier removes subtracts mass from some rate constant bins and adds it to others for each mineral based on a per mineral kavg and Rmax multiplier and constant value in the form of a linear equation Hence for each mineral 1 oa Cr maxmod ES M Rmaxmod Dean where IE Rei C Maximum recovery of the product from the modifier Maximum recovery of the feed to the modifier u Rmax constant value in the modifier Mind an ue Rmax multiplier value in the modifier and
31. here ag Vw volumetric flow of water in the feed streams S 1 Z S Ma ye S l 5 2 3 where oy Mi mass flow of the Jth floatability class for the Ith mineral in the feed 5 2 4 streams S 1 Z Oo M o M Y Mi J J 1 5 2 5 J N M M 5 2 6 M Csoia x 100 M Vw 5 2 7 M C X 100 M 5 2 8 SGS Minerals Services IGS User Manual 5 2 9 recovery of mineral in the Jth floatability class in the feed streams S 1 Z mass flow of the Ith mineral in the feed streams S 1 Z SGS Minerals Services 62 IGS User Manual 63 8 0 Splitter SE Eta i Ns 5 4 1 where Ns the number of output streams ae gt Vy rr Ns 5 4 2 Pa M Mis Ns 5 4 3 o ME M Ns 5 4 4 e LF M 2 Ns 5 4 5 Csolia x 100 M Vw 5 4 6 M es x100 M 5 4 7 Ri xM Rez x 100 Rio xM 5 4 8 a a M 5 4 9 SGS Minerals Services IGS User Manual 9 0 Water adjuster 64 SG SG 5 6 1 C C 5 6 2 Ri Ri 5 6 3 O O F M 5 6 4 e M se M Y M J A 5 62 5 O N O M M 1 5 6 6 When the water addition option selected is Change Solids then s F M AF LF X 100 NC F o M Vy 5 6 7 Colia where I Solid change in concentration solid defined in the input When the water addition option selected is Target Solids Dilution only then I Csotia Csotia 5 6
32. is effectively given by k multiplier for mineral 1 N 8 9 10 11 12 13 14 15 Bin J It is evident that this set of ratios is nearly linear resulting in a slight bias towards a greater number of bins at low k values The theoretical basis for a greater number of bins at low k is well founded and this distribution should be examined in terms of the number of bins required and the relative distribution of those bins relative to kmax to optimize the accuracy vs calculation speed l S Val ue e normaliseBinEdgePoition 0 5 sigmoidStepness 2 2 4 Calculating k The first bin centre is taken to be zero The remaining bin centres are simply determined as the average of two consecutive k values in the distribution yielding ki ja 0 SGS Minerals Services IGS User Manual 39 and E kija K k a 1 J 2 M 2 2 2 4 1 Where the j values are taken to be the bin edge values and the J values are the bin centres used in the calculations that follow The ratio ofthe kj and kJ values multiplied by alpha is determined but this ratio is not used further in the calculations and should be removed from the code 2 3 Determining the distribution of the feed in the flotation rate classes k s 2 3 1 Description The proportion of the Ith mineral in the feed falling in each of the J flotation rates must be determined to calculate the recovery and mass balance per flotation rate kl J A cyclone partition curve e
33. is given by O ails J a noHoldup A column Where Ja noHoldup PT itv j i Superficial slurry velocity ignoring the effect of gas holdup Q aits Tails volumetric flowrate including wash water A i column Cross sectional area of the column Then the true or effective slurry superficial velocity is given by J sl noHoldup J Cf LE 4 3 2 Slurry residence time Assuming the effective slurry residence time is used the slurry residence time is given by collection J Where Ta Ts she 5 Residence time of the slurry in the collection zone 4 3 3 Mean particle density SGS Minerals Services IGS User Manual 50 The mean particle density is derived from the mass flow matrix in fractional form and the density of the particles minerals M M fractional I J M 2M Then P p gt M fractional I J P I 4 3 4 Particle Reynolds Number Given an assumed value of the particle slip velocity for example U 0 002 Particle slip velocity m s U Particle Reynolds number is calculated using the assumed slip velocity and recalculating via the relation PU d sp p 50 Re ae Where Re P Particle Reynolds number dimensionless Pi Density of the fluid kg m3 P Particle slip velocity m s d 2 50th percentile of the particle size distribution um l u 0 001 Viscosity of the liquid water Pa s or kg s 1 m 1 for water at 20C Note that the existing column model correct
34. is important and used in the column cell model to calculate the mass balance The most important of all is the collection zone which is where the particles adhere to the gas bubbles column column H froth column H airHoldup H collection g H H H H H H collection effective collection column froth belowSpargers V V collection effective H belowSp arg ers y belowSp arg ers 4 2 Water balance 4 2 1 Balance of the concentrate water The concentrate water flow is calculated from the concentrate mass flow and the target concentrate solids fraction SGS Minerals Services IGS User Manual 48 O _ a l P oone w conc w conc S Conc Deo Q A The concentrate water derives from three sources the wash water water from channeling through the froth Qs concchanneting and potentially water from a negative bias known as water from the pulp g REED SA LA O iie pulp ati 4 2 2 Wash efficiency factor There is inefficiency in the froth referred to as channeling whereby a fraction of the feed water is not washed from the froth by the wash water For the purposes of calculating recovery this entrained material contributes to the water recovery Rw and entrainment A wash efficiency factor Ewash is defined and the concentrate water flow from channeling is calculated relative to the concentrate water flow Q w conc channeling l En O cee Rearranging N E l E E O RR 4 2 3 Wash ratio a
35. is the simplest of the three and this value is used directly in the recovery calculation 43 The second method is to use a linear function of the froth recovery to determine the water recovery The equation for this form is simply R C C R ye ee 3 1 3 1 where R W water recovery R froth recovery C C N It is interesting to note that if Rw is a function of Rf and Rf is a function of an input parameter Rw may change depending on simulation run inputs SGS Minerals Services the constant parameter specified in the input sheet the linear parameter specified in the input sheet IGS User Manual 44 The concentrate percent solids calculation is performed iteratively in the sense that the water recovery is recalculated once per loop over all simulation units Note that this does not mean that the water recovery mass recovery relationship is solved within each unit for each outer loop iteration Instead the mass recovery is calculated once on the basis of the last mass recovery calculation This is likely to contribute to a large number of loops required for convergence and instability in the model calculation By definition M vonc t s Ri f M joed t J Hele 2 2 and M iava M onis I J Then the water recovery is given by R eef L Ms peed Peone 3 1 2 3 conc total total mass flow rate M w water flow rate Digs concentrate solids fraction and on a stage basis R
36. ja Ceras Throughput Curl Deriniton The simulation results can be exported to excel xls xlsx or csv file Click on Export on the report menu bar and select Results Browse to the folder where the file will be saved enter a filename and SGS Minerals Services IGS User Manual 21 click Save The simulation summary detailed block output the circuit configuration parameters and the report plot s x y coordinates are reported To save the simulation report click on Export on the report menu bar and select Save report Browse to the folder where the file will be saved enter a filename and click Save To open an existing report click on File on the main window menu bar and select Open report Browse to the folder where the report file is located open the file by selecting the file and click Open or by double click on the file 10 FLOTATION SIMULATIONS 10 1 SELECT DATASET Datasets containing flotation feed must be loaded for simulation To select the dataset follow the instructions outlined in 8 1 If a dataset containing both flotation and grinding feed is selected only the matching blocks in both flotation and grinding feed will used in the simulation The matching blocks in the grinding feed will be used to simulate the expected product size and throughput for each block The results are then used as feed parameters for flotation simulation Unmatching blocks are ignored and will not be simulated 1
37. l discrete values of D that fall adjacent to the 50th percentile of the distribution at D 0 5 We will denote these Do for the value immediately below D 0 5 and Dis for the value immediately above D 0 5 The rate constant values that correspond to these points are denoted kso and kso respectively Then by linear interpolation Ko Kso Ds Di os E Da Kan Kso Calculating the gamma parameter As defined above for a given mineral 1 k G M TAE avg F avg P avgmod Now we define an adjustment to the rate constant distribution y that will be used to redistribute the mass between rate constant bins Gamma is taken to be the ratio of the kavg values for the product and the feed k avg P k avg F Then _ cad i M eh avg F aa M u k u k At kavg mod avg F avg F SO kavg mod M kavg mod K 50 3 2 NF SGS Minerals Services IGS User Manual 56 Applying the gamma adjustment to the mass fractions The rate constants for the entire simulation are fixed so the rate constant values for the bins cannot be adjusted Therefore the mass fractions in each bin must be changed to duplicate the effect of the change in rate constant For all J 2 N rate constants the target product rate constant value is derived from gamma and the Jth rate constant value k J target r k Consider the mass fraction redistribution for a given rate constant source value ky In general two rate k constant bins
38. le size distribution To achieve this the first step in the calculation is adjusting for each of the minerals the input maximum recovery and rate constant values from the SGS flotation test MFT particle size to the plant particle size using a correction factor calculated in the MFT parameter extraction process A linear adjustment is made to the maximum recovery values E S I I I R naxs a Rest x Pl ur T Pot R nax 2 2 1 where F mar feed fractional maximum recovery of the Ith mineral R meet input fractional maximum recovery of the Ith mineral from MFT R ODE input correction factor linear slope for Rmax for the Ith mineral p input 80th percentile of the MFT test particle size distribution Pisce input 80th percentile of the plant particle size distribution An analogous linear correction is applied to the rate constant values SGS Minerals Services IGS User Manual 37 F I I I I k k x Pier T o Plant k avg avgSlope avgl 2 1 2 where kE avg yl feed flotation rate constant of the Ith mineral k avgi input flotation rate constant of the Ith mineral from MFT k avgslope I input correction factor linear slope for kavg for the Ith mineral p men input 80th percentile of the MFT test particle size distribution I Eso Plant input 80th percentile of the plant particle size distribution R k For the remainder of the calculations all references to and 8 refer to these corrected feed
39. mum error of the objective function is reached The first two tabs plots the survey data versus simulated data on two different axes linear and logarithmic The remaining two tabs are standard flotation simulation report tabs See section 10 4 for more information SGS Minerals Services IGS User Manual 32 a Bene ip F 7 E a q l aalala Bass lao 12 OPTIMIZATION IGS can automatically optimize the froth recovery to achieve the user s desired grade and recovery ratio This functionality is enabled by the dataset provided by SGS Canada When a dataset with optimization functionality enabled the Optimize option will appear under Flotation on the menu bar Grinding Flotation Help tg Simulate Order Connections Order Connections EEE DE d 12 1 SELECT DATASET AND FLOWSHEET CONSTRUCTION Datasets containing flotation feed and an optimization target must be loaded for simulation To select the dataset follow the instructions outlined in 8 1 Construct the plant s flowsheet by following the instructions outlined in 10 2 12 2 OPTIMIZATION AND REPORTING With the appropriate dataset selected and the flowsheet constructed click on Flotation on the menu bar and select Optimize If the Optimize option is not available please contact SGS Canada at IGS sgs com for more information A dialog indicating the optimization progress will
40. nd wash water We define a wash ratio as the ratio of the wash water addition to the concentrate water flow O ratio O w conc Case 1 Wash water calculated from specified wash ratio On SS RR ratio Case 2 Wash water rate specified as a constant C Oi 4 2 4 Bias and water from the pulp If there is not sufficient wash water to fully displace the pulp water negative bias If Q ww lt O rene Qs concehanneline then Ooi pulp O ves On a Ord Else if the wash water is sufficient to fully wash the froth positive bias Oo e O igs EZ O conschamelins 0 elseif Ossie pulp 4 2 5 Water recovery and overall water recovery SGS Minerals Services IGS User Manual 49 For the purposes of calculating entrainment in the recovery equation we define water recovery as the water in the concentrate that derives from the feed therefore having the pulp composition Ra O gua T O enan Ww O idad The overall water recovery is R O eis w O ista ae oe However in the overall water balance for the circuit we can treat the wash water as an additional feed stream a junction before the column so that it modifies the residence time correctly so in practice R sans Ma O feed 4 2 6 Reporting bias velocity For reporting the bias velocity is required Oye Ooi bias A C J 4 3 Residence time 4 3 1 Effective slurry superficial velocity The vertical velocity of slurry in the column without air
41. nstructed by the user can be represented using a matrix The flowsheet configuration matrix is built as the user creates and joins the units together For each newly created unit the builder appends new row corresponding to the number of output port s and new column corresponding to the number of input port s For example fresh feed unit has one output mechanical bank cells and flotation column units have three ports one input two outputs and junctions have multiple inputs and one output The rows and columns that represent a specific unit are arranged in the order of input then output s For units with more than one output the concentrate precedes the tails Once the flowsheet matrix is setup a number of systematic steps are taken to reduce the matrix by substitution and decomposed into an upper and lower triangular matrix 1 3 Calculation Sequence The calculation sequence used by IGS is vastly different from FLEET because of the new mathematical model The calculation sequence is depicted below SGS Minerals Services IGS User Manual 36 Evaluate Unit Parameters Populate Matrix Solve Matrix Yes Report Results Construct Flowsheet Matrix Block Data 2 0 Flotation Kinetics 2 1 Correction of Rmax and Kavg A key advantage of the calculation process is that predictive modeling is performed at the plant particle size based on laboratory measurement of the flotation kinetics with a different partic
42. nto consideration ore variability lo appropriate timescale Fit for purpose solutions and better understanding of the system and potential solutions Financial planning and production scheduling can take into account the quantitative prediction of production rate and product quality to maximize revenue ADVANCED SYSTEMS Geometallurgical services from SGS i Laboratory testing of all aspects of the ore including chemical and geochemical assay mineralogical analysis and all globally recognised metallurgical tests Onsite laboratories for production planning and near real time analysis and diagnostics Sample selection to maximise client returns from sampling and testing Remote or onsite pilot plant services to investigate variability of pulk samples selected by the geometallurgical approach Integration of geological mineralogical and metallurgical te maximize data integrity and usefulness now and in the future Forecasting of production parameters such as plant throughput grade recovery P so and concentrate grade on a monthly quarterly or annpal oasis with a statistical confidence interval Status bar Displays Dataset name flowsheet name and simulation status regults in a database to taset None Flowsheet None E The flotation main window default will appear after creating a new IGS project T test IGS r pr neg E a al me spo Simluation type E tab al
43. o be manually configured All newly created units will have typical values set Select a unit on the construction frame stage or the stage view frame and the units configuration inputs will appear in the unit property frame SGS Minerals Services IGS User Manual 24 Tip Placing the mouse over an input parameter will display the detailed description of the input parameter Note An invalid input will cause a red outline around the text box A red dot will also be placed on the top right corner of the corresponding unit on the construction frame 10 2 3 Stage Setup Several units can be grouped into one stage The stage will be reported as a single unit with one feed and two output streams concentrate and tails This feature is useful for looking at the grade and recovery across several units as one cohesive unit 1 To setup a stage right click on the stage view frame and select Add Stage P Junetion 6 P Junetion 7 F Mechanical Bank 2 FA Mechanical Bank 3 E Regrind Modifier 9 T Column 4 2 Click and drag the units to be reported in that stage File Edit View Flowsheet Data Grinding Flotation Help Es Feed 0 iP Product 1 Br Product 8 E Regrind Modifier 9 7 Column 4 Stage P Junction 6 P Junction 7 Fl Mechanical Bank 2 El Mechanical Bank 3 OPTIMIZATION SGS Minerals Services Flotation Guide Flotation Guide File Edit View
44. ow of the total feed to the unit i mass fraction of the Ith mineral relative to the feed also referred to as the assay value F CUNA cumulative mass fraction of mineral apportioned to the Jth floatability class follows from the definition Also Mio M omo 2 3 3 2 and M M out J E M oom JA 2 3 3 3 follow from the definition of the cumulative distribution SGS Minerals Services IGS User Manual 41 3 0 Mechanical Bank 3 1 Recovery For each mechanical bank the recovery of each mineral is calculated by balancing the amount of water and solids entering and exiting the system The two compartment model by Savassi is used to calculate the solid flow and one of the three mechanisms is used to calculate the water recovery The recovery of each mineral and water across each stage or cell must be calculated for the mass balance The two compartment model of Savassi is used to calculate the solids mass flow and one of three mechanisms are used to calculate the water recovery 3 1 1 Residence Time IGS first calculates the residence time required using the following formula y T Q 3 1 2 3 where T residence time of the cell 4 volume of the stage where V N en cen Q otai volumetric flow of the feed to the cell as opposed to the technically correct tails basis and M o Ooi gt SG Tr Q tee a 3 1 2 4 where SG ae specific gravity of the Ith mineral O M volumetric or mass flow
45. owsheet f permanently Flowsheet 3 User Name User Created 12 2 2010 4 18 02 AM Modified 12 2 2010 4 18 02 AM Delet 1 To modify the flowsheet name and description click on Edit associated to the flowsheet The flowsheet name and description will become editable Flowsheet name edit box Flowsheet 3 Flowsheet description U User Name User edit box 010 4 18 02 AM 2 Click Save to save the changes Press Cancel to discard the changes 3 Press Close to exit the flowsheet management SGS Minerals Services IGS User Manual 16 8 DATA MANAGEMENT The dataset files igsdata are vital for simulation and are provided by SGS It contains all the mineral floatability and ore grindability information 8 1 SELECT DATASET ST File Edit View Flowsheet Data Grinding Flotation Help A dataset containing the appropriate feed must be selected to run a simulation 1 To select the appropriate feed information or use another change the dataset for simulation select Data and select Select 2 Click on the dataset to be used for the simulation and click Select To cancel the selection click Cancel The selected dataset s name will appear in the status bar SGS Minerals Services IGS User Manual Select dataset Flotation Example Example Dataset for flotation simulation Flotation Feed Flotation example No Items 80 Minerals CuSulph Au U308 Barit Py Created 11 9 2010 11 10 19
46. quation is used to fit the floatability distribution in the parameter extraction and is therefore used in the simulation to apportion the mass to each of the bins 2 3 2 Calculation of mass fractions per floatability class The equation to calculate the cumulative mass fraction in each floatability class is given by ki g ers a ng l u Roax Rush kiy Rei fe A i 2 3 2 1 where mi cumulative mass fraction of mineral apportioned to the Jth floatability class R max fractional maximum recovery of the Ith mineral corrected to the analysis P80 k me flotation rate constant of the Jth floatability class for the Ith mineral Ko I j e average flotation rate constant for the Ith mineral O slope of the flotation rate constant cumulative distribution at the 50th percentile Note that this calculation is split into the calculation of EAUX by krj ka EAUX e 0 322 which is substituted in to yield the above equation The cumulative mass fraction appears to be given the variable name r This calculation is performed for the fresh feed only Subsequent cells use the values of TPH or are passed from the concentrate or tails of the preceding cell 2 3 3 Calculation of feed mass flow per mineral per floatability class The relation M MxF xF cum l J I cum I J 2 3 3 1 where SGS Minerals Services IGS User Manual M il cumulative mass flow of the Ith mineral in the Jth floatability class M mass fl
47. s the Re for particle fraction but this is incorrect Also note that the units used in the existing column model are not SI The units used are g cm and s which invalidates the value of Re but these are used in the calculations due to constants calibrated for these units Therefore ds gt A s0impur 10000 and units are Re P Particle Reynolds number dimensionless incorrect Pi Density of the fluid tons m3 SG P Particle slip velocity cm s initially 0 2 cm s d Pan 50th percentile of the particle size distribution cm Ly 4 0 01 Viscosity of the liquid water g cm 1 s 1 for water at 20C http en wikipedia org wiki Reynolds_number SGS Minerals Services IGS User Manual 4 3 5 Particle slip velocity d 2 di 3 lo P li Dj le U 0 184 1 0 15Re Where G 981 cm s Unit check 2 m 2 kg ke 0 00018 0 00016 0 00014 0 00012 0 0001 0 00008 oe E Q 7 0 00006 0 00004 0 00002 0 Particle Reynolds number and slip velocity as a function of particle size after three iterations of substitution Maximum relative error is 0 3 at 140m 4 3 6 Particle residence time Particle superficial velocity is defined as J J stop Uy Where IGS Model Development Rev 23 xls SGS Minerals Services 91 IGS User Manual 52 Jp Particle superficial velocity Taeg Effective slurry superficial velocity accounting for gas
48. the Jth rate class between the feed and the product SGS Minerals Services IGS User Manual 57 X dd The mass fraction of material in the Jth rate constant bin in the feed Kor J 2 N The sum of all mass fractions in the rate constant bins from bin 2 to the end of the array X a The mass fraction in rate bin one the non floatable material in the feed X The mass fraction in rate bin one the non floatable material in the product So A F Xp Ar Xp AX Kur J 2 N A F Xp x F Xp X jp l X 1 X yr yee Xo Com X p J 1 N gt 3 X jp IRN J 2 N where er J 1 N The sum of all mass fractions in all bins defined to be one And A J 2 N So Xip X Xp 1 X which is true SGS Minerals Services IGS User Manual 58 6 0 Feed The feed is defined from the input values as follows M M xC i 2 5 1 1 where ME I mass flow of the Ith mineral in the feed M input mass flow of the total feed I C concentration or mass fraction of the Ith mineral in the feed also referred to as the grade or assay R R Bun TE 5 1 2 where R L i i i i R J Rm L er fractional maximum recovery of the Ith mineral in the feed If lt 0 001 ax O R R if 2100 72400 R tee input fractional maximum recovery for the Ith mineral F_ I ar d 5 1 3 where F 1 slope of the flotation rate constant cumulative distribution at the 50th percentile in the feed I By input slope of the flota
49. tion rate constant cumulative distribution at the 50th percentile ar ar ar ar 3 lf is less than 0 1 then 0 1 if is greater than 20 then 7 20 1f0 lt lt 0 1 the I A F flotation rate constant see following section and if Korg is greater than 200 then r 200 EAUX 1 Ri a 2 x By uF 100 u N EAUX e 5 1 4 where kiji 2 Ky ET XA recovery of the J floatability class for the I mineral When avg FI is greater or Rij equal to 30 then 100 SGS Minerals Services IGS User Manual 59 M _ M xR 100 5 1 5 where M mass flow of the 1st floatability class for the Ith mineral M x R Rija 100 5 1 6 N Ey lI mass flow of the Jth floatability class for the Ith mineral NS o SG I I 921 7 where SG specific gravity of the pulp solid fraction SG specific gravity of the Ith mineral J J F M M 5 1 8 where M mass flow total NE Osotia C said 5 1 9 where Csoria concentration solid also referred to as percent solid Cc Solid concentration solid in the feed 3 Mx 100 Coria C soria 5 1 10 volumetric flow of water V ine Cm i as BS 5 1 11 SGS Minerals Services where volumetric flow of pulp IGS User Manual SGS Minerals Services 60 IGS User Manual 61 7 0 Junction S 1 92 1 where e 9 Vp volumetric flow of pulp in the feed streams S 1 Z o Z o S Vy gt Vw S 1 5 2 2 w
50. to the technically correct tails basis and oe gt SG Du Q Br I 3 1 2 4 where SG TE specific gravity of the Ith mineral O M volumetric or mass flow rate of the water since SG 1 Note that this is for the case of fixed water recovery or water recovery as a function of Rf For fixed concentrate percent solids and therefore water recovery as a function of solids recovery the water recovery is calculated as per the following section SGS Minerals Services IGS User Manual 3 2 Concentrate and tail mass flows By definition for all minerals and for water M vonc t s R M red 1J 3 2 1 and the mass balance dictates that M tail I J M feed I J M EI 18 22 SGS Minerals Services 46 IGS User Manual 47 4 0 Flotation Column The column model differs from the mechanical cell model in that It uses different collection zone recovery equations The residence time is that of the particles in the column Column flotation recovery may be limited by the carrying capacity of the bubbles or unit dimensions The flotation kinetics in a column efficiency are lower than in a mechanical and this is represented by a rate constant kavg modifier After the collection zone recovery is calculated overall recovery is determined from the collection zone and froth recovery in a manner analogous to the mechanical cell model 4 1 Definitions Height and volume There are several dimension of a column cell
51. values 2 2 Determining the rate constants k s 2 2 1 Description For the modeling it is necessary to use fixed k values as the k distribution cannot be passed directly into the recovery calculation Therefore for each of the 1 N minerals J 1 M individual k values must be calculated for each distribution This section describes the method of calculating the kl J values 2 2 2 Calculating Kmax The kmax value is determined from the kavg and a alpha values for each of the minerals by the following equation A Foss 1 Fle pt se max a D where Orivaldo takes F D 0 9999 2 2 2 1 kmax is the 99 99th percentile of the k distribution this is an adequate approximation for our purposes k lf 7st is less or equal to 0 001 kmax 0 2 2 3 Calculating Kmuttiplier Once kmax is determined for the lth mineral this value is multiplied by a fixed arbitrarily defined set of k ratios defined here as kmultiplier to define the edges denoted kj where j 1 M of the bins denoted kJ where J 1 M that will be used to approximate the k distribution for each of the minerals The kmultiplier progression for all minerals is given by SGS Minerals Services IGS User Manual 38 lt E I D amp 2 2 2 2 5 x 123 45 67 8 9 10 1112 13 14 15 16 17 18 19 20 Bin J The values that exceed one are not used any further in the calculation and hence the progression
52. ve the flowsheet into the project file 7 5 EXPORT FLOWSHEET The active flowsheet can be exported to a file igsflsh The flowsheet diagram and the inputs parameters will be saved in the flowsheet file Note The datasets will not be exported SGS Minerals Services IGS User Manual 13 1 To export flowsheet select Export under Flowsheet on the E New E El Open menu bar El sue ly Export E Generate Image 2 Navigate to the destination folder and enter a name for the E Moxy flowsheet Press Save TEST SERVICES MO Enter the flowseet name T EA m OO de Computer NEW VOLUME Ej User manual Flowsheets rganize Hew folder Documents Name Date modified Type al Music _ Flowsheet expert 1 flsh 2111 3010 5 34 PM FLSH File l Pictures Flowsheet expert 2 flsh 02 12 2010 3 22 BB Videos Destination ed Homegroup fold er Computer EL Local Disk C ca Local Disk De mar inact Enter flowsheet ca Backup I F o ca Backup IM G filename MEW VOLUME E ca Local Disk k File name Flowsheet name Save as type Flowsheet Files flsh Hide Folders 7 6 EXPORT FLOWSHEET TO IMAGE The active flowsheet can be exported for reporting This option will save the active flowsheet as a portable network graphics file png f File Edit View Eiowshset Data Grinding Flotstion Help 1 Click on Flowsheet on the menu and select Generate EPs
53. wsheet Data Grinding Flotation Help F SGS Minerals Services IGS User Manual 26 5 The stage input s and output s need to be specified Below the Name field specify the streams that make up the stage s feed concentrate and tails stream Repeat for all stages File Edit View Flowsheet Data Grinding Flotation Help E gt Feed 0 B gt Product 1 FEED 0 iP Product 8 E gt Y Rougher P Junction 6 Junction 7 SA Mechanical Bank 2 Feed stream A Mechanical Bank 3 com ponents Cleaner ZZ Regrind Modifier 9 7 Column 4 Concentrate stream components Name L un Lu a un WA s iJ O co Feed Column 4 tail Feed 0 Concentrate and tails Junction 6 Concentrate lA Tails stream Mechanical Bank 3 tail Tail wA com ponents 6 Repeat steps 1 to 5 to create additional stages E gt Feed 0 iP Product 1 i Product 8 Rougher P Junction 6 P Junction 7 mA Mechanical Bank 2 Es Mechanical Bank 3 Cleaner Regrind Modifier 9 j Column 4 10 3 ORDER CONNECTIONS The stream reporting order can be changed By default IGS reports the stream in the order they are created To change the stream order click on Flotation on the menu bar and select Order Connections SGS Minerals Services IGS User Manual 27 Connection rdering Each stream can be identified by the source unit s output node or

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