Chapter 39
J. M. Richardson
Supervisor , Wineer ing System
Fluor mgineers, Inc.
Northern California Division
Redwod City, California
Metallurgical balances are
fundamental t o the successful design
and operation of concentration and
dewatering circuits. With caquter-
ized balance techniques gaining
praninence in recent years, it is
essential that engineers understand the
basic principles that underlie the new
methods, a s well as the varicus
a~plicationsfor design of new plants
and analysis of existing operations.
This chapter discusses tw inportant
types of metallurgical balance:
(1) steady-tate design
(2) operating data adjustment
Application of carputer ized steady-
state design balancing is demonstrated
through the exanple of a typical caFper
concentrator f lowsheet. -rating data
adjustment t o achieve a consistent
balance is demonstrated for a typical
concentrator aperation.
Definition of Metallurgical Balance
The term "metallurgical balance" is
ccrmPnly applied to mean the overall
accounting of material and energy
flawing into and out of a metallurgical
Professor,
Mineral Process Ehgineer ing
University of British Co-ia
Vancower, British Columbia
process. A s the design and installa-
tion of concentrating and dewatering
circuits does not usually require heat
balance calculations, this chapter w i l l
be limited t o discussion of material
balances.
lb "balance" a system inplies that
the system is a t steady-state. A t
steady-state, the mss i n p ~ trate
equals the mass cutput rate, whether it
is the entire process that is being
considered, or individual unit
aperations. For a system a t
steady-state, no m t e r i a l accurmlates
internally; each u n i t operation is
assumed t o be functioning w i t h an
unchanging vollw of material already
present.
A metallurgical balance for a typi-
cal concentrator may apply t o any or
a l l of the follawing measurable items:
- total material (solids plus fluids)
- individual m t e r i a l phases
(solids, fluids)
- individual, "assayable" conponents
(cogper, molybdenum, etc .
- individual size fractions
Categories and Applications of
Metallurgical Balances
With the advent of carputerized
 CONCENTRATIONAND DEWATERING CIRCUITS
balance calculations, two distinct
categories of metallurgical balance
have arisen:
- process design
- operating data adjustmnt
Each category contributes signifi-
cantly, but in a different manner, to
the engineering goal of optimization of
process plant design and operation.
This section takes a closer look at
both categories and identifies specific
applications found in each.
Process Desian In this balance
category, engineers endeavor to
accurately calculate material balances
for individual unit operations, cir-
cuits within a plant, or an entire
process flowsheet. Typically, the
calculations are based on the use of
predictive mathematical models, usually
of individual unit operations. Such
models normally function to transform
specified or k n m inplt stream data
into outplt stream values. In
practice, the use of such models is
further dependent on parameters ihich
help define operating conditions and
performce of the particular unit
operation. Model sophistication varies
widely:
- highly theoretical, mechanistic
models which attenpt to explain the
unit operation from first principles
- semi-enpirical models having
grounding in both theory and
operating or experimental data
- fully-enpirical models based on
engineering assunptions and opera-
ting or experimental data
Steady-state design balance results
are used for the following applications:
- equipnent sizing
- evaluation of alternative processes
- modification to existing plants
Table I represents a -ling of the
recent literature on conplterized
steady-state design balance systems for
minerals industry processes. The table,
which is bv no means conplete, indi-
cates which system appear to be
process- or plant-specific and which
are general-plrpose. Some of the work
referenced includes discussion of
operating data adjustment as related to
developnent of process-specif ic models .
DaQ Miustment Data adjustment
procedures for metallurgical balances
involve the non-model-based statistical
adjustment of inconplete or inaccurate
operating plant data to obtain a
consisitent material balance. Data
adjustmnt is one step involved in the
developnent of models (Mular and Herbst
I197811 and should not be confused with
sinulation programs enployed for pro-
cess design. me latter may utilize
adjusted data in a suitable rmnner, so
that data reconciliation programs and
process design programs are closely
connected.
The need for data adjustment pack-
ages a w r s to be unique to the
minerals industry, where the physical
and chemical nature of the materials
treated and the processes used have
corrbined to make accurate measurement
of process conditions extremely
difficult, if not inpossible. The
inherent inability to measure or infer
flow of material results in either
under-defined (inconplete) balances or
overdefined (inaccurate) balances
around individual equipnent and even
entire plants. By providing a
reasonable estimate of what the actual,
consistent balance around a unit
operation, circuit, or plant should be,
data adjustment program can be used
in the following applications:
- metallurgical accounting
- process instrument / control system
calibration
- data verification for enpirical
model developnent
Table I1 gives a very brief listing
of sane of the most recent and m r e
frequently referenced efforts in the
area of steady-state data adjustment.
 METALLURGICAL BALANCES

A m E I G CF DESIGN BAGANCE SYETENS

DEVFXOPIEX; UTILITY
QBatwam
general-plrpose,
minerals industry
ASPEN MIT

ASPEN-PLUS general-plrpose,
nulti-industry
Fluor mgineers general-purpose,
minerals industry
U. of Idaho general-plrpose,
nulti-industry
(Gotffried, et. al.) U. of Pittsburgh/ coal-preparation
USEP1/US#)E plants only
r'WmAL*-II SAmWv. of -tern general-plrpose ,
Chtar io minerals industry
Mineral Processing Jblius Kruttschnitt general-plrpose ,
Sirmlator Mineral Research Centre minerals industry
U. of Witwatersrand general-plrpose,
minerals ind.~stry
Pimock, Allen c general-plrpose ,
Aolt lkgineers minerals industry
(Rular, et. al.) U. of British plant-specif i c
Colmbi&d Brenda Mines
u. of Utah general-plrpose,
minerals industry
Lava1 University general-plrpose,
minerals industry
U. of California, general-plrpose,
Berkeley minerals industry
SWC CAEMET general-pllrpcee,
minerals industry
 CONCENTRATION AND DEWATERING CIRCUITS
TABLE 11
A SAMPJ,IK OF RECENT DATA ADJUSJMWl SYSl'FNS
SYSTEM
0
(Mular, e t . a l . )
U s e of Complters for Metallurgical
Balances
&j& m i l e the need for
calculating metallurgical balances has
always been apparent, several factors
have ccmbined historically t o retard
t h e developnent and widespread use of
conplterized system for automating
calculations. A key factor was t h e
lack of econanic incentive t o develop
s@isticated techniples for process
cptimization. The availability of high
grade ores t h a t were easy and
inexpensive t o process limited the need
t o understand and model the processes
used. Conplter equipnent was expensive
t o own and operate. Personnel with
adequate carputer training were scarce.
A noticeable change occurred in the
1960's and 1970's. Ore grades had been
steadily declining bile processes were
becoming ever more carplex. Universi-
t i e s began t o broaden t h e exposure of
engineering students t o conputer
science. In t h e l a t e 197OWs,t h e per-
m i t cost of conputer hardware plunged
dramatically, starting a rapid proli-
feration of small, inexpensive, but
b u t powerful conplters.
Lava1 University
U. of Utah
U. of Minnesota
U. of Minnesota
Michigan Tech. University
U. of British Colurtbia/
Brenda Mines
U. of Arizona
EARCY PROCESS DESIGN SYSTPIS: De-
sign balance programs have been carmDn
i n t h e Chemical Process Industry ( B I )
since the mid-1960's. Program
designed specifically for minerals
industry flowsheets did not begin
appearing u n t i l the l a t e 1970's
(Gottfried and Abara t19781, Bartlett
t19791, Gupta and Messa t19801,
Richardson, et. a l . t1980, 19811,
.
Izurieta and Edwards l19801) Most such
system were written for use on large
"mainf ramen c-ters. Recently,
h m v e r , new system a r e appearing more
frequently (King t19851, Laguitton
r19851, W e e l19851 , Richardsan and
Sredanovic t19851 and most a r e de-
signed t o run on t h e present generation
of popllar "micro" carplters.
DWA AIUuSMEW PRXWW: m i l e de-
sign balances have been calculated
since long before the advent of canplt-
ers, the c a x e p t of data adjustment for
operating flowsheets did not really
progress u n t i l c c q u t e r s were available
t o permit t h e lengthy, canplex statis-
t i c a l calculations involved. Reviews
of t h e subject, detailing early and
recent efforts, a r e provided by Mular
(1979) and by Reid, et a l . (1982).

DESIGN BRLRNCES
% i s section explains the basic
principles of design balance programs.
Basic Principles of Conplterized Design
Balances
A design balance is the starting
point from which logical selection of
alternatives can be made. In some
cases, marginal f lawsheet ar rangernents
can be eliminated from consideration
by carparing balance results for such
item a s circulating loads, quality of
product, waste-product build-up, etc.
me design balance is also the basis
for further calculations such a s e q u i p
ment sizing and determination of
reagent and power consumption. This
leads t o develapnent of capital and
operating cost estimates which are then
used t o further narrow the field of
viable process alternatives.
IterativePsrJroach~Simultaneous
There are two basic
techniques which have been applied t o
the task: the iterative (trial-and-
error) approach, and the method of
simltaneous equations. m i l e the
l a t t e r has not disa~pearedaltogether
from balance system, developers aFpear
t o favor the use of iterative tech-
niques over s h l t a n e o u s equations.
%is chapter focuses on the iterative
approach; but f i r s t , a brief review of
why sinultaneous equations a r e rejected:
With sinultaneous equations, the
engineer mst s e t up and solve a system
of equations that exactly describes the
exchange of m t e r i a l in a f lowsheet.
Conplex flowsheets are thus attacked in
their entirety, rather than in syste-
mat ic, manageable chunks. Either
the user or the program designer rmst
ensure that a l l possible equations are
specified. This makes it difficult t o
design a general-purpose program which
can accept the rmlti-equation defini-
tion of many different flowsheet
arrangements. Dedicated programs
written t o balance a specific flow-
s h e e t a r e easier t o achieve, but rmst
be rewritten for each new flowsheet or
major change.
While mthermtical techniques abound
for solving almast any given s e t of
s h l t a n e o u s equations, a satisfactory,
easily programable method for auto-
mating the specification and set-up of
equations has yet t o emerge from the
literature. The fact that process flow-
sheets can vary widely has nearly
eliminated the use of sinultaneous
equation-solving in general-plrpose
design balance program.
Modular Method. Most of
today's design balance program use
some variation of t h i s technique, which
grew from the traditional m u a l "trial-
and-errorn method. Sam key concepts:
PFWESS PICrORlAL ANI B W F m
A pictorial diagram is
D1PIC;RAMS:
essential t o understanding the inter-
relationship of material flows and unit
operat ions. A typical capper/mlykde
num concentrator is shown a s Figure 1.
The unit operations shown in t h i s f l o w
sheet mst be modelled (described
mathematically) in order t o solve the
balance. The mathematical models are
implemented a s program subroutines
called modules. These modules usually
replace the unit operations cne for
one, but there may also be reason for
having several unit operations rep-
resented by one module, or vice versa.
A drawing which shows the modules
chosen is defined here a s a "block flow
diagram". Figure 2 is the block flow
diagram representing the flowsheet of
Figure 1. Each module and stream is
labelled with a unique n&r for easy
reference and so that no stream or
module nunber occurs twice.
UNIT OPERATION MC6XlLES: Before
continuing with the exarrple flowsheet,
it is useful t o f i r s t look a t a typical
module in claser detail. The module
chosen is the flotation module ( W T ) .
. .
DescrlPtlon: The F W module
perform a balance about a flotation
c e l l , a bank of cells, or an overall
circuit such a s rougher, scavenger,
cleaner, etc. The module accepts a
single inplt stream and calculates two
 CONCENTRATION AND DEWATERING CIRCUITS

n
STOCK PILE

APRONFEEOER

BELT COIJVEIOR

4 7
WATER

111. CLEARER

I
WATER
REGRINDMILL

FIGURE 1. Copper / Molybdenum Concentrator Pictorial Diagram

 METALLURGICAL BALANCES

MIXER

MIXER

- -

FIGURE 2. Copper / Molybdenum Concentrator Block Flow Diagram

614 CONCENTRATION AND DEWATERING CIRCUITS

outplt streams (concentrate and XsG = solid conpnent mass

tailings). concentration, stream n,
ith cofiponent
The overall solids flowrate in the
concentrate is based on the concentrate Wf, = total fluid mass flaw, stream n
grade and recwery of a designated
"primryn solid ccargonent. Up to two Parameter Definitions: The nuher of
additional "secondary " ccnponents may equipnent parameters required for the
be designated in the concentrate. The operation of EUXT will vary depending
"seccndaryn conponent recoveries do not on the n&r of solid capnents
affect the overall solids balance but defined as "recoverable".
do determine the balance for each such
conponent. The overall fluid flowrate Percent solids in the concentrate
in the concentrate is based on a user- stream:
specified concentrate percent solids.
All tailings stream solid flowrates are
calculated by difference. Any solid
canpcnents not designated for recovery,
and any size fractions present, are
assumed to be split in the same ratio
as total solids. Grade of p r h r y ccipmnt in
concentrate:
Diaaram: A flaw diagram for
the FLQRT module is s h m in Figure 3.

Recwery of primary conponent in

concentrate:

Recovery of secondary cmponent in

cancentrate:

~Calculations:
Concentrate Solids Tailings Solids
FIGURE 3. F m T Mcdule Flow Diagram ma= x BL m3=W8,-
p3
The variables show with each stream
are defined as:
m, = total solids flwr stream n
Cshi = solid conponent mass flow,
stream n, ith conponent
 A1 BALANCES 615

a single recycle group my contain a l l

Concentrate Fluids Tailings Fluids the modules of a f lawsheet. f i e
exanple of Figure 2 has three recycle
groups: group 1, which contains the
semi-autogenous grinding circuit;
group 2, which contains the ball m i l l
circuit; and group 4, which is mde up
of the regrind circuit, cleaner
lumHEEz TOPOIM;'Y: If material flotation, and scavenger flotation.
streams do not recycle or loop back in
a f lorJsheet, mas balance calculations
are single. Unfortunately, moat
processes contain recycle loops that
make mass balance calculations dif-
f icult and t Wmwning. me sequen-
t i a l modular method sirrplifies calcu-
lations by subdividing the flawsheet
into groups of unit operation modules
.
that can be solved indivudally Groups
are categorized according to certain
characteristics, and each is solved by
a calculation method amropriate for
that group. The type and nmber of
module groups occurring in a f lawsheet
is also referred t o as the flowsheet
topology. The two categories of module
groups are k n m as 'serial" and
"recycle".
SerialnngRSYGkGroMs: A
serial group i s the largest group of
modules that can be calculated in
sequence, working from the beginning of
the group. All input stream flawrates
to each module are known before the FIGURE 4. Recycle Group
output flaws are calculated. Serial
groups can be solved in a single pass, ?he calculation of
without repetition of the calculations. serial groups i s straightforward.
In Figure 2, there are only two serial Hawever, t o understand the calculation
groups in the exanple f lowsheet. me of recycle groups, it is f i r s t
such group is the rougher flotation necessary t o understand the concept of
(module 110) and the Launder water "tearing." lb illustrate this concept
addition mixer (module 111). 'Ihe other refer t o one of the recycle groups of
serial group contains the second the exanple flowsheet. The singlest
cleaner launder water addition mixer case i s group 1, the semi-autogencus
(module 119) and the final tailings grinding circuit, which is ahown
sunp (module 122). isolated in Figure 4. The definition
of a recycle group is satisfied; that
A recycle group i s the m l l e s t is, there is no module for which a l l
group of a l e s that cannot be solved input stream are k m before
in a single calculation pess. I n a calculating. A l q i c a l calculation
recycle group, there is no apparent path through the circuit is not readily
starting point for orderly calculation, apparent. Tb resalve this, one or mre
since no module exists for which a l l streams in the circuit met be 'torn,"
inplt stream are known prior t o any i.e., arbitrarily and artificially
calculations. A recycle group mat
contain a t least two modules; however,
divided into two new streams as shown
in Figure 5. After tearing, stream 7
becomes two streams: stream 7 and
stream 801. Stream 7 is the oversize
from the screen and stream 801 is an
i n w t t o the feed conveyor.
FI(;URE 5. "Tearing" a Recycle Group
Orderina=m-Seauence:
The objective of tearing is t o a l l w a
recycle group t o be re-ordered in a
sequential manner. This is demn-
strated for the exanple circuit in
Figure 6. By assuming that the flows
in stream 801 are known, there is n w a
serial calculation path through the
group. Using an assumed (guessed)
value for stream 801, the conveyor
(MIXER) module can calculate f l w
values for stream 2. The water addition
(MIXER) module subiequently r d v e s
known-valued input stream 2 and 3, and
can in turn calculate stream 4. T h i s
allows the m i l l (C(mIN) module t o next
calculate stream 5 values, and the
screen ~~) module can, in its
turn, calculate stream 6 and 7.
However, unless the i n i t i a l guess for
stream 801 was accurate, stream 7 w i l l
not be equivalent t o strean 801. Since
these two stream are really the same
stream, they nust be equal or nearly
equal before the circuit is "converged"
(balanced). If the circuit has not
converged, a new guess w i l l be
required, and the calulation sequence
nust be repeated. The entire procedure
w i l l repeat until convergence is
achieved. The principles of tearing and
ordering as shown in t h i s exanple are
the same for any recycle group, and the
objective is always the same, t o
provide a straightforward, serial path
through the group, with a l l module
inputs known or assumed known when each
module is calculated.
FI- 6. "Serial" Structure After
Tearing
Conversence Modules:. Design
balance program use convergence
modules t o help solve recycle groups.
mis type of module conpares torn
stream guessed and calculated values
and generates new guesses (if the guess
is not equal t o the calculated value).
Tb demonstrate, Figure 7 shows the
exanple circuit reassenbled with a new
module, the convergence module, insert-
ed be- stream 7 (the calculated
stream) and stream 801 (the guessed
stream). Since the cmvergence module
is like any unit aperation module,
given an input stream, it w i l l calcu-
 METALLURGICAL BALANCES
late an outplt stream by projecting new
values for the outplt stream based on
the recent history of calculated
values.
FIGURE 7. Recycle Group with Converge
Module
The numerical method used by many
design balance program t o canverge
recycle loops is actually a conbination
of two techniques known respectively as
succesive substitution and the
unbounded Wegstein convergence accel-
eration method. In successive substi-
tution, the calculated value of the
torn stream obtained from the previous
iteration becomes the guessed value
which starts the current iteration.
This method usually works but often
requires many iterations t o reach a
solution. The kgstein method solves
considerably faster. It uses a secant
projection from the previous two
calculated values t o determine what the
current guessed value should be. The
objective of the projection is t o solve
for the following :
where x is the guessed value and f(x)
is the calculated value. Wen f (x) = x
for any particular stream variable, the
circuit is converged for that variable.
The Wegstein method requires suc-
cessive substitution t o give it the
f i r s t two points from which to nrake a
projection. After that it can generate
i t s awn points and w i l l solve in many
fewer iterations than successive
substitution.
For the exanple circuit, the
calculational order begins with the
convergence module and ends w i t h the
screen. Any initial f lawrate values,
including zero, for stream 801 are
sufficient t o start the iterative
calculation process. The order is
repeated until the convergence module
"signalsn the program that recycle group
1 has converged. Then the next group in
the flowsheetcan be calculated. If the
recycle group is corrplex and contains
mre than one torn stream, and therefore
mre than one converqence module, the
calculation sequence-will be repeated
until a l l converqence modules "signal"
that convergence-has been achiwd.
The a m t of error remaining a t
convergence is knawn as convergence
tolerance, defined as the absolute value
of the relative ratio of guessed and
calculated values:
convergence tolerance =
For each stream variable being
balanced, the convergence module
carpltes the current value of this
expression and conpares it against a
value supplied initially by the user.
If it is less than or equal t o the
user-sumlied nunber, convergence is
achiwed for that variable. All stream
variables rmst be converged before the
module w i l l stop projecting new
guesses.
618 CONCENTRATION AND DEWATERING ClRCLllTS
. .
--TowsraPhv:
Some balance program require extensive
m u a l network analysis of a flowsheet
before the actual balance can be per-
formed. This means that the engineer
m s t f i r s t organize the modules into
serial and recycle groups and determine
*ich stream in each recycle group
should be torn. He then has t o place
convergence modules into the flowsheet
and determine a calculational order.
With certain balance programs, these
t a s k s are performed automatically by
the program, with the user only
required t o specify overall flawsheet
topography (interconnection between
streams and modules). Special program
network analysis subroutines perform
grouping, tearing, insertion of
convergence modules, and calculational
ordering. The algorithm used in these
types of subroutines are discussed in
greater detail by Coles (1982) and
Wsterberg, e t . al. (1979).
A c m n convention is used t o
specify process stredmodule inter-
connections: For each module, a l l
module input streams are given positive
nunber labels, and a l l outplt streams
are given negative nunber labels. A l l
module input stream are always listed
before output streams. lb specify the
topography of the entire exanple flow-
sheet of Figure 2, a table, such a s the
data sheet shown in Figure 8, m s t be
constructed.
STREAM M A R48JIREMENl'S: When
calculating the balance , the flow
variables balanced usually include
t o t a l solids, t o t a l fluid, and
conponents of the solid and fluid
phases. "Conponent" means the
individual chemical elements or
conpounds that make up the solid or
fluid phases; anything that might be
assayed for in real life. The
definition can also be extended t o
solid particle size fractions.
Same programs such as FLEXMF2.
consider each variable as independent
with respect t o the overall flowsheet.
Therefore, convergence modules work
separately and independently on each
variable, but do not "signal"
convergence until every variable is
converged. The nm&r of individual
conponents from each phase that can be
balanced depends on h i c h program is
being used, as do the maxirmm nuher of
unit operations and streams allowed for
each flowsheet. Concentrations are
dependent values calculated from
individual conponent mass flows and
total phase flow rates on a stream by
stream basis.
The item balanced in the
cgper/n-olybdenum flowsheet example
include:
- t o t a l solids
- t o t a l fluids
- solid-phase c o m r
- solid-phase molybdenum
-
MEEXIE SPECIFICA!CIOW THE USE CF
CDNl!ROUEEt MODULES: When a l l process
feed stream flow rates and unit
operation module parameters are known
in advance, a balance is easily
achieved. Hawever, in m y cases
several of these variables are not
known i n advance. For exanple, two
parameters required by the FU3.W module
are the concentrate primary conponent
grade and the per cent recovery of the
primary conponent. In complex copper
circuits, m y flotation unit
operations are enployed, but for some
of these, such a s cleaner or scavenger
circuits, it is often difficult t o
determine beforehand what the actual
grade and recovery of copper might
actually be. Thus, the system is
underspecified. However, scavenger
circuits often recycle copper toward
the front of a process, and it is
likely that a circulating load of
copper, or the grade of a process
tailing of copper, w i l l be known.
Mten, an overall process recovery of
copper w i l l be k n m . Any of these
values can be used t o replace an
unknown d u l e parameter or feed stream
value, and the system w i l l be
conpletely specified.
mConceotnfConttollers: To
enable users t o specify internal or
product stream flowrates and concen-
trations, design balance programs use a
 METALLURGICAL BALANCES
FIGURE 8. Data Sheet Specifying Flowsheet Layout
special-plrpose module called the
"controller". Controller d u l e s can
be inserted into a flOW6heet to modify
feed stream or module parameters to
m e t a constraint. In effect, a
controller is instructed by the user:
" m r ing the calculational sequence,
specified internal or product Stream
values nust be made to occur." Wile
the use of controller
d u l e s aFpears analogous to the
utilization of process cantrollers in
an actual operating plant, the end
plrpose here is only to solve a
steady-state mass balance. Transient
conditions are not considered, even
though the algorithm enployed by
controller modules cause them to behave
like real process controllers when
converging towards a balance solution.
It is the end result achiwed by these
modules that is most inportant.
There are usually two types of
controller modules: feedforward and
feedback. Each type has several
parameters associated with it that
allw the user to specify how it is
used.
Feedforward Controller Module:
This type of moclule monitors a stream
variable ahead of the feed etream
variable or unit operation module pa-
rameter that is to be adjusted. The
plrpose of the adjustment is to meet a
specified stream value, or setpoint,
downstream fram the adjustment. This
is illustrated by examining the rougher
launder water addition (MMER) module
ran the example flowsheet. The module
is shown in closeup in Figure 9. A
water stream is being added to dilute
the solids concentration in the rougher
concentrate from 40 weight percent
solids down to 25 percent solids.
620 CONCENTRATION AND DEWATERING CIRCUITS
Usually, an engineer w i l l know these
solids concentrations rather than the
exact t o n ~ g eof water t o be added in
stream 18. Therefore, a feedforward
controller can be applied as shown i n
Figure 9. In the calculational
sequence, the controller is called
before the MIXER nudule. The
controller monitors the value of the
solids concentration of stream 16.
Using the setpoint of 25 percent solids
supplied by the user, the controller
enplays a special dilution equation, or
algorithm, t o calculate the amxlnt of
water in stream 18 that w i l l cause the
setpoint value t o be met for stream 19.
Different f eedforward control
algorithms are required to meet other
situations, such as dilution of fluid
st ream containing dissolved
conpments, proportional addition of
reagents, and so forth.
M r a mlr lPl
I I1 44 Yl :! SOLIDS
FICXlRE 9. Fgplication of Feedforward
Controller Module
FeeQackControllerModules:A
feedback controller can monitor a
stream -re in the f l m h e e t and
adjust a module parameter or feed
stream value in order t o cause the
monitored value t o equal a s e t p i n t
supplied by the user. Feedback control
requires only one algorithm t o solve
any control situation, but the
algorithm is considerably more conplex
than any of the feedforward control
algorithm. It is similar to the
unbounded Wegstein method used by the
convergence nodule and uses the same
convergence tolerance to determine i f
the setpoint has been achieved.
Several adjustments by a feedback
controller are usually necessary t o
meet a constraint; therefore a fe-ck
controller w i l l always be a part of a
recycle group, even if there are no
material streams recycled. The
"recycle" of control information alone
w i l l cause a recycle group t o be
formed.
DILUlB WCmRlll
I1 LI m 1 lOLIDI
FIGURE 10. m l i c a t i o n of Feedback
Controller Module
An exanple of a f-ck controller
i s the ball mill-qclone-sunp portion
of the e x q l e flowsheet. The module
representing the cyclone is a
circulating load classifier (CLCLAS)
This module has two parameters: (1)
.
circulating load (defined as the
percentage ratio of underflow solids to
overf low solids) and (2) fluid split
(defined as a percentage of the total
fluid flow in the cyclone feed) which
 METALLURGICAL BALANCES
reports t o the overflow stream. Using
these parameters, it is likely that the
circulating load value w i l l be known,
but that the fluid s p l i t w i l l not.
m v e r the solids concentration of the
underf low w i l l also be known. Figure 10
shows how a feedback controller can be
applied t o resolve the situation. 'Lhe
controller monitors the solids
concentration of stream 15, the
underflow, which has been calculated by
C X L S . 'Ihe controller then canpares
the monitored value with the
user-sugplied setpoint. If the two
values are not equivalent (within the
limits of the user4efined convergence
tolerance), the controller calculates a
new value for the fluid s p l i t
parameter. 'Ihis new parameter w i l l be
used on the next iteration through the
group, resulting in a new underflow
solids concentration. Since t h i s
circuit is also a conventional recycle
group, a convergence module is
necessary. 'Ihe calculations continue
u n t i l both the controller and the
convergence module signal convergence
in the same iteration.
Performing Design Balances
'Ihe actual solution of a conplete
design balance is derronstrated using
the c w r /mlybdenum f lowsheet example
of Figures 1 and 2. The solution was
achieved using the FLI9MET design
balance program system (Richardson, et.
a l . 1198111.
Flowsheet Iaw>ut. 'Ihe flowsheet
layout, as explained previously, is
specified for inplt as in the data
sheet of Figure 8. 'Ihe program then
perform an organizational analysis ,
s a i v i d i n g the flowsheet into s e r i a l
and recycle groups, inserting
convergence modules &re required, and
r-rdering recycle groups t o prepare
for iterative calculations.
Desiqn Criteria. The reminder of the
information required t o initialize the
program is obtained from the design
criteria. These are the specifications
governing the particular f lowsheet
under study. 'l%ey w i l l have an inpact
on unit operation module parameters, as
well as controller strategy chosen.
Table I11 shows the c i t e r i a for the
example f lowsheet.
Controller s e q y , Before developing
controller strategy for a flowsheet, it
is of p r h r y irrportance t o f i r s t
def ine the design criteria, as
discussed above. Criteria that are not
obtainable with defined equipnent
modules are met through the use of
controllers, as follows:
1. Solids concentration i n the
feed t o the SAG m i l l , b a l l m i l l ,
and cyclone are specified as 70,
60 and 50 % solids, respectively.
'Ihese particular solids
concentrations can be achieved by
adding feedforward controllers
h i c h use a special algorithm t o
calculate how mch dilution water
should be added t o each feed
stream. 'Ihe controllers are
indicated in the block flow
diagram of Figure 2.
2. Operation of the screen and
cyclones i n the f lawsheet was
modelled by use of a circulating
load classifier (QICLAS) module.
This module has two parameters: 1)
the circulating load, which was
defined in the criteria, and 2)
the weight % of feed fluids
reporting t o the overflow, which
was u n k m .
!his second parameter is
calculated for each cyclone
through the use of feetback
controller modules. Criteria
used were: 90 % solids for the
SAG m i l l screen oversize, 35 %
solids for the ball mill cyclone
overflow, and 60 % solids for the
regrind m i l l cyclone underflow.
In each case a controller adjusts
the s d QI=LRS parameter,
fluid split, t o achiwe the
desired solids concentration in
the product stream.
3. Determination of launder Mter
addition t o dilute flotation
concentrates is a calculation not
performed by the flotation
 CONCENTRATION AND DEWATERING CIRCUITS

W L E 111

DESIGN CRITERIA FOR C O F P ~ L Y B COKXNTFWDR

D ~

Plant feed Feed, mtph

Moisture, %
Copper grade, %
Molybdenum grade, %
sffimill Feed, % solids
Circulating load, %
Screen Oversize, % solids
Ball mill Feed, % solids
Circulating load, %
Cyclone Feed, % solids
Cwerflow, % solids
bugher flotation Copper recovery, %
Molybdenum recovery, %
Concentrate grade (ccpper), %
Concentrate, % solids at lip
Diluted concentrate, % solids
Regrind mill Circulating load, %

Regrind cyclone Underflow, % solids

1st Cleaner Copper recovery, % varied
flotation Molybdenum recovery, % varied
Concentrate grade (copper), % 15
Concentrate, % solids at lip 25
Diluted concentrate, % solids 15
2nd Cleaner Copper recovery, %
flotation Molybdenum recovery, %
Concentrate grade (copper), %
Cancentrate, % solids at lip
Diluted concentrate, 8 solids
Scavenger flotation Copper recovery, %
Molybdenum recovery, %
Concentrate grade ( c w r ), %
Concentrate, % solids at lip
Diluted concentrate, % solids
Overall plant Copper, %
recovery Holybdenum, %
 (FLOAT) module. The f i r s t
parameter of the FLQbT module
defines the percent solids of the
concentrate a t the c e l l lip. The
values of the f i r s t parameter and
the concentrate percent solids
after being diluted with launder
water are established by the
design c r i t e r i a of Table 111.
The amount of launder water
addition required t o achieve the
specified dilution can be
achieved by use of feedforward
controllers enploying the same
dilution algorithm as in the
exanple of Figure 9.
4. Cverall process recovery
c r i t e r i a for each cmponent
(cogper and mlybdenum) can be
met in two ways. Cne way is t o
hand calculate a l l recoveries
that mst be achieved by the
individual FUW modules t o
achieve the specified overall
recwery. lhese recoveries can
then be entered as parameters of
the individual FIBAT modules.
The second option requires a
review of a l l flowsheet modules
t o determine i f any of their
parameters w i l l affect overall
conpcnent recovery. For t h i s
case, it is found that only FZ,aAT
rrodules affect cmpnent
recovery. A t t h i s point it is
helpful t o determine h t
individual flotation stage
recoveries may be best known,
perhaps based on testwork or
experience. For t h i s exanple, the
rougher, scavenger and second
cleaner recovery values were f e l t
t o be more reliable than the
estimate for f i r s t cleaner
recovery of both ccmponents .
Controllers were used t o adjust
the individual recovery
parameters of the EUlW module
representing f i r s t cleaner
flotation. In t h i s way, the
specified overall recwery was
achiwed. Any of the EUXT rwd-
ules could have been selected as
the adjusted equipnent, i f jus-
t i f ied by testwork or experience.
By adding controllers t o achieve
these special criteria, there was no
need for prior manual calculations or
the design of special new equipnent
Rodules.
&&rxg Results. The final report
obtained by the program is shown as
Tables IV and V. These final balance
results, which converged t o within a
tolerance of 0.0001, were obtained
after some 40 iterations of the most
corrplex recycle group.
OPERATINS DlUN AIUUslMENI?
Steady s t a t e material balances
calculated from operating data gathered
a t key sanpling points are inportant
for many purposes including metallur-
gical accounting and rmdel building.
Often, raw data acquisition is such
that the system is over-defined (mea-
surement information is in excess or
there is redundancy in the data), so
that a balance can be calculated in
several different ways. In the absence
of error, such balances would agree
with each other. mfortunately, var-
ious sources of error in measurement
create serious disagreement. This has
led t o the developnent of s t a t i s t i c a l
data adjustment program which account
for measurement errors. Data points,
adjusted i n a minimal sense, lead t o
consistent balances. Programs usually
minimize a suitable form of R for n
data points:
where w, is a weighting factor for M;,
the i t h data point and 8; is the cor-
responding adjusted data point. Each Ri
is such that a l l mass balance con-
straints are satisfied.
Techniques t o minimize o m of R
can be placed in two major categories,
namely m e which involve Lagrange
m l t i p l i e r s and derivatives and those
which involve direct search methods.
 CONCENTRATIONAND DEWATERING CIRCUITS

TABLE IV
B&?WCE RESULTS - WTAL SOLID5 / FLUIDS

PROBLEM: CASE 21 BENEFlCIlTION CIRCUIT-COPPER MIE (ORIND-FLOTATION) DATE: 9130185

TOTlL STREAM INFORMlTIOH

STREAM STREW DESCRIPTION SMlD FLOW FLUID FLOW SOLIDS COlCENTRlTION

LABEL TIH TIH YT. Z SOLIDS
ttttttttttttttttt1ttttttttttttttttttttttttttttttttttttt+t+ttt~+t+ttt*tttttttttttttttttttttttttttttttt~tttttt*tt
1 New F e ~ d 500.00 20.83 96.00
7 Screen O'Size 75.00 8.33 90.00
2 Hew Feed L Screen O'Sife Undiluted 575.00 29.16 95.17
3 Process Water .OO 217.30 .OO
4 Total Sag H i l l Feed 575.00 246.40 70.00
5 Sag H i l l DischarqelScreen Feed 575.00 246.40 70.00
6 Screen U'Size 500.00 238.10 67.74
15 Cyclone U'FIor 1498.00 1070.00 58.33
8 Screen U'Sife ICyclone U'FIor 1997.00 1308.00 60.43
9 Process Water .OO 23.94 .OO
10 B a l l H i l l Feed 1997.00 1332.00 60.00
11 B a l l H i l l Discharge 1997.00 1332.00 60.00
12 Process Water .00 665.80 .OO
13 Cyclone Feed 1997.00 1997.00 50.00
14 Cyclone O'Flor 499.30 927.30 35.00
I6 Rwgher Concentrate 64-29 96.43 40.00
17 Rougher T a i l 435.00 830.90 34.37
19 Rougher Concentrate Diluted 64.29 192.90 25.00
23 Regrind H i l l Discharge 73.53 49.02 60.00
36 Scavenger Concentrate Diluted 9.26 52-46 15.00
20 Regrind Cyclone Feed 147.10 294.30 33.32
21 Regrind Cyclone O'Flor 73,53 245.30 23.06
22 Regrind Cyclone U'Flow 73.53 49.02 60.00
30 2nd Cleaner T a i l 14.49 127.50 10.21
24 Total 1st Cleaner Feed 88.02 372.80 19.10
25 1st Cleaner Concentrate 31.50 94.50 25.00
26 1st Cleaner T a i l 56.52 278.30 16.88
27 Launder Water -00 84.00 .OO
20 2nd Cleaner Feed 31.50 178.50 15.00
29 2nd Cleaner Concentrate 17.01 51.03 25.00
31 Launder Water ,00 45.36 -00
32 Final Concentrate 17.01 96.39 15.00
33 Scavenger Concentrate 9,26 27.77 25.00
34 Scavenger Tail 47.26 250.50 15.87
35 Launder Y a t r ,00 24.69 .OO
37 Final Tails 482.30 1081.00 30.84
18 Launder Water .OO 96.43 .OO
 METALLURGICAL BALANCES

TABLE V
BALANCE RESUETS -

PROBLERI CASE 21 BENEFlClIITIDll CIRCUIT-COPPER ORE (GRIND-FLOTIITION) DATE: 9130105

SOLID COHPOWENT FLOHRRTES CONCElTRRTlOlS

STREM STREIIH DESCRIPTION COPPER MLY COPPER lMLY

LLBEL TIH TIH 2 2
ftttfttfttttttftfft+t#fttttt+tftfttftftfttffftftfff+tftftttt+tttttttttftftftfffffftffffffHIfffffftff+ffftftfffftff
I New Feed 5.00 -25 1.00 -05
7 Screen O'Size .75 -04 1.00 -05
2 N e Feed k Screen O'Size Undiluted 5.75 .29 1.00 .05
3 Proce~sHater -00 .00 .OO -00
4 Total Sag H i l l Feed 5.75 .29 1,OO -05
5 Sap H i l l DischarpelSEreen Feed 5.75 .29 1.00 .05
6 Screen U'Size 5.00 .25 1.00 -05
15 Cyclone U'Flor 15.00 .75 1.00 ,05
0 Screen U'Size k Cyclone U'Flw 20.00 1.00 1.00 .05
9 Process Hater .00 -00 $00 .OO
10 Ball H i l l Feed 20.00 1.00 1,OO .05
11 Ball H i l l Discharge 20.00 1.00 1.00 .05
12 Pracns Hater .00 .OO .OO .OO
13 Cyclone Feed 20.00 1.00 1.00 .05
I4 Cyclone O'Flow 5.00 .25 1,OO -05
16 Rougher Concentrate 4.50 -20 7,OO .31
17 Rougher Tail .50 05 , I1 -01
19 Rougher Concentrate Diluted 4.50 .20 7.00 -31
23 Rrgrind H i l l Discharge 4.07 .27 6,62 .37
36 Scavengtr Conctntrate D i l u t t d .37 .07 4.00 .76
20 Regrind Cyclone Feed 7,74 ,54 6.62 .37
21 Regrind Cyclone O'Flolr 4,87 -27 6.62 .37
22 Regrind Cyclone U'Flon 4.07 .27 6.62 .37
30 2nd Cleaner Tail .47 .04 3.26 29
24 Total 1st Cleaner F t t d 5.34 .31 6-07 -36
25 1st Cleantr Concentrate 4.72 .21 15.00 .67
26 1st Cltantr Tail .62 .I0 1.09 .I0
27 L d e r Hater -00 .OO .OO -00
28 h d Cltaner F t d 4.72 .21 15.00 .67
29 2nd Cleaner Concentrate 4.25 .17 25.00 1.00
31 Launder Yater .OO .00 .OO .00
32 Final Concentrate 4.25 -17 25.00 1.00
33 Scavenger Concrntrate ,37 a 07 4.00 .76
34 Scavenger T a i l .25 03 .52 .06
35 Laundrr Hater -00 .00 -00 -00
37 Final Tails
10 Laundw Yater
,75
.OO
.00
.DO
.I5
.OO .
-02
00
Over-Defined Data Sets

Consider a rougher flotation circuit

a t steady state. From a mass balance,
F = C + T, where F, C and T are mass
flow rates of feed, concentrate and
tailing respectively. If a l l three
flaws are measured in some way, then i n
general F w i l l not equal C+ T. nis
situation arises because of errors in
each measured data point and the prob-
lem is noticed because the data s e t is
over-defined. Only two of the terms are
necessary - the third is calculated
from the other two. It is tenpting t o
drop, say, F and calculate it (e.g.,
= C + T, where means calculated)
A

m v e r , this is arbitrary - why not

.
drop C or T? In a l l fairness, despite
the fact that one of the measured data
p i n t s is redundant for balancing
Furposes, a l l three should be permitted
t o have some influence on the "true"
balance. In fact, data adjustment pro-
cedures "thrive" on r-dancy, and
accuracy w i l l increase as the nlmber of
redundant data points increases.
Program Not Involving Derivatives
To minimize R for a s e t of raw data,
methods which involve neither deriva-
tives nor Lagrange rmltipliers have
been fornulated. Black (1968) enployed
the Hooke-Jeeves direct search routine
t o adjust measured flows of solids and
water in a bank of rougher flotation
cells. The objective function mini-
mized was R with w inversely propor-
tional t o the square of the correspond-
ing i t h data point. A unique feature
was the use of a direct search. Using
different search techniques, Mular
(1976,1979,1983) and m i t e (1977) have
adjusted metallurgical data with suc-
cess. To illustrate camon features
of such methods. consider the sinple
flotation circuit shown in Figure 11.
A bulk concentrate of Cu-Mo is t o be
separated where Mo minerals w i l l float.
Cu minerals constitute a tailing.
Elements t o be assayed in each stream
are a,Mo, Fe and C. Mass flow rates
of each stream, except the tailing, are
t o be measured.
FIGURE 11. Sinple Flotation Circuit
A standard procedure has been de-
vised (Mular, e t . al., t19761) t o ad-
j u s t raw data by means of search
methods. It involves (a) choosing
synbols for a l l flaws and measurements
in the circuit, (b) tabulating measured
data points, (c) writing a l l mass
balance relationships t o be satisfied,
(dl choosing search variables, (el
showing how t o calculate measured data
points from search variables, (f
writing an objective function t o mini-
mize, (g) picking a search method
and (h) writing a canplter program.
Qloose Synbols selected t o
represent mass flows and assays are
shown in Figure 11 and Table VI. Mte
that the tailings flow rate was not
measured.
Tabulate Table VI shows the raw
data a s measured from sanples/sensors
a t suitable locations, the tailing
stream mass flow rate being excluded.
Note that synbols w i t h a bar above them
mean raw data popints (i.e., measured
data p i n t s ) .
 METALLURGICAL BALANCES

TABLE VI
RAW FLUl'ATION CIRCUIT DATA

3 = 30.00WJFH of dry feed

l!7 = 1.12 WJFH of dry Conl
gs = 1.51 WJFH of dry Con2
C3 = 0.79 MTPH of dry Con3
T = - of dry Tail

Balances. Balances that m s t be There are 20 degrees of freedom, so

satisfied a t steady s t a t e involve t o t a l
mass flows and element mass flows as
follows:
Equation (2) above introduces 5 new
there are 20 search variables which may
be chosen arbitrarily. Choose F, CI, C,
, C,. cfi (i = 1 t o 4 and j = 1 t o 3)
and t i = 1 t o 4).
CalculatemEEQmsearchVariables.
Each data point shown i n Table VI rnay
be calculated from some suitable c m
bination of the search variables,
although not a l l w i l l be required in a
particular conbinat ion. Bcpressions
for calculation of data points mst be
written in preparation for the objec-
t i v e function. Letting the synt>ol A

variables; equation (3) involves 4 mean a data point calculated from

equations each with 5 new variables. search variables, then:
Hence there are 25 variables and 5
equations - 20 degrees of freedom.
This means that 20 variables mst be
kncrwn t o determine the balance.

Choose Search Variables. Search

variables are the mininuin nlmber of
variables that are necessary t o A
determine the abwe balances. For C" = CiJ
example there are 5 new variables "(j = 1,2,3 and i = 1,2,3,4)
introduced in equation (2) and one
-
equation. Hence 5 1 = 4 variables
are necessary t o define the balance,
since the 5th can be found from the
other 4.
Note that each "hatted" term w i l l
appear i n the objective function and
 CONCENTRATIONAND DEWATERINC CIRCUITS
that each depends only upon some
conbination of search variables.
Construct Cbiective Function. Equation
(1)may be written as follows for the
adjustment problem being considered:
where the weighting factor, wt for the
i t h data point has been set t o one.
OFten, w i is estimated as the inverse
of the error variance associated with
the i t h data point. For t h i s exanple,
error variances (24 of them, one for
each variable measured) were not
estimated.
In same situations, w ; has been s e t
t o the inverse of the measured data
point squared. In t h i s cbse, the frac-
tional dwiatiom squared are t o be
minimized.
Search A search method
is a ma-tical procedure which finds
that m e conbinatiar of the search
variables which causes R t o be a mini-
mnn. M m the unique set is known, then
a l l data points (hatted terms) calcu-
lated from it would constitute the
adjusted data.
h e way t o find the s e t , would be t o
guess a t their values (20 of them) and
calculate R. Anather guess muld be
nede and R again calculated. If the
prwious R is larger, then the second
gusss is best. Clearly, with 20 search
variables t o the set, it w i l l be many
years before an answer is found1
Direct search methods are the prefer red
route t o find the minimmi R. These
have been reviewed (Kcmlik and m r n e
[I9741 ), and a t least tvo, namly, the
Sirrplex search @War and farsen 119821)
and the m i t e march ( m i t e [I9771)
have been used for data adjustment in
recent years.
The sirrplex direct search begins
with n t l s e t s of n search variables.
The sinplex mves on the R surface by
reflection into an adjacent sinplex and
is forced t o adapt itself t o the local
landscape, elongating dawn inclined
planes, changing direction on encoun-
tering a valley a t an angle, and con-
tracting in the neighborhood of a mini-
m R. 'Ihe search is rapid a t the
s t a r t , but slows considerably in the
vicinity of R.
The m i t e search involves three
routines, namely, a step search,
repetitive quadratic f i t t i n g , and a
search along a vector defined by two
vertices most likely oriented in the
direction of m i n i m R. The step
search and repetitive quadratic f i t t i n g
are patterned after Coggin (Kuester and
Mize 119731) and enployed for each
search variable t o find two vertices,
Vl and V2. Then a vector V is f i t t e d
t o Vl and V2 by:
where V2 is a vector of the current
5 e e t " search variables, and V1 is a
vector of the prwious "best" search
variables. The variable a is treated
l i k e a search variable in the Coggin
routine but is constrained between
limits that make elements of V greater
than or equal t o zero. A new best
vertex, V, Occurs at OI = an;,,
routine has been described in detail
.
The
( m i t e 119771 and Mular, et al.
[I98311 .
For less than about 30 search
variables the sinplex search is not
t b w x n ~ ~ u m i n g .Above 30, the m i t e
search is preferred because it is
faster by a factor of 10. For the
exanple herein, the sirrglex search
routine was selected.
W Proarrrm. The Sinplex
search routine may be programed f ram
the original paper by Nelder and Mead
(19651. Alternatively, most conplting
centers w i l l have the program available
as a general minimization routine. 'Ib
set up the starting sinplex, s t a r t
values for search variables a r e esti-
mated from raw data. Starting s t e p
sizes shwld be selected t o make t h e
sinplex a s "regularn a s possible.
A program was written in BASIC t o
adjust the raw data shown in Table VI.
EQsults fromthe adjustment a r e tab-
ulated in Table VII, where it is a p r -
ent that adjustments tend t o be m i n h l .
'Ihe R value a t the m i n i m was 2.04.
M t e t h a t the largest discrepancy is
with the mass flow r a t e of Con3
(approximately a 30 % difference) . 3. Close each element balance with
Programs Involving Lagrange Ftultipliers
Nielsen and Diaz (1970) described a
method t o adjust data for metallurgical
balances. Equation (1) ffom above was
employed with w; = ;;k / S; (k is a
weighting factor with value of zero or
one and ST is an estimate of the error
variance associated with the i t h data
point). Lagrange multipliers were
introduced to locate the extremes of a
differentiable objective function with
the nlmber of multipliers equal t o the
nunber of constraint equations (element
balances). 'Ihe procedure was adopted
a s follows:
1. Adjust tonnages such t h a t a
mininum adjustrent occurs using
element balances a s constraints.
If one tonnage is grossly i n
error, it may be assigned a zero
weight (k = 0).
2. Close the tonnage balance using
the i n i t i a l l y adjusted tonnages
with the tonnage balance a s the
constraint.
its respective element balance
a s the constraint.
For the f i r s t step, element assays
a r e assumed t o be correct and then
gross tonnages a r e adjusted t o best f i t
element material balances with assays
held constant. 'Ihe objective function
t o minimize is:

TABLE VII
WARISON BETWEEN MEASURED AN) A I U U m QATA

Feed
Con1
Con2
Con3
Tai 1

Feed call Con2 Con3 Tail

Meas. 30.00 1.12 1.51 0.79 -
Adjust. 30.00 1.21 1.83 1.03 25.93
630 CONCENTRATION AND DEWATERING CIRCUITS
where h; is a rmltiplier for the i t h
balance, XjI is the assay of element i
in stream j, S i is the variance as-
ciated with a measured gross tonnage Wi
for the jth stream, Wj is a f i r s t
estimate of gross tonnage for the jth
stream, and rj is f 1 (-1 if the stream
is an o u t p t , +1i f the stream is an
.
inplt) Partial derivatives of 2,
.
.
respect t o hi (i = 1,2,. ,n) and W e ( j
= 1,2,. ,b) are determined and se6 t o
zero. The resulting normal equations
are solved s h l t a n ~ u s l yt o obtain
.
i n i t i a l estimates, W j
In the second step, the tonnage
balance is closed by minimizing:
where ho is a rmltiplier and W j w i l l
be the final adjusted tonnage in the
jth stream.
The third step is analogous t o step
two, except that the objective function
for the i t h element balance is:
where Xji is the measured assay of
element i in stream j, X,; w i l l be the
corresposlding final adjusted value and
$1 is the corresponding error variance.
Xjiis determined for each balance (i =
.
1,2,. ,n) by minimizing the correct 4;
mveday (1971) extended the above
method t o incorporate measured size
analyses along with a m p and mass
flows. In addition, a technique t o
estimate standard errors for f lowrates
was introduced.
Because each measured tonnage and
assay is subject t o error, the element
balances are essentially non-linear
Weigel (1972) ) utilized a technique
such that R could be minimized wing
Lagrange mltipliers. Cross-product
t e r n in material balance equations
which included error terms were
linearized in approximate fashion. An
approximate solution was obtained and
inproved upon in an iterative fashion
t o whatever accuracy was desired. The
program was generalized t o permit
balancing of any circuit.
with 'Ihe lagrange rmltiplier method has
been used t o minimize R in a different
way by Smith and Ichyen (1973). They
eliminated by substitution the hi in
the n o m l equations by solving them
for assay adjustments, O X j i . If an
inihial estimate of an assay is denoted
by X j i then a better estimate w i l l be
Xji = 4+ . q i Yji was tha replaced
by XJiand the Rosenbrock direct search
method was enplayed t o find a s e t of W j
values that minimized 4;. A new s e t of
AXJ\values were then determined and the
procedure repeated t o suitable comer-
gence. A disadvantage is that measured
tonnage values are not permissible data
points.
Hockings and Callen (1977 enployed
the Lagrange method for a general cir-
cuit using an incidence m t r i x nota-
tion, where process units were called
nodes and streams were referred t o as
branches. 'Iheir objective function was
written as:
. where fju are weighting factors, Fij are
+1 or -1 from the incidence matrix, and
the greek syrrbols are the rmltipliers.
The Wj values in the second and fourth
terms of the equation are treated sepa-
rately as a s t a r t (similar t o Nielson
and Diaz a t t h i s point). If any of the
W j are fixed, such as the feed rate, a
subset of those that are independent is
determined. Start values for the sub-
. s e t a r e selected and the dependent WJ
are calculated t o give a conplete t r i a l
set. The t r i a l set is tenporarily
regarded as constant. Next, the equa-
tion is differentiated w i t h respect t o
 :A1BALANCES
each Xj* and each of the nultipliersk,,
Each equation is set equal t o zero.
The s e t of equations are solved s h l -
tanecusly and t h i s results in an ad-
justed s e t of X ~ l u e s . These are now
the best estimates. The independent Wj
then beccane search variables for the
Pawell search routine. Each objective
function evaluation called for by the
search uses estimates of X j u found from
the nonnal equations, until is mini-
mized t o a suitable value. The problem
of missing analyses and size reduction
equipnent was recognized.
The above method, although general-
ized for any circuit, is really similar
t o that praposed by 9nith and Ichiyen,
except that measured mass flows m y be
introduced a s constants and the Fuwell
search replaces the Rosenbrock search.
Haever, i f mass flows are measured
variables (i.e., such as by combined
density/flow meter sensors), the errors
associated with the measurements are
not taken into account.
Since 1978, data adjustment programs
involving Lagrange multipliers have
became extremely general. A user
enters h i s circuit and raw data in
standard format and runs the program.
Because minly analytical solutions are
enployed by the programs, carrplting
time is reduced substantially. Thus
program such as BILMAT and MATBAL
(Laguitton l19851) written for the SPOC
project are accanpanied by colrplete
user-oriented documentation. Statis-
tical routines have been incorporated
to assess raw data reliability.
The authors wish t o thank the management
of Fluor Engineers for permission t o use
certain m t e r i a l Aich was excerpted
from the FrS(MET User's Q,I& (Fluor
Engineers [I98311.
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 CONCENTRATIONAND DEWATERING CIRCUITS

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