METSIM ® For Windows The World’s Premier PC Simulation Package for complex Metallurgical & Chemical Engineering Processes. BROCHURE CONTENTS - Introduction ................................................................................................................................................ 3 Model Planning .......................................................................................................................................... 5 Model Flowsheet Development & Key Definitions ............................................................................ 6 Files & Directories .................................................................................................................................... 7 Components ................................................................................................................................................ 8 Drop Down Menus ..................................................................................................................................... 9 Unit Operations Overview & Overview of Some Generic Unit Operations ............................... 1 2 Unit Operations - General, Mining, Materials Handling & Comminution ................................ 1 3 Unit Operations - Benefiticiation, Hydrometallurgy, Pryometallurgy & Gas Handling ........ 1 5 Dynamic Simulation Unit Operations & Costing Module ................................................................ 1 5 Operating Cost Report ........................................................................................................................... 1 6 Stream Data ............................................................................................................................................. 1 7 Reactions ................................................................................................................................................... 2 0 Process Controls ...................................................................................................................................... 2 1 METSIM Mechanics ............................................................................................................................... 2 3 APL ............................................................................................................................................................. 2 4 Value Functions Overview .................................................................................................................... 2 5 Value Functions ....................................................................................................................................... 2 6 METSIM Flowsheets .............................................................................................................................. 3 1 METSIM is Developed by: PROWARE Mr. John Bartlett Tel: (1-520)-299-7834 Fax: (1-520)-299-8009 E-Mail:
[email protected] Homepage: http://www.metsim.com Mr Kevin Charlesworth, Director Kevin Charlesworth Consulting Australian and Asian Agent For METSIM PO Box 2021 Port Macquarie, NSW 2444 Australia Tel & Fax: 612) 6583 3274 Email:
[email protected] Web Page: http://members.ozemail.com.au/~ozmetsim/ Introduction The basis for analysis of all chemical and metallurgical processes is the mass and energy balance. Plant design, capital costs, and technical evaluations are all dependent on such calculations. METSIM is a general-purpose process simulation system designed to assist the engineer in performing mass and energy balances of complex processes. METSIM uses an assortment of computational methods to effect an optimum combination of complexity, user time, and computer resources usage. METSIM originated as a metallurgical process simulation program, written to perform mass balances around the major unit operations of complex process flowsheets. Application of the program proved so successful that it was expanded to include detailed heat balances, chemistry, process controls, equipment sizing, cost estimation, and process analysis. The unique nature of the programming language, APL, allows modification and expansion of the system with minimum effort and permits the incorporation of continuing technological innovations in process simulation. Many diverse processes, including chloride leaching of molybdenum concentrates, hydrochloric acid leaching of alumina clays, gold cyanidation / precipitation, roasting and flash smelting of copper concentrates, SAG milling of various ore types, acid and carbonate leaching of uranium and vanadium ores, heavy media coal preparation plants, base metal smelting, and gold and copper heap leaching, have been modeled with METSIM . METSIM can perform mass and energy balance calculations for: 1. 2. 3. 4. 5. 6. Process feasibility studies. Alternative flowsheet evaluations. Pilot plant data evaluation. Full scale plant design calculations. Operating plant improvement studies. Actual plant operations. Some advantages of using METSIM are: 1. 2. Computer simulation is less costly than operating a pilot plant. METSIM facilities extrapolation and scale-up of process options. 3. METSIM requires the engineer to develop a detailed understanding of the process and provides a format for evaluating process design criteria. 4. METSIM allows evaluation of operating techniques and anticipation of potential problems. The complexity of METSIM models created is dependent on the purpose of the computer simulation and the ingenuity of the engineer. It is suggested that users become familiar with the program through the on line-help system before attempting to build a model. Only in this way can the user take full advantage of all the unique attributes of the METSIM program. This on-line help is organized such that the user is first acquainted with the basic components of the system and the procedures to be followed to get the program running. It also provides the detailed data requirements of the various components and the mechanics of entering process model data in the METSIM program. METSIM provides the power of the largest computers with the complexity of advanced engineering mathematics. METSIM was designed to take full advantage of the work space characteristics, interactive capabilities and functional power of APL. The need for complicated job control language, file handling, text editing, and debugging programs has been eliminated. 3 METSIM performs mass and energy balances for chemical processes using the sequential modular approach. This method is used because of its elegance and amenability to simplify divers and complex flowsheets. METSIM can easily be expanded to encompass new processes and techniques. A major advantage of this approach is that intermediate results may be obtained from any stage of the process in an intelligible form. This attribute of METSIM is invaluable when attempting to detect possible modeling or specification errors. In conformance with the sequential modular approach, METSIM comprises modules containing subsets of equations describing the design specifications and performance characteristics for each process step. The system solves the equation subset for each module, allowing for an individual analysis of each unit operation in the flowsheet. Given data on design variables and input stream composition, each module calculates all of the output stream variables, which can then be used as input stream values for the next process step. The modules access data on all independent stream variables from the data arrays contained within the APL global workspace. Additional input data required to solve the equations in each module are requested by the program and are stored as global variables. The user may supply actual data obtained from operating or pilot plants, from similar processes, or from estimates supplied by the engineer. Unlike several process simulation programs currently in use within the chemical process industry, METSIM eliminates the need for user involvement in recycle stream tearing. METSIM employs a technique whereby the user is required only to provide initial estimates of the recycle stream content of critical process streams. Multiple stream numbers are not required and METSIM determines which streams are to be torn. Rapid recycle stream convergence is assured by using the Wegstein convergence accelerator. This technique almost always results in recycle stream convergence in less iteration than the direct substitution method. METSIM ’s flexibility is further enhanced by the use of feedforward and feedback controllers for process adjustment and control. Since the dynamic behavior of METSIM ’s controllers is similar to that of process controls in operating plants, unstable control strategies can often be located during the modeling stage, avoiding costly field modification and retrofit. The successful application of the METSIM system of programs involves more than simply entering fixed data on standardized input sheets. Due to the wide variation in chemical and mineral processing techniques, available data, process criteria, and output data requirements, the development of process models is as much an art as it is a science. METSIM is not a panacea for the engineer; it supplements not replaces, sound engineering practices and judgment. The user must be familiar with process engineering mass and energy balance calculations. Familiarity with mathematical modeling, numerical analysis, and process control is most helpful when modeling complex processes. 4 5 . The following sequence is strongly recommended from experience with many flowsheeting projects. especially about new processes. Sketch a process flowsheet with all unit operations and streams present. 1 6 Execute main calculation program and debug the model. 1 1 Provide precise flowrates and compositions for all input and estimates for recycle streams. Due to the wide variation in metallurgical and chemical processes. and trace elements to completion. 6 7 8 9 1 0 Add unit operation data. 1 3 Calculate flowsheet and check results to verify input and mechanisms. and separation parameters. purposes of models. and compile the data required to execute each. They failed to plan‘. 1 4 Add process controls to adjust parameters to meet design criteria. Load METSIM. Select appropriate METSIM unit operation modules listed under the screen object buttons. and debug the model. Whilst it is recognized that information. Modeling is not a trivial task. Make a list of all phases present and list all components in each phase. Select the components from the database ‘DBAS Component Database‘ and edit component data ‘ICOM Edit Components‘. 1 2 Enter stream names and input stream flowrates and composition. Use the 'Model Parameters' Task Bar Button to set the major switches and select the units of mass and time. and add unit operation chemistry and heat balance data. which can easily be abused by not ‘getting it right’ from the beginning. 1 8 Provide a detailed process description. equipment sizes. and track revisions of the model underneath. applies to process modeling as any other complex activity. Initialize the model to zero all data. and availability of data. individual judgement must be made as to the amount of time and detail given to each step. will be incomplete. Write out chemical components and reactions in each unit operation. Build the flowsheet using the Screen Interface palette entering all unit operations and streams section by section. this sequence should be followed as closely as possible. METSIM is a powerful tool. 1 5 Add detailed algorithms. 1 2 3 4 5 Assemble all available information before beginning. 1 7 Generate the required output reports.Model Planning The old adage ‘No one planned to fail. minor streams. MODULES . Key Definitions To prevent misunderstanding and confusion the following key definition should be noted: COMPONENTS . however. 1 One or more streams join to form a new stream. phase change. Unit operations and their data are renumbered automatically. and infiltration air. but it is desirable to make allowances for the addition of flowstreams and unit operations as complexity increases. particle size change.Model Flowsheet Development The developed flowsheet should be as complete as available data permit and structured to produce levels of accuracy desired in the final results. METSIM allows addition of unit operations through the screen interface and changes in the sequences of calculations through the routine ‘ IFLS Use "ONLY" to Rearrange Flowsheet “. Typical omissions included pump gland water. The user need not be concerned with the precise nature of the unit operation module at this time. MATERIAL BALANCE . UNIT OPERATIONS .measured plant data adjusted to give a perfect mass balance. STREAMS . These types of flows are often omitted in general process evaluations but should be included in detailed design calculations. experience gained through repeated use of the system will enable the user to assign unit operation numbers to maximize system efficiently.process flowsheets composed of unit operations and streams. which adjust variables to meet process criteria. open tank off gases. Unit operations modules forming recycle loops should be listed consecutively. CONTROLLERS .groups of components. PHASES . which do not physically mix. pure elements. interact and separate. evaporative losses. etc. 2 One or more streams split into two or more streams.unit operation programs or groups of programs.calculated or simulated flows into and out of a process. MODELS . temperature change. or any physical changes resulting in the formation of a new stream of different chemical or physical properties. One should examine the flowsheet carefully for omission of any streams. All mass entering or leaving the process must be associated with a process stream. Input data can be readily revised as the flowsheet evolves from general to detailed.material flows of components between unit operations.process units where streams merge. MASS BALANCE .mass balance entities such as molecular compounds. pseudo compounds.programs. METSIM unit operation modules should be defined at each point where one or more of the following conditions exist. 6 . Flowsheets having multiple and / or nested recycle operations complicate application of this guideline. 3 One or more streams undergo a chemical reaction. ions. Generally unit operations are numbered sequentially following the path of process flow. SF. where xx is the element symbol.sf Stemp MEX contains the following examples of flowsheet models: MWXAP MWXCC MWXUCIP MWXCuHL MWXDPS MWXDTNK MWXFC MWXFF MWXHYL MWXNG MWXpHCTL MWXSMLT MWXSXEW MWXAUT Stemp XXX Sulphuric Acid Plant SAG Mill/Ball Mill Comminution with Costing CIP/CIL Unit Operation Copper Heap Leach Dynamic Pierce Smith Converter Dynamic Tank with XCEL DDE Exchange Lead/Zinc Flotation Flash Furnace Smelting Direct Iron Ore Reduction using HYL Process Natural Gas Burner FEM pH Control Demonstration Smelter with Sections Solvent Extraction and Eletrowinning Autoclave Contains APL Windows 95.sfw Mettab. 7 . User Created APL Calculation Routines contains all METSIM screen objects Icons contains the following METSIM operating files: File containing Licensee configuration File containing METSIM tabulated data METSIM windows initiation file METSIM Security Device files and programs Fnc Icons MET Metmacw.Files and Directories When METSIM is installed. and application S file setup additional sub-directories can be created to store model files in. It should be noted that these sub-directories should not have further sub-directories.sf Metwini. or the file handling will indicate an error. METSIM DIRECTORY File Type Description Install LOG File log of selections and installation METSIM Adf APL Definition File METSIM Application APL runtime METSIM program METSIM Help File All METSIM online HELP METSIM Icon METSIM screen icons METSIM W3 METSIM APL Program files Units Application Uninstall program for METSIM Unwise Application Uninstall program for Wise METSIM DIRECTORY SUBDIRECTORIES DBF contains about 100 thermodynamic database files as METDBxx. a METSIM directory is created containing the following files and subdirectories. The pointer to the model sub-directory may be changed to any directory on any drive. 98 and NT subdirectories. Components are stored in file with the highest element number first. The process model components are saved with the model in the model storage file Filename. first prepare a comprehensive list of the components. Salts Coal.Components METSIM carries out mass balance calculations by tracking material flows. These are the chemical species. Dissolved Salts Fuel. Components are assigned to the phases in which they are present. and automatically reloaded when the model file is re-loaded into the workspace. Halides Molten Oxides. minerals or elements. Kerosene. Speiss Molten Sulfides. 8 . which are made up of a mixture of components. The phases are: Component Groups Solid Components Solid Inorganic Solid Organic Fluid Components Liquid Components Liquids Inorganic Liquid Organic Molten 1 Molten 2 Molten 3 Gaseous components Phase Phase Variable Number SC SI SO FC LC LI LO M1 M2 M3 GC Types of components Includes SI & SO Minerals. This file is automatically loaded with the METSIM database.METSIM Database stored in the METSIM DBF sub-directory.sfw. and can exist in one or more of eight phases. Using the routine ‘ DBAS Component Database ‘ 2 . M1. Metal Vapors 1 2 3 4 5 6 7 8 Components can be entered into a flowsheet model through one of three methods: 1 . Acids. 3 – Created directly through the component input/edit routine ‘ ICOM Edit Components’. The file is created and edited via the routine ‘IUSR Edit User Database ‘. stored in the file METDBUS. Organics Molten Metals. Gaseous. Prior to using any of the component input routines. Model components can be saved into the User Database file using the routine ‘ IUS2 Add Model Comp to database’. Carbon Includes LC & GC Includes LI. LO. The phases are identified by their phase number. Slags Air. This ensures continuity of data. such as pure chemicals.SF in the DBF sub-directory. which it is anticipated will appear in the flowsheet. M2 & M3 Water.User Database . Resin. analyze and save flowsheet models i. saving and retrieving Models Flowsheet palette setup parameters for fonts.e. case. calculation plotting and output routines for weather patterns for heap leach and solar evaporation flowsheets data All Routines associated with Heap Leach Option -Input. and saving and comparing flowsheet data. parameter definition. flow matrix. Routines for merging models and model sections Menu for calculating and checking routines Standard and Custom display routines Input and output operating cost data routines Graphics setup and output routines Design. checking. colors and objects Definition of flowsheet parameters.: Files Setup Input Components We a t h e r Heap Merge Calc Display Costs Graphics EquipList Output To o l s New Help Handling files i. build. calculation and outputs. stream qualities and controls Selection and definition of flowsheet components Input. Editing and Output of Equipment Lists and Equipment Specifications Standard output reports Miscellaneous programs for developing user objects. flowsheet evaluation. develop. on line Help and Version Information 9 .e. Menu for New Program Features METSIM Services.Drop Down Menus The following drop down menus are located along the top of the screen and contain programs used to create. used to clear and initialize the METSIM workspace ready to build a model. On activation it requests the user to confirm replacement of the existing model in memory. Move Text – used to move unit operation text descriptions on the screens. Print Flowsheet – used to print either the full flowsheet or selected sections. Locate Stream – used to locate model streams. Box Item To Move – used to box flowsheet areas which can be moved separately Moves flowsheet drawing up the page. streams and controller data. Moves flowsheet drawing to the right on the page. Model Parameters – used to set flowsheet site.used to loading an existing flowsheet model file On activation it requests the user to confirm replacement of the existing model in memory.used to enter ore types tonnes and grade data 10 . Enlarge Drawing Size – enlarge the palette area. Load Model . Copy Object Data – used to copy data from one object to another. Moves flowsheet drawing down the page.New Model . to expand the flowsheet Reduce Drawing Size – reduce palette area. Renumber a Stream – used to renumber a stream in the flowsheet. Move object – used to move screen objects i. Weather Data – used to enter daily or monthly weather data Ore Tonnes and Grade . to fit the flowsheet into a smaller area. unit operation icons. Edit Object Data – used to edit data in unit operations. Zoom Out used as an editing tool to reduce the flowsheet. controllers icons. On activation it overwrites the old file data with that in memory. calculation setup and calculation limit parameters. Error Checking – used to check out a flowsheet model immediately it has been loaded into the workspace. Save Model – used to save a flowsheet model directly to file. Zoom In – used as an editing tool to enlarge the flowsheet. Reverse Unit Op – used to reverse unit operation icons around the vertical axis Change Object size – used to change the unit operation icon size.e. Renumber Controls on this Page – used to renumber controllers in the current section. Center Flowsheet – to re-center the flowsheet on the screen. Draw Flowsheet – to redraw or refresh the current flowsheet section. Moves flowsheet drawing to the left on the page. The routine checks for: Stream errors. Delete object – used to delete objects from the palette area. case. Stream routes. On activation will immediately stop flowsheet calculations. Display Value Function for Streams .used to plot screen analysis data for and selected stream(s).used to plot screen analysis data for and selected stream(s). APL Keyboard . Display Section Spreadsheet . Page Down – used to page down through the sections of the flowsheet. Streams .used to display a spreadsheet of Instrumentation Controls on current section.used to display/select components in the flowsheet. Maths Functions . Lock Model for Security – used to setup model security options DDE . 11 .used to display/select elements in the flowsheet.used to display data for all streams in the current section according to the selections made via the DSDO Spreadsheet Items Standard.used to display the list of DDE. Calculate All Unit Operations – used to calculate the full flowsheet from any section.used to display/select the streams in the current section.Contours . Select Section – used to change between sections.Under development.gives access to the APL Keyboard. Plot Dynamic Data . Useful for situations where the user may wish to observe flowsheet changes during simulation. Follow Connecting Stream – used to check on flowsheet connections.for use with the Heap Leaching Module. Elements . links. Stop Execution . Calculate one unit operation – on activation any selected unit operation can be calculated. Components . User Created Objects . Unit Operations .used to display/select Value Functions.used to display the unit operations in the current section. and DCSI Spreadsheet Items Custom routines located in the Display drop down menu. Value Functions .Under development.used to display/select the phases in the current section.used to display the list of User Created Objects. Used to abort calculations as determined by the user. Display Instrument Spreadsheet . Plot Screen Analysis .Used to display the instrumentation/controlls. Phases . Calculate Unit Operation Range – used to repeat calculations over the range determined by the user through SCAL. Dynamic Data Exchange. Calculate Current Section – on activation all unit operations in the current section will be calculated.used to create and select value functions to replace stream number on the flowsheet screen. Instrumentation/Controlls . Check Elemental Balance – used to calculate and display the section elemental balance. Page Up – used to page up through the sections of the flowsheet. Tools Help . filters. flowrate. a reaction extent or another unit operation parameter to achieve the desired results. S T R . Phase Splitter allows phases to be split differently in output streams. It is possible therefore because of the structure of the program. ponds S U B . Chemistry and heat balance data may be added to any of these units. reactors. That mechanism can be preceded by chemical reactions or a phase change and if the result required is not achieved then the mechanism or chemical reaction can be changed or a control applied as a feed forward or feedback loop. The calculation sequence for a typical unit operation is according to the following procedure: Retrieve unit operation data add all input streams component flows calculate reactions calculate unit operation mechanisms/routines separate the output streams according to the unit operation parameters save unit operation parameter data If an output stream parameter is to be controlled. MIX . Can be used to simulate flotation cells. Can be used to simulate solvent extraction. Can be used to simulate tanks. PID.Stream Distributor allows streams to be closed for water balance. Stream Splitter is used to split one or more input streams into two to six output streams. sumps. CIP/CIL and furnaces. bins. Feedforward and density controllers may be used to adjust streams and parameters prior to calling the unit operation module. a feedback controller must be added to sample the output and adjust an input stream. S P C . Logic. mills.Solid/Liquid Separator simulates solid/liquid separations classifiers.Component Splitter allows components to be split differently in output streams. They are: S E C . Overview of some Generic Unit Operations METSIM was originally developed to calculate mass and energy balances around any type of flowsheet in a timely manner.Stream Mixer mixes all of the input streams and has a single output stream. S L S .Stream used to add streams to a flowsheet RCY .Recycled Stream Links is used to facilitate convergence of multiple recycle streams in flowsheets. To facilitate this task several generic unit operation modules were used. Most unit operation modules mix the feed streams then the mechanism is applied. 12 . thickeners. gravity concentrators and recovery plants.Section used to add sections to a flowsheet.Unit Operations Overview The basic calculation philosophy used in METSIM is to take the feed streams to a unit operation module and have a mechanism to handle the inputs and to output according to the module. Controlled at different flowrates and totaled as for reagents. to add chemistry to any unit operation and then add controls to simulate any type of reactor without having a specific reactor model. pumps and conveyors. FIFO or MIXO method Stockpile. Trommel Mill. Ball Mill. Container Ship. Stacker Conveyor. Pneumatic Conveyor. Verticle Pump.agitated tank with internal coils for heating or cooling Tank .electrolyte or compartmented tank Tank . Cone Crusher. Decantor Centrifuge. DMS/Banana Screen.decant tank for separating organic from aqueous Tank . Centrifugal Pump. Roller Rock Scrubber Hydrocyclone Classifer. Container Truck.with external jackets for heating or cooling Tank . Hydro Classifer Centrifuge. Static Screen Grizzly. Separator Compactor 13 . SAG Conveyor. Rod Mill.GENERAL Unit Operations Section Stream Recycle Stream Links Stream Mixer Sloid/Liquid Separator Stream Distributor Component Splitter Phase Splitter Stream Splitter Sump Launder Pump. Flop Gate Conveyor. Jaw Crusher. Bucket Elevator Conveyor. Gyratory Crusher.agitated storage tank Tank . Positive Displacement Pump. Reclaim Static Screen Bin Screen Grizzly. by the LIFO. Metering MINING Unit Operations ORE from mine ORE Tonnes & Grade Shovel Front End Loader Haul Truck Truck. Screw Conveyor. Drop Box Splitter. Derrick Screen. Roll High Pressure Grinding Screen. Belt Conveyor. Reclaim Conveyor. Vibrating Chute/Hopper Bin Silo Hopper Chute. Blended Stockpile.storage tank without agitation or heating Train Dredge Clam Shell Barge Ship. Vibrating Screen. Tanker Pump.agitated tank with external jackets for heating or cooling Tank . Transfer Agglomerator Heap Leach Column Heap Leach Test Heap Heap Dump Heap Leach Heap Leach Extension Heap Leach Drainage Mill. Screw Classifer. Tanker MATERIALS HANDLING Unit Operations Stockpile. Impact Crusher.simulates a storage tank Tank . MMD Sizer Crusher. Sump Pump.with internal coils for heating or cooling Tank . Vacuum Pipe Pipe Connection Pipe Header Tank . Chain/Drag COMMINUTION Unit Operations Crusher.process tank with agitation Tank . Apron Feeder Conveyor. Degasidier Desuperheater Steam Compressor Steam Turbine Barometric Condenser Steam Ejector Tower. Reverse Solvent Extraction. Settler Furnace. Dual Media Filter. General Dense Media. Spiral Gravity Separator. Larox Thickener. Sump Dense Media. Steam Condenser Heat Exchanger. Tailings Crystallizer Crystallizer. Direct Rotary Dryer. Drum Filter. Screen Dense Media. Column Flotation. Indirect Furnace. Drum Dense Media. Cyclone Dense Media. Electric Furnace. Rake Countercurrent Washing Water Spray Pond. Parallel PYROMETALLURGY Unit Operations Autoclave Flash Separator Heater. Cone Gravity Separator. Acitvated Carbon Column. Vessel Screen Desliming Water Only Cyclone Filter. Solar Evaporation Pond. Table Gravity Separator. Storage Pond. Bath Dense Media. Gas Steam Boiler Waste Heat Boiler Steam Trap Daerator. Top Submerged Lance Furnace. Collection Point Venturi Scrubber Wet Scrubber Blower Fan Flue/Stack Gas Compressor Gas Turbine Coal Spiral Dense Media. Noranda Furnace. Ion Exchange Absorption Column Hydrochloric Acid Stripper/Absorber Equilibrium stage Solvent Extraction Solvent Extraction. Vaporizer Crystallizer.BENEFITICATION Unit Operations Flotation. Membrane Electro Refining Cell Electrowinning Cell Filter. Direct Free Energy Reactor Burner Fluid Bed Roaster Packed Bed Reactor Rotary Dryer. Column Eectrolytic Cell Eectrolytic Cell. Slag Cleaning Furnace. Casting HYL Bottom HYL Top Joule-Thomson Valve Heat Exchanger Heat Exchanger. Jig Gravity Separator. Cooling 14 . Draft Tube Baffle Furnace. Reverabatory Furnace. Slag Pots Wheel. Mosley Gravity Separator. Verticle Heat Exchanger. Outokumpu GAS HANDLING . Inco Flash Furnace. Leaf Filter. Kiln Furnace. Belt. Uptake Furnace. Cartridge Filter. Belt. El Teniente Furnace. Jameson Cell Flotation. General Dry Magnetic Separator Wet Magnetic Separator HYDROMETALLURGY Unit Operations CIP/CIL Column. Anode Ladles. Pierce Smith Furnace. CCW Filter. Hood Furnace.STEAM Unit Operations Absorber Acid Plant Converter Spray Cooler Baghouse Dust Cleaning Cyclone Dust Collecting Cyclone Electrostatic Precipitator Dust. Cell Gravity Separator. Pressure Filter. such as a Pierce-Smith converter. In a steady-state simulation. The most serious drawback with this mechanism is that it is not possible to specify a logical condition determining the end of the period. however. editing and output. and the controller must wait to determine whether the change made was sufficient. which. and are accompanied by a specific action. All the logical if conditions. For example. In a dynamic model. It is a considerable undertaking to design logic controllers to describe the appropriate action for every state in which the flowsheet may exist. Operating costs can be determined. A schedule may be constructed most easily from an existing plant: in this case.Dynamic Simulation Unit Operations Dynamic modeling of flowsheets has been possible for many years. and each must evaluate either true or false. with the cost items listed in rows and the costs in columns. These steady-state model feedback controllers are used primarily to automatically calculate parameters (such as the mass of coal that must be burnt to dry a given quantity of wet feed) that the modeler would otherwise have to calculate by repeated trial and error. Other dynamic software simulation packages exist. been used successfully in at least one case. calculation. METSIM offers a much simpler way to describe the flowsheet. (as in a real plant) the effects of changing a variable used previously in the flowsheet are not felt until the next time step. For most flowsheets. by providing a schedule. and the various unknown reaction rates and extents may be varied to ensure a good match. There are two mechanisms for controlling the dynamic operation of a flowsheet: firstly.) needed for the model should therefore be the same as for the PID controller in the real plant. the actual operating parameters of the plant may be used. These packages use systems of differential and algebraic equations (DAEs) to describe unit operations. and output itemized costs for display. far simpler and faster. concentrate grade. The tuning parameters (the proportional gain. from the error in the measured variable. by using logic controllers. are queried on every pass through the flowsheet (that is. which are targeted more towards the chemicals industry. if a furnace is to be emptied. printing and export. Once the schedule or logic program has been completed. then the items in each area with their costs and then their types. This makes calculations of the effects of changing. Costs can be incurred in different currencies and assembled in a single currency. at any time following the calculation of a model. A series of routines are provided in a menu structure for input. This mechanism has. Having constrained the chemistry in this way. for example. Most straightforwardly. such as speedup. the recommended time step is no longer than one-twentieth of the residence time of the material in the principal units. but METSIM has not been widely employed in that role. the role played by feedback controllers is not strictly analogous to that played by feedback controllers on a physical plant. materials etc. obviously. the other details of a dynamic simulation are exactly as for steady-state simulations. on every time step). triggering an appropriate action. the entire operation of the plant may be dictated solely by logical if…then statements. and METSIM incorporates the two most popular. however. Costs are output in spreadsheet format and can be itemized by flowsheet section. various hypothetical schedules may be tested against the original. Alternatively. specifying what action is taken for each. when linked together can describe sections of plant or entire flowsheets. 15 . unit operation. it is not possible to specify that its contents should be transferred at a specific rate until the furnace is empty. for each unit operation and plant section as appropriate. are well established by the manufacturers of control equipment. Costing Module Operating costs are generated as a spreadsheet. a schedule may be provided for the entire flowsheet. Instead. such as labor. The menu structure is designed to enable the user to input data by classification. or secondly. and cost types. METSIM operating costs module is designed to enable the user to use the data generated by the flowsheet model to generate tables of operating costs. if the chosen time step is short enough. The algorithms necessary to calculate the change to be made to the controlled variable. with the exception of feedback controllers. or whether further corrections are needed. This works best for single batch operations. Each mechanism has its merits. the rate must be calculated in order that the transfer takes a specific length of time. blowing. and its solution is similar in nature to the numerical methods used to solve the systems of DAEs. Thus a user must have a great deal of knowledge as to what equations and models govern the system they wish to model. and we hope that future versions of METSIM will incorporate a combination of the two. when the charging. It is surprising how quickly such a scheme becomes unmanageable. fixed period of time. The spreadsheet is set up by defining the cost areas. etc. skimming and transfer periods last for a fixed time. 69 BALL MILLING $0.53 -$35.021.377.65 TOTAL -$35.60 -$367.65 -$11.392.612497 0.69 -$748.819.51 -$7.00 -$5.80 -$367.31 -$64.6417433 11 11 13 14 15 15 15 17 18 2 1 kwh Set kwh Set Tons kwh Set 48 24 206.00 -$7.00 201 Raw Materials -$144.0034 21.00 $0.889.497.51 -$391.68 -$70.00 203 Electric Power -$461.40 -$735.00 -$11.63 102 Operator -$1.658.51 -$316.22555 0.70 -$18.61 -$4.228.7955407 308.037955407 3.67 Detailed Operating Costs UNIT OP 1 1 1 1 1 3 3 ITEM CRUSHING Ore Feed Foreman Operator Maintenance Electric Power Electric Power Crusher Liners TOTAL AREA COSTS SAG MILLING Electric Power 5" Balls Lub Oil SAG Mill Liners Electric Power Screen Decking TOTAL AREA COSTS BALL MILLING Operator Maintenance Electric Power Cyclone Fittings Electric Power Ball Mill Liners 2" Balls Electric Power Cyclone Fittings TOTAL AREA COSTS TOTAL PROJECT COSTS UNITS Tonnes 1 4 1 kwh kwh Set QUANTITY 13063.51 $0.24 $0.00 -$12.63 -$2.116.63 -$1.95 -$574.92 $0.65 -$98.00 -$18.45 $0.00 $0.021.65 -$948.658.052.31 Total $0.00 -$7.790.61 -$3.Operating Costs CRUSHING 100 LABOR $0.43 -$303.98 -$19.00 101 Supervision -$98.51 200 MATERIALS $0.1306346 2288.77 -$104.246.052.00 -$98.00 $0.67 9 9 9 9 10 10 kwh Tons Gallons Set kwh Panels 5600.85 -$656.302.029.67 SAG MILLING $0.601.88991 19 0.02 $0.67 -$8.05 -$32.23294 0.674.497.74 204 Feed Stock -$32.016417433 1234 1.06 -$144.85 $0.00 $0.46 24 96 24 255 45.302.658.00 -$2.53 202 Reagents $0.65 -$64.629.00 $0.2964 0.60 103 Maintenance -$367.37955806 16 .80 -$367.228.11 -$473.00 -$20.00 -$748.15 $0.009635645 COST -$32.89 -$759. For phase colors see ‘Select Object Colors‘. The second and third lines are for stream data variables Data Field Input Field Output Level Box Number Input Field Input Field Design Factor Input Field Input Field Input Field Maximum Flow Variables 1 2 3 Input Field for Output Level. This can be either the stream number. the program returns to the palette and the edited stream number and route will change to the color of the predominant phase. 17 . The stream data is displayed. Stream data is displayed along the top of the screen above a series of data entry spreadsheets. If the stream output level matches the display level as defined in DVAL Display Value Functions for Streams.g. Stream data is used to switch on/off the stream display. stream description. A series of spreadsheets are displayed to allow stream data to be entered or edited as described below. The stream data input screen set out as follows. The stream data is as follows: The top line is used for text entry e. On exiting the stream data screen.Stream Data When activated the input data screen is displayed. a stream value function or a stream box as defined in ISBX Design Stream Graphics Boxes. . Maximum Flow and Variables 1 2 and 3 are not used at present. The first component listed for the phase will be allocated all of the material and its assay will change to 1 i.The lower is for the stream label. Box types are listed in ISBX. This is achieved by setting up simultaneous equations. Only the buttons for the phases present in the flowsheet are displayed. In the aqueous water is always the first aqueous component as every other component is dissolved in water. The elements spreadsheet is designed similarly to that for components. Finally the desired total flow is entered and the program will recalculate both solids and aqueous flows to give the total entered 18 . Hence by choosing the first component in each phase to be either the inert or bulk material. As each phase field is activated. initially defaults to flowsheet stream number. METSIM will re-adjust the aqueous flow to match that value. which will not cause major errors in chemistry through error in input. with the components and their elements according to and in the order of the component list. by moving the mouse pointer to the relevant field PL. fractions. Exact values are required for input streams estimates for controlled input and recycle streams. Quick Access buttons are displayed to the left of the above. element composition can be entered. METSIM will be unable to arrive at a solution. temperatures. with columns for weight fraction and gpl entries.e. Two direct Data entry fields located below for: . Data Entry Spreadsheets for: Mass and volumetric flow rates. Stream washability or gravity separation data (which is entered through the WAS button). However where the chosen element is in several components. The percent solids are next adjusted to the required value. the phase is 100% of that component. the phase assay is always balanced with a component. Similarly as with other phases the assay of the first component is balanced with each entry to maintain the composition to 1. The mass flow of the phase is entered. Individual component assays are entered as weight fractions or mole. components and elemental composition spreadsheets will appear. Initially it defaults to flowsheet stream number. pressures and operating time Phase compositions by component Phase elemental composition Stream particle size distribution (which is activated through the SSA button) Stream component size data (which is entered through the SSM button). In this case the user will have to make judgment. The suggested method for entering stream data for the first time is to first enter the Mass for each phase. A blue border highlights the field. which will be in the units defined in the column header.Input Fields for Design Factor. Input Filed for Box Number is used to replace data as defined in DVAL above by a graphics box as defined in ISBX.the upper is for the stream name or description. there may be several solutions. on which data is the best for the material. The phase buttons can also be used for data entry. If there are no components listed for a phase no spreadsheet will appear. For solid flows such as ores. which is generally an alphanumeric P and I D flowsheet identifiers. METSIM will calculate the total flow and the percent solids. the ore and adhering moisture flow generally relate to a measurement from a weighing device. In this case METSIM will recalculate the component assay for that element composition. Aqueous phase components are often referred can be entered as weight fraction or grams per liter (gpl). The above procedure is repeated for each phase present in the stream. Enter the flow PL. In cases where elemental data is available. As each assay is entered the phase composition is recalculated and the assay of the first component will be adjusted to ensure the total assay is always equal to 1 (100%). In this case first enter an estimated flow of solids and aqueous phases to match the total flow. N. 19 .. Stream temperatures are entered if the heat balance switch (in ICAS) is on.SSM[IS. Quick Access buttons . Sieve Size Entry.Particle size analysis. for input stream IS STR[IS. and the assays will be reproportioned in SSM to match the total component assay in the stream array STR. If the flow of a stream is normally measured volumetrically e. This will result in a mismatch of SSA and SSM and give inaccurate simulations.]=+/STR[IS. estimates may be entered for controlled input and recycle streams. slag Molten Sulfides/Halides Gaseous The following buttons also appear dependent on options switches: SSA SSM WAS . located at the top center of the screen appear for the phases present in the component list.SI]= +/. On completion. a mass flow estimate is entered and the composition fixed.g. gaseous streams.whilst maintaining the desired percent solids. solids component assays may be adjusted in the normal manner. This takes president over SSA screen size analysis. The mass flow will be recalculated to match the volumetric flow. Then the required volumetric flow is entered using the flow functions in the spreadsheet. the sieve analyses are entered at this point.] The array SSA refers to mass flowrates of solids for each size fraction This array is recalculated on completion of entry via SSM such that: +/SSA[IS. as with normal assay entry. – Multicomponent size analysis – Washability or specific gravity NOTE 1 : If the SCM option has been chosen. Similarly stream pressures can be entered in Kilo Pascal’s (kPa) or Pounds per square inch (psi) The operating time (Time) or availability of a stream can be entered as a fraction of 1 Note: Exact compositions are required for input streams. Temperatures can be entered in Celsius or Fahrenheit. solids inorganic component data must be entered using the SSM button. METSIM uses degrees Celsius in all calculations. The total solids inorganic mass flowrate is calculated on each entry in SSM and the assay of the first solids inorganic component is set to unity. The latter array data is derived from SSM. Hence for component N. On completion of entries the OK button is used to exit and save or cancel to quit without saving data input.] NOTE 2: Do not attempt any data editing or entry via the size analysis screen.N] = +/SSM[IS. ON entry of other solids component assays the assay of the first solids inorganic component at the top of the component list is recalculated to ensure the total is always 1. These can be used for entry of phase assay data: SI SO LI LO M1 M2 M3 GC Solids Inorganic Solids Organic Liquids Inorganic Liquids Organic Molten Metal Molten Oxides. Chemical reactions are at the heart of the success or failure of many METSIM models. activate PL the + Prod button and select the first product component. As each subsequent component is selected. They dictate the amounts of new compounds. “ REACTION DOES NOT BALANCE “. or there is no single solution to the chemical reaction METSIM will warn. + sign will appear followed by the component CNM. The unbalance equation must be evaluated to determine whether it is incorrect and corrected. Repeat for the remaining reactants. solids. METSIM will rewrite the equation with the number of molecules of each component in the equation. the new reaction must be re-balanced. . and the consumption of raw material fed to the process. On completion activate the Balance button and METSIM will balance the equation. melts and gases. METSIM uses simultaneous equations to calculate the reaction balance. liquids. Reactants and products components can be removed or added to the equation by activating the + or – reactants or + or – products buttons. Reactions are entered in the order in which they will be performed. An = sign followed by the CNM of the selected component will appear in the reaction equation display field. whether valuable or hazardous. formed throughout the process. and the benefit obtained from the model. A plus sign will be inserted between each selection. Upon completion. Chemical reactions must be specified for a particular unit operation. The editing screen provides a list of the abbreviated chemical names (CNM) of all components in the model according to the major phase type they exist in i.e. If a chemical reaction occurs in many unit operations. The reactant CNM will appear in the reaction equation display field. and their extents can be a prime determinant of the quality of results. Once input the balance button will confirm the user-input reaction does balance. If the equation does do not balance. Individual reactions are input or edited using the edit button. If desired the complete reaction can be cleared and re-input. their order. If the reaction cannot balance the User button will open an input screen whereby the stochiometry can be input directly. it must be specified for each of them individually The unit operation ‘Reactions’ page contains input data screen for entering reactions.Reactions This section describes the different ways that chemical reactions may be written in METSIM . and highlighting the appropriate components in the component list PL. by selecting the first reacting component from the list by placing the mouse pointer over the chosen reactant and PL. and will then occur only within that unit operation. On completion. The way in which they are written. The chemical reaction is entered. If the reactants and products of the chemical reaction balance. When activated a list screen is displayed. but can also be used to control variables which it may not be possible to control in practice. matter is neither created nor destroyed. the extent of a chemical reaction in a furnace to ensure that a slag has a compatible copper content to the matte. Each feedback control loop adds flowsheet convergence time due to the controller iterations and also does not give an exact value. These controls function similarly to those in operating plants. In steady-state simulations. The controller calculation routine is iterative and the set point is achieved when it is within a convergence tolerance. During development of METSIM . similar to transducers in real life. Note: Flowsheets converge faster when feed forward controls are used rather than feedback controls. The process model is developed using these standard constraints. The type of control. This type of feedback control can best be thought of as simply imposing additional constraints on the process.g. The latter are controlled and the balance between inputs and outputs is achieved by varying the unit operation contents or inventory.In dynamic simulation. There are no process inventories . due to the convergence tolerance.g. The distinction between each mode is: In steady state simulation the material balance is achieved by ensuring that there is a balance between inputs and outputs for all unit operations i. it was found that numerous alternatives were possible in fixing or setting process parameters. The tolerance is set to 10 to ¯10. It is good practice to keep feedback controls to a minimum. and then the control module is used to release the constraints that are not applicable and to impose those that are desired. 21 . Thus they can also be used to simulate process control loops and evaluate control strategies. a flow rate of natural gas to a burner. e. The following control modules are available FBC FFC FRC PSC LOG Feedback Control Feedforward Control Flow Rate Control Percent Stream Control Logic Control In addition to controls instruments (INS) and totalizers (TOT) can be included in the flowsheet to measure parameters in streams and unit operations. METSIM was developed by choosing the most common set of constraints and programming them into the calculation code. Feedforward type controls apply prior to the calculations for a unit operation and consist of: FFC – Feedforward to control input stream ratios FRC – Flowrate to control input stream flowrate parameters PSC – Percent to control input streams to achieve preset component percentages FBC – Feedback controls are used to adjust parameters or stream(s) flow(s) to achieve a set point value at the output of a unit operation. process control is used to determine an appropriate value for.Process Controls Constraints may be applied to the process flowsheet in addition to those parameters specified in the unit operation modules through the use of process controls. will depend on whether the model is used for steady state or dynamic simulation.e. In steady state simulation constraints are applied using either feedforward or feedback control. e. which can be applied. process inventories are used to balance inputs and outputs. Control is applied after a unit operation calculation routine has been completed. which would actually be controlled in practice. the feed forward controllers can used to control . set point parameters and values. In addition to the above controllers. INS – Process controls instruments are used on streams and unit operations to measure operating parameters similar to transducers and instruments on process plants. Controllers loop numbers. METSIM has several alternative P and ID algorithms. The same controller module can be used and in this case the controlled variable is modified for the calculation of the next time step on the basis of the effect of the last change. Controls can be accessed either directly from the flowsheet using the ‘Object Editor’ or via the ‘ICTL Process Controls’ in the Input drop down menu. which are used in most commercial controllers.Outputs from unit operations Unit operation inventory will vary dependent upon the difference between input and output and existing inventory. In dynamic simulation instruments are used to plot and record data for each time interval during the calculation of the flowsheet. . LOG – logic controllers can be used directly by all unit operation modules. and controlled variable values can be view vie the ‘OCTL . The feedback controller in P and ID mode should be used to control the variable. location.Print Controls' routine located in the Output drop down menu. 22 .In dynamic simulation. Instruments are used in steady state calculations to monitor critical parameters during whilst the model calculations are in progress.Inputs into the model. Feedback control cannot be used in dynamic simulation and must be replaced by an appropriate P and I D control (PID ). Typically the P and I D controller would use a flowrate controller as the adjusted variable. D Duplicate Line Item Del Delete Line Item Ins Insert New Line Before Ctrl -Ins Insert New Line After PgDn Move Down One Page PgUp Move Up One Page Home/End First/Last Data Item on Page Ctrl Home/End First/Last Data Item in Total Set Esc Exit to Previous Menu Data Input Screen Enter Move Cursor To Next Field Cursor (AT) Move Cursor Ctrl .Inputs requiring a yes or no response. first delete the line with Del. insert the old line with Ins. however. third.R Repeat Value Esc Exit Screen with Updating Ctrl . all data must be entered as decimal fractions.A.The comma will act as a delimiter in place of a blank.Pressing the enter key without any data entry will cause METSIM to continue execution of the program in progess.METSIM MECHANICS The Mechanics of entering data into METSIM have certain guidelines which should be followed in order to ease data entry and avoid errors.“ APL CHARACTERS METSIM requires some common but special characters in generating APL expressions for process controls and various output forms.Break Cancel Printer Output Line Item Menu Enter Select Item for Data Input Ctrl . second.Keypad Move Cursor Keypad Numeric Data Ctrl . will default to no (N or n) for any entry other than a yes (Y or y). APL negative sign + x ÷ asterisk ← X[.] () +/ Negative number sign Subtraction sign Addition sign Multiplication sign Division sign Power sign Assign sign Array subscripts Equation hierarchy Plus reduction METSIM uses various keystrokes to simplify usage of METSIM. its main use is to join variables or variables and numeric data into one vector of data. COMMA . ENTER . DECIMALS . move the cursor to a new point. Fortran + * / ** = X(. SCREEN TYPE KEYSTROKE FUNCTION Program Menu Enter Select Item Cursor keys Move Cursor PgUp/Pgdn Move to Next Menu Page Home/End First/Last Menu Item Esc Exit to Previous Menu Ctrl .) () N. Y or N ? . For those not familiar with the APL characters set.Q Exit Screen without Updating Note: To move an item. 23 .Irrespective of the use of the word percent in the prompts. BLANK .] () + Keyboard Alt 2 Shift = Alt Alt = Shift 8 Alt [ X[.METSIM was designed to use the blank as a delimiter between numeric data elements of the same type. the following keystrokes are provided. 3 + 3 × 2 12 .3 + 3 × 8 ÷ 2 + 2 3 The expression above is evaluated in the following manner: 12 . The plus reduction adds all values to the right of the +/ symbols.APL executes an expression from right to left with no symbol hierarchy. Another example with the solution is the following: 12 . For example: 3×4-2 6 The order of execution for the above expression is: 3×4-2 3×2 6 The order of execution is always from right to left. APL Arithmetic Order Of Execution A. this is handy for summing multiple stream data in controller expressions. parentheses are used to alter the calculation sequence.3 + 3 × 8 ÷ 2 + 2 12 .3 + 6 12 . You can enter two or more arithmetic functions in the same line.9 3 24 .3 + 3 × 8 ÷ 4 12 . Since all symbols are treated equally. SO. Element(s) represented by their atomic number(s). and M are to be replaced with the following numbers: S P C E M Stream number(s) from the process. 25 . 2. This is analogous to the input signal to process controllers. Monadic functions require only stream numbers. The value functions are used by the data display and output report programs to convert stored stream data to the desired output variables. component. phase(p). LO. They are of the form. 1. One or more component numbers or a variable containing the component numbers such as SI. In the following table. They must also return a value. M1. or element atomic numbers. phase. cC V*** sS EXAMPLE: c12 VGPL s10 returns the grams per liter of component 12 in stream 10. A list of available value functions is tabulated on the following pages. 3. Particle size in microns. V*** sS EXAMPLE: VGPM s15 calls for the gallons per minute in stream 15. the abbreviations for S. C. 1 through 8 representing the phase. M3. Dyadic functions require two data items. Value functions require data in their accessing statements consisting of stream.VALUE FUNCTIONS OVERVIEW Value functions are used by METSIM to recall or evaluate stream data in a manner analogous to that in which instrumentation is used to monitor an operating process. This is analogous to a control room operator checking instrumentation readouts to guide the process during startup or upset conditions. P. The value functions can be called by the METSIM user during data entry and program interrupts to provide current data as an aid to debugging or model building. One or more phase numbers. or GC. The trailing variable is a stream number(s). They are of the form. LI. E. The preceding variable usually are component(s). LC. SC. monadic and dyadic. NOTE: Numbers or variable names may be used as arguments in the value functions. Value functions can be of two forms. These functions are used in three ways. or element atomic number(s). The feedback and feedforward controllers use value functions to provide current data for process control. S in grams per second.Pressure .Flowrate . in cubic inches.Temperature . millimeters of mercury 0C. kilograms per cubic meter. millimeters of mercury 0C.Volume of phases P .Flowrate . K. S in metric tons per minute.Pressure .Pressure .Flowrate .Temperature of of of of of stream stream stream stream stream S S S S S in in in in in degrees degrees degrees degrees degrees C. P in stream S. in cubic feet. inches of water 60F. S in pounds per hour.Flowrate .Pressure .Temperature .Flowrate . pounds per square inch. S in metric tons per hour.Pressure . S in kilograms per day. in cubic meters.Volume of stream S . in current units.Volume of phases P component C in liters. millimeters of water 4C. actual. bars. S in kilograms per hour. of media in coal stream S.VALUE FUNCTIONS Density and Specific Gravity Value Functions P P P P VKM3 VPF3 VPGL VPSG VSGC VSGM VSPG S S S S S S S .Flowrate .Specific gravity .Pressure . gauge. millimeters of water 4C. S in grams per hour. gauge. in stream S in stream S in stream S in stream S.Flowrate .Pressure .Specific gravity . of phases P in stream S. inches of water 60F. of coal in stream S.Density of phase .Flowrate .Flowrate . S in metric tons per year. bars.Pressure .Flowrate . actual. kiloPascals.Flowrate . S in short tons per day. P in stream S.Flowrate . gauge. 26 . gauge. gauge. actual. Pressure Value Functions VATMa VATMg VBARa VBARg VKPAa VKPAg VINWa VINWg VMHGa VMHGg VMMWa VMMWg VPSIa VPSIg S S S S S S S S S S S S S S .Pressure .Flowrate . of all phases plus total of stream S. pounds per gallon. actual.Flowrate .Flowrate .Pressure .Specific gravity P in stream S.Pressure . S in kilograms per minute. S in short tons per hour. actual.Volume of phases P . atmospheres. gauge.Pressure .Temperature .Pressure . S in pounds per minute.Specific gravity . pounds per cubic foot.Density of phase .Pressure in in in in in in in in in in in in in in stream stream stream stream stream stream stream stream stream stream stream stream stream stream S S S S S S S S S S S S S S in in in in in in in in in in in in in in atmospheres.Temperature . S in kilograms per second. S in pounds per day. S in grams per minute. C. F. pounds per square inch.Flowrate of of of of of of of of of of of of of of of of of of of components components components components components components components components components components components components components components components components components components all phases C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream C in stream in stream S S in grams per day.Flowrate .Specific volume of . Mass Flowrate Value Functions Adjusted for Operating Time C C C C C C C C C C C C C C C C C C VGMD VGMH VGMM VGMS VKGD VKGH VKGM VKGS VLBD VLBH VLBM VMTD VMTH VMTM VMTS VMTY VSTD VSTH VTOP S S S S S S S S S S S S S S S S S S S . S in metric tons per day. kiloPascals.Density of phase . actual. Temperature Value Functions VTEC VTEF VTEK VTEM VTER S S S S S . gauge.Flowrate . S in metric tons per second. Volume Value Functions C VSPV VLTR P VICF P VICI P VICM S S S S S . actual. R.Flowrate . Molar flowrate of components C in stream S.S.Mass flowrate of element E in solid components in stream S.Weight .Weight .Weight . . Volumetric Flowrate Value Functions Adjusted for Operating Time P VCFD S P VCFM S P VSCF S VCMC S P VCMD S P VCMH S P VCMM S P VCMY S P VNM3 S VDM3 S P VGPD S P VGPM S P VIGH S P VIGM S P VLPD S P VLPH S P VLPM S P VLPS S . phase(s) P in stream S in cubic feet per minute.Flowrate . .Mass flowrate of element E in phase 6 M2 of stream S.Molar flowrate of phases P in stream S.Flowrate of of of of of of of of of of of of of of of of of of phase(s) P in stream S in cubic feet per day. gallons per minute. . coal in stream S in cubic meters per hour. solid phases of stream S.Weight .Flowrate . .Flowrate . .Flowrate . . liquid organic phase of stream S. .Molar flowrate of element E in stream S. dry gas in stream S in normal cubic meters per hour. . matte phase of stream S. 27 . .Molar flowrate of element E in phase 7 M3 of stream S.Flowrate . phases P in stream S in liters per day. .Flowrate .Flowrate .Mass flowrate of element E in total stream S. molten metal phase of stream S. liquid phases of stream S. phases P in stream S in Imperial gallons per hour. .Flowrate .Molar flowrate of element E in phase 6 M2 of stream S. . phases P in stream S in cubic meters per hour.Weight . .Mass flowrate of element E in liquid components in stream S. phases P in stream S in cubic meters per year.Mass flowrate of components C in stream S.Molar flowrate of element E in phase 8 GC of stream S. solid organic phase of stream S.Flowrate . matte phase of stream S. phases P in stream S in U. .Mass flowrate of phases P in stream S.Flowrate .Molar flowrate of element E in phase 4 LO of stream S.Mass flowrate of components C in stream S.Molar flowrate of element E in phase 2 SO of stream S. . . dried stream S. phases P in stream S in cubic meters per minute.Flowrate . .Weight . . phase(s) P in stream S in standard cubic feet per min.Molar flowrate of element E in phase 1 SI of stream S.Mass flowrate of element E in phase 4 LO of stream S. slag phase of stream S.Weight . phases P in stream S in cubic meters per day. . liquid inorganic phase of stream S. phases P in stream S in Imperial gallons per minute. . .Flowrate . .Mass flowrate of element E in phase 1 SI of stream S.Mass/Molar Flowrate Value Functions Not-Adjusted for Operating Time The following flowrates are in the units specified in ICAS. .Mass flowrate of element E in phase 8 GC of stream S. phases P in stream S in liters per hour. .Flowrate .Mass flowrate of element E in stream S in ounces per day. phases P in stream S in normal cubic meters per hour. .Weight fraction fraction fraction fraction fraction fraction fraction fraction fraction fraction fraction fraction of of of of of of of of of of of of element element element element element element element element element element element element E E E E E E E E E E E E in in in in in in in in in in in in solid inorganic phase of stream S. phases P in stream S in U.Flowrate .Flowrate . phases P in stream S in liters per minute.Mass flowrate of element E in phase 7 M3 of stream S.Mass flowrate of element E in phase 2 SO of stream S.Weight .Mass flowrate of element E in stream S.Molar flowrate of comp components C in stream S.Mass flowrate of element E in phase 5 M1 of stream S.Weight . E E E E C P C E C E C P E E E E E E E E E E E E E E E E VEFR VEWL VEWS VEWT VCWT VPWT VSTR VOZD VCMT VEMT VMFR VPMT VME1 VME2 VME3 VME4 VME5 VME6 VME7 VME8 VWE1 VWE2 VWE3 VWE4 VWE5 VWE6 VWE7 VWE8 S S S S S S S S S S S S S S S S S S S S S S S S S S S S .S.Weight . Elemental Assay Value Functions E E E E E E E E E E E E VESI VESO VESA VELI VELO VELA VEM1 VEM2 VMAT VEM3 VEGC VEWD S S S S S S S S S S S S .Mass flowrate of element E in phase 3 LI of stream S. . .Molar flowrate of element E in phase 5 M1 of stream S. gallons per day. phases P in stream S in liters per second. gaseous phase of stream S.Molar flowrate of element E in phase 3 LI of stream S.Flowrate .Weight .Flowrate . Weight fraction of components C in stream S.Assay of element E in liquid organic phase of stream S in troy ounces/ton. . components C in stream S in total liquor (at 25C).Grams . element E in stream S (at 25C).Grams . .Assay of element E in solid inorganic phase of stream S in troy ounces/ton.The assay of element E in component C of stream S. element E in stream S in total liquor (at 25C).Grams .Assay of element E in solid organic phase of stream S in troy ounces/ton. .Weight fraction of component C in component C's phase in stream S. . Fe+3 in components C in stream S.Grams .Parts per billion of element E in aqueous in stream S. .Moles .M3.Grams . element E in stream S in organic only.Weight fraction of SO2 in the gas phase of stream S. components C in stream S in organic only (at 25C).Grams .Volume fraction of phases P in stream S.Dry gas volume fraction of component C in stream S. . .Assay of element E in melt 2 phase of stream S in troy ounces/ton. . Fe+2 in components C in stream S.Assay of element E in liquid inorganic phase of stream S in troy ounces/ton.Particulates in gas stream S in grains per actual cubic foot.Grams .Weight fraction of SiO2 in solids and slag in stream S.Grams . default C is SC.Parts per billion of element E in solids in stream S. .Grams .Iron silica ratio in components C in stream S.Concentration of components C in stream S in grams per 1000 grams of water.Volume fraction of solids in stream S . Vanadium in stream S reported as gpl V2O5.Mole fraction of components C in stream S. Fe+3 in components C in stream S (at 25C). .Grams . . components C in stream S in total liquor.Parts per million of element E in aqueous in stream S. .Particulates in gas stream S in grains per standard cubic foot.Grams .Moles .Weight fraction of solids in stream S. . components C in stream S (at 25C). . solids in stream S. . .Mole fraction of phases P in stream S.Basic/acid ratio of slag in stream S. . components C in stream S.Grams . . Gram Per Liter Value Functions E E E E E E C C C C C C C C C C E E C C VGLE VGLEa VGLEo Vgle Vglea Vgleo VGPL VGPLa VGPLo Vgpl Vgpla Vgplo VGLS VFE2 Vfe2 VFE3 Vfe3 V2O5 VMLE Vmle VMPL Vmpl S S S S S S S S S S S S S S S S S S S S S S . .Particulates in gas stream S in grams per normal cubic meter.Grams .Grams .Particulates in gas stream S in grams per actual cubic meter.Concentration of components C in stream S in moles per 1000 moles of water.Moles .Weight fraction of element E in total stream S. . components C in stream S in aqueous only. Component Assay Value Functions C C C C C C VCWF VCPA VCMF VGPC VDGV VISR VM3B VSIO VSO2 C VGHW C VGTW C VMKW S S S S S S S S S S S S . element E in stream S.Grams .Grams . . Fe+2 in components C in stream S (at 25C). . element E in stream S in organic only (at 25C).Assay of element E in melt 3 phase of stream S in troy ounces/ton.Parts per million of element E in solids in stream S. .Parts per million of element E in total stream S.Volume fraction of component C in gas phase of stream S. . .Concentration of components C in stream S in grams per 100 grams of water. components C in stream S in aqueous only (at 25C).E VEWF S E VOZT1 S E VOZT2 S E VOZT3 S E VOZT4 S E VOZT5 S E VOZT6 S E VOZT7 S E VOZT8 S E VEPB S E VEPBa S E VEPBs S E VEPM S E VEPMa S E VEPMs S VECA S C E .Assay of element E in melt 1 phase of stream S in troy ounces/ton. components C in stream S in organic only. .Grams . . . element E in stream S in aqueous only (at 25C). .Grams . . element E in stream S in aqueous only.Assay of element E in gas phase of stream S in troy ounces/ton. 28 . .Weight fraction of phases P in stream S. Solid Phase Value Functions Vgf3 VGF3 Vgm3 VGM3 VPCS VVPS P VPWF P VPMF P VPVF S S S S S S S S S .Parts per billion of element E in total stream S.Moles per per per per per per per per per per per per per per per per per per per per per per liter liter liter liter liter liter liter liter liter liter liter liter liter liter liter liter liter liter liter liter liter liter of of of of of of of of of of of of of of of of of of of of of of element E in stream S in total liquor. . . S . .Saturated steam condensate enthalpy at temperature T. T . . Steam and Air Value Functions VDEW VGAH VGRH VARH VGDB VGWB VSTP VSTT VHCT VHCP VHST .Estimated pH of stream S. .Relative humidity from dry bulb (D) and wet bulb (W) temperatures in degrees C. . Note: U and R references are 'not' updated with changes. kJ/kg as function of pressure P.Estimated BTU value for coal stream S. .Particle Size Value Functions VCPS F VMIC VP80 M VPAS M VPPM M VCPR VPCP VPCR M VSIZ S S S S S S S S S .Saturated steam temperature in ùC at pressure P in kPa. . S .Dew point of gas phase in stream S in degrees C.Dry bulb temperature of stream S in degrees C. Miscellaneous Value Functions VEPH E VEXT VVIL VVIS W VWAS VAHP VTHP VTKW S S2 S S S H . .Weight fraction of solids in stream S passing M microns. . . .Wet bulb temperature of stream S in degrees C. . T .Micron size of fraction F passing in stream S.Enthalpy in BTU/lb and Kcal/kg mole of superheated steam at pressure P in psi and temperature T in ùF relative to 25ùC.Value of heat content of stream S in Btu/pound. . .Cp of components C in stream S at current stream temperature kcal/kg/ùC Chemical Reaction Value Functions U VHTR R .Calculates the total kilowatt power draw for the entire flowsheet. kJ/kg as function of temperature T.Weight fraction of solids in stream S retained on micron size M.Wash ratio of liquor in stream W to solids in stream S. . Requires EPH factors in ICOM.Heat capacity Cp of stream S at temperature T.Average coal particle size in millimeters or inches.Weight fraction of solids in stream S passing all mesh sizes.Enthalpy in Kcal/kg of superheated steam at pressure P in kPa and temperature T in ùC relative to 0ùC. P .Available motor horsepower equal to or larger than H.Saturated steam enthalpy in Btu/lb.Calculates the total installed horsepower for the entire flowsheet. . . in kilocalories/kilogram/ùC . 29 . S . . no solids correction. .Absolute humidity of stream S. D W .Weight fraction of solids in stream S retained on each mesh size. P .Saturated steam enthalpy in Btu/lb. Heat Content Value Functions (experimental) VBTU VBPP VSHC C VCHC T VSCP C VCCP S S S S S S . . S .Heat content of stream S in kcal/hour.Heat content of components C in stream S in kilocalories/hour.Enthalpy in BTU/lb of superheated steam at pressure P in psi and temperature T in ùF relative to 25ùC.Estimated viscosity of liquid in stream S.Weight fraction of solids in stream S passing M microns. .Enthalpy in BTU/lb and Kcal/kg mole of superheated steam at pressure P in kPa and temperature T in ùC relative to 25ùC. T . . . S .Relative humidity of stream S. . VHSP P VDSS S P VESS T P VMSS T P Vesse T P VESSE T P Vessm T P VESSM T . .Heat of reaction in kcal/hr for reaction R in unit operation U.Estimated viscosity of a slurry streams S.Weight of solids in stream S passing M microns.Degrees of superheat of steam in stream S in degrees C.Mesh size in microns which passes 80% of the solids in stream S.Extraction of element E from solids between streams S[1] and S[2].Saturated steam pressure in kPa at temperature T in ùC. .Saturated steam condensate enthalpy at pressure P. kcal/kg.Enthalpy in BTU/lb of superheated steam at pressure P in psi and temperature T in ùF relative to 0ùC. .Enthalpy in Kcal/kg of superheated steam at pressure P in kPa and temperature T in ùC relative to 25ùC. kcal/kg. Loss on ignition of stream S.Returns .Returns . .Returns the long label for stream S. used in conjunction with other value functions. . . .Estimated vapor pressure of brine in streams S. Format: VSET 'VLPS s10=123' .Value of equation number E solved with parameters X.Returns list list list list list list list of of of of of of of blocks blocks blocks blocks blocks blocks blocks with same block identification as block ib in column containing block ib in cell containing block ib in column of cell containing block ib in level containing block ib in column of level containing block ib in heap containing block ib VHEP B .Value of output variable from analog input device N.Value of output variable from analog output device N. Format: 'RM' VFLS u10 . .Returns .Special Value Functions E VEQN VSET VCTL VAID VAOD VDID VDOD V VFLS VHRD VLAB VSNM VTMP VAPK VBVP VLOI VTMP X X N N N N N U S S S S S S S S .Places data from HEP0 into STR in an unused stream number and returns the stream number.Returns . e. .Returns value of variable V from unit operation U.Value of output variable from digital input device N.g.Returns the control temperature for stream S in degrees C. VHEP0 B Sn Ausmelt Furnace Example 30 .Places data from HEP into STR in an unused stream number and returns the stream number. .Returns . . .Value of output variable from digital output device N. . (experimental) . Heap Leach Value Functions 1 2 3 4 5 6 7 VHLG VHLG VHLG VHLG VHLG VHLG VHLG ib ib ib ib ib ib ib . used in conjunction with other value functions.Returns .Value of output variable from Controller N.Execute expression X to set flowrate.Surface area in M3/kilogram of solids in stream S.Value of water hardness of stream S in ppm calcium carbonate.Returns the short label for stream S. C VGPL VHEP 3 VHLG ib Returns the grams per liter of component C in all of the blocks in the cell containing block ib .Control temperature of stream S in degrees C. . .