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JKSimMet V6

JKSimMet

OVERVIEW
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James Didovich 2014

JKSimMet V6

JKSimMet Overview
JKSimMet is a package developed by the JKMRC/JKTech
for the modelling and simulation of comminution circuits.
It includes models for crushers, autogenous mills, ball
mills, rod mills, screens, and hydrocyclones.

It is a closed package: you can not add your own


process models.

There is detailed information on the models included


with JKSimMet in the user manual.
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JKSimMet V6

JKSimMet Overview
Flowsheet Design

Mass Balance
Mass Balancing

Data Input

Model Fit
Model Fitting

Simulation

Simulate
Results Analysis
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JKSimMet V6

JKSimMet References
JKSimMet V6 User Manual

JKSimMet V6 Help Files

(PDF)

(HELP FILE)

Mineral Comminution Circuits: Their Operation and Optimisation


(Published by JKTech)

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JKSimMet V6

JKSimMet User Manual

Part I Overview
Part II Changes from Version 5
Part III Installing JKSimMet
Part IV Learning JKSimMet
Part V Using JKSimMet

Read Once

JKSimMet 101

Part VI Mass Balancing


Part VII Model Fitting

JKSimMet Reference

Part VIII Model Descriptions

MODELS REFERENCE

James Didovich 2014

JKSimMet V6

JKSimMet Help File

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JKSimMet V6

JK Blue Book
CONTENTS
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1 Introduction
2 Models of Comminution Processes
3 Mineral Liberation
4 Rock Testing
5 Surveying Comminution Circuits
6 Crushers
7 AG and SAG Mills
8 Rod Mills
9 Ball Mills
12 Screens & Hydrocyclones
13 Optimisation of Comminution Circuits
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JKSimMet V6

Steps to Building a Circuit Simulation

2. Setup the feed.

3. Setup the models.

1. Draw the flowsheet.

4. Run the simulation.

5. Review results.
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JKSimMet V6

JKSimMet

FLOWSHEETING
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JKSimMet V6

Starting with JKSimMet


1. Create a new Project and save it.
2. Press No when prompted about V5 icons
V5 used bitmap icons;
V6 uses vector images.
Cant mix so need to
make a decision. Best
just to go with No.

3. Should now have a blank project on screen:

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JKSimMet V6

JKSimMet Flowsheeting

List of models available

Flowsheet drawing area

List of Flowsheets in project

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JKSimMet V6

Ex F1: Sandbox Flowsheet


Experiment with:
1. Adding models to the drawing area by dragging and
dropping;
2. Connect models using streams (red ports are outputs,
blue ports are inputs connect red to blue);
3. Adjust stream lines to be aesthetically pleasing (right
click Add/Remove stream node).

4. Name the flowsheet Ex F1: Sandbox


James Didovich 2014

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JKSimMet V6

SAVE
Save, and save often.
JKSimMet can often crash seemingly right when you
have significant unsaved changes.
Network licenses can cause increased frequency of
crashes (compared to a local dongle).
Become OCD about saving!
CTRL + S does not work. Must use the disk
icon.
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JKSimMet V6

Ex F2: Ball Mill Circuit


Experiment with:
1. Adding nodes to streams
(right click Add node to stream)

1. Resizing units
(drag and drop)

2. Changing unit orientations

3. Naming streams and equipment


(double click on unit/stream)

4. Adding autolabels

NOTE:
A JKSimMet flowsheet must have at
least one feed unit and one final
product

5. Adding water feeders where

appropriate for this circuit


James Didovich 2014

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JKSimMet V6

Ex F2: Ball Mill Circuit

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James Didovich 2014

JKSimMet V6

Ex F3: SABC Circuit


Draw the following circuit:
Ore is fed into a SAG mill.

SAG mill has a pebble crusher (closed with a

Experiment with
adding Info Blocks to
your flowsheet

screen on SAG Discharge).


SAG Discharge screen U/S feeds a cyclone

cluster.
Cyclone underflow feeds a ball mill in closed
circuit.
There are water additions to the SAG feed,
Cyclone Feed, and Ball Mill Feed.
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JKSimMet V6

Ex F3: SABC Circuit

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JKSimMet V6

JKSimMet

SIMULATE I
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JKSimMet V6

Steps to Building a Circuit Simulation

2. Setup the feed.

3. Setup the models.

1. Draw the flowsheet.

4. Run the simulation.

5. Review results.
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JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Clone your Ex F3: Flowsheet Layout Design

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JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Feed Needs:
1. Feed Rate

2. Feed Size Distribution

James Didovich 2014

Feed Sieve Series

Feed PSD

Required Feed Size Distribution:


Screen Aperture
mm
190
165
140
125
100
63.0
45.0
31.5
25.0
19.0
13.2
9.50
6.70
4.75
3.35
2.36
1.70
1.18
0.850
0.600
0.425
0.300
0.212
0.150
0.106
0.075
0.053
0.038
-0.038

WEIGHT
%
0.0
0.0
4.1
4.3
23.9
23.6
12.2
3.0
0.5
2.2
8.4
4.7
3.0
2.0
1.2
1.1
0.8
0.8
0.5
0.5
0.4
0.3
0.3
0.2
0.2
0.2
0.2
0.1
1.3

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JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Feed Needs:

Setting the Ore Feed Rate


Set to 500 tph

1. Feed Rate

2. Feed Size Distribution

Feed Sieve Series

Feed PSD

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Feed Needs:

Feed Sieve Series

the entire simulation.

Feed Sieve Series

Feed PSD

However survey data from the lab will use


different sieves for different streams.

1. Feed Rate

2. Feed Size Distribution

JKSimMet uses one master sieve series for

JKSimMet allows each stream can have a

custom sieve series.

JKSimMet will then convert all streams to


the master series by interpolation.

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JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

The Root 2 button is a quick


way to set a sieve series.

Feed Needs:

Specify which series


each stream is to use
here

1. Feed Rate

2. Feed Size Distribution

Feed Sieve Series

Feed PSD

Add sieve series here

TIP: Entering a size of 0 will delete all size fractions below.

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JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Feed Needs:
1. Feed Rate

2. Feed Size Distribution

Feed Sieve Series

Feed PSD

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Feed Needs:
1. Feed Rate

2. Feed Size Distribution

Feed Sieve Series

Feed PSD

PRESS Transfer to perform the


conversion to master sieve
series.

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Need to specify models for:

SAG Mill
SAG Discharge Screen
Pebble Crusher

Ball Mill
Hydrocyclones
Water addition

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JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Water Feeders
Use a simple model to set a specified % solids in the
downstream unit.
Parameter

SAG

Ball Mill

Cyclone

Req. %S

65

70

30

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

SAG, BALL, PEBBLE CRUSHER


Simple model that creates a product PSD by moving
it sideways on a Cum % Passing vs size plot to give a
user specified product P80.

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

SAG, BALL, PEBBLE CRUSHER


Simple model that creates a product PSD by moving
it sideways on a Cum % Passing vs size plot to give a
user specified product P80.
Parameter

SAG

Pebble

Ball Mill

Req P80 (mm)

10.0

5.00

0.500

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JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

SAG Discharge Screen, Hydrocyclone


Efficiency (partition) curve that describes what
fraction of a particular particle size reports to the
product stream.

The underflow and overflow curves

are complementary.
Traditionally the underflow curve is
used for efficiency curves

JKSimMet uses the overflow curve


given that this is the product
stream in a grinding circuit
classifier.
James Didovich 2014

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JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

SAG Discharge Screen, Hydrocyclone

Draw the flowsheet.


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Efficiency (partition) curve that describes what


fraction of a particular particle size reports to the
product stream.

Efficiency Curve:
0

50

= .

Parameters

Alpha

50

50

Sharpness of Efficient Curve


Initial Dip in Efficient Curve
Water Split to Fine Product (%) -
Corrected d50c (mm) 50

Beta

( is calculated internally and is not a parameter)

For more on Efficiency curves see:


1.
2.

JKSimMet Manual pp. 346


JK Blue Book pp. 276

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet


Setup the feed.
Setup the models.
Run the simulation.
Review results.

SAG Discharge Screen, Hydrocyclone


Parameter

SAG Disch
Screen

Cyclones

Alpha

1.5

2.5

Beta

C (%)

90

75

d50c (mm)

10

0.10

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet


Setup the feed.
Setup the models.
Run the simulation.
Review results.

PRESS THE
SIMULATE ICON

PRESS START TO
RUN SIMULATION

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet


Setup the feed.
Setup the models.
Run the simulation.
Review results.

DO NOT TRUST A BLACK BOX


This is where you use your subject matter knowledge to review
and interpret the results.

Do they make sense?


Are they realistic?
What needs to be improved/changed/corrected?

JKSimMet Tools:
1. Data Blocks
2. Graphing
3. Reports (Export to Excel)

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Data Blocks:

What is the final product P80?

What is the circulating load in the ball mill circuit?

What are the reduction ratios for each comminution


machine?

Are there any concerning numbers?


(HINT: Pebble crusher tph, ball mill % solids)

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Graphs:

Cant print from JKSimMet, can copy to


clipboard and paste into Word, Excel,
PowerPoint etc.

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Graphs:

Plot all the feed/products for comminution machines (SAG,


Ball, Pebble)

Plot Feed/US/OS for Cyclone

Plot Fresh Feed SAG Screen US

Plot SAG Screen US Final Product

Plot Fresh Feed Final Product

Review Graphs:

What do these charts tell you?

Where is the most size reduction taking place?

Which machines are working harder than others (too hard?)?

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JKSimMet V6

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JKSimMet V6

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet


Setup the feed.
Setup the models.
Run the simulation.
Review results.

Reports:

Allows you to export data for analysis in Excel

(Cant view reports within or print from JKSimMet)

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James Didovich 2014

JKSimMet V6

Ex SIM1: Simple Models


1.
2.
3.
4.
5.

Draw the flowsheet


Setup the feed.
Setup the models.
Run the simulation.
Review results.
This has described the process of running a single simulation.
Having reviewed the results of the model we can then:
1) make appropriate changes to our model parameters, our feed, our circuit configuration;
2) rerun the simulation; and,
3) compare the results.

Baseline

Scenario 1

Scenario 2

Scenario 3

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James Didovich 2014