V5.1 Full Manual Feb 2003 English

steady state
mineral
processing
simulator
Version 5.1
November 2001
Revised February 2003
Isles Road
Indooroopilly Qld
AUSTRALIA 4068
Telephone 07 3365 5842
Facsimile 07 3365 5900
Email JKTech@jktech.com.au
Internet www.jktech.com.au
JKSimMet is a powerful tool for analysis and simulation of
mineral processing plant data. As the program developers do
not control data collection, analysis or interpretation, it is the
sole responsibility of the JKSimMet user to verify that input
data are accurate, and that both process unit operation conditions
and stream outputs are reasonable.
In no event will JKTech Pty Ltd be liable for direct, indirect,

special, incidental or consequential damages arising out of the
use or inability to use the software or documentation.
Note: The detailed descriptions of the mathematical models in
this manual are provided for the information of the software
licensees. These models are not public domain and they may
not be used in other software without written permission from or
a licensing agreement with JKTech Pty Ltd.
Copyright © 1987 - 2003 JKTech Pty Ltd

All rights reserved.
Both the software and documentation of JKSimMet are
copyright.
JKTech Pty Ltd

Isles Road
Indooroopilly
Queensland
Australia 4068
Telephone - (07) 3365 5842 International: +61 7 365 5842

Fax - (07) 3365 5900 International: +61 7 365 5900
Email - jktech@jktech.com.au
JKSimMet Internet URL- www.jksimmet.com
JKTech Internet URL - www.jktech.com.au
Preface Contents
CONTENTS
Page No
ACKNOWLEDGMENTS iv
ABOUT THIS MANUAL vi
1. OVERVIEW
1.1 About JKSimMet 1-2
1.2 Equipment Requirements 1-4
1.3 Cautionary Tales 1-5
1.4 Program Structure 1-6
1.5 JKSimMet Support 1-7
2. INSTALLING JKSimMet
2.1 Contents of the Package 2-2
2.2 Computer Hardware/Software 2-3
2.3 JKSimMet V5 Installation 2-4
2.4 Compatability Between V4 and V5 2-5
2.5 What Is New in Version 5.0 2-6
2.6 What Is New in Version 5.1 2-8
3. LEARNING JKSimMet
3.1 How JKSimMet Works 3-2
3.2 The Mouse 3-6
3.3 The JKSimMet Display 3-7
3.4 JKSimMet Startup 3-8
3.5 Working with an Existing Project 3-9
3.5.1 Selection of a Flowsheet 3-10
3.5.2 Simulation 3-11
3.5.3 Displaying the Simulation Results 3-16
3.5.4 Printing the Simulation Results 3-20
3.5.5 Summarising the Results - Overview 3-22
3.5.6 Summarising the Results - Report 3-23
3.5.7 Exporting Data from JKSimMet 3-25
3.58 Finishing a JKSimMet Session 3.25
3.6 Making Changes to an Existing Flowsheet 3-27
3.6.1 Selecting the Flowsheet to Use 3-27
3.6.2 Altering Operating Conditions 3-29
3.6.3 Saving the Session 3-33
3.6.4 Graphing Your Results 3-35
3.7 Creating a New Project 3-38
3.7.1 Starting a New Project 3-38
3.7.2 Define Flowsheet Name 3-40
3.7.3 Drawing a New Flowsheet 3-41
3.7.4 Create Connecting Streams 3-44
3.7.5 Adding a Circuit Feed Stream 3-47
Version 5.1 February 2003 Contents Page i

Contents Preface
3.7.6 Adding Water to the Circuit 3-47
3.7.7 Adding Information Blocks and Labels
to the Flowsheet 3-50
3.7.8 Entering Data 3-54
3.7.9 Define Data for Rod Mill 3-55
3.7.10 Examining Data 3-57
3.7.11 Rod Mill Circuit Exercises 3-58
3.8 Learning Simulation 3-60
3.9 Learning Graphing 3-63
3.9.1 Drawing a Graph 3-65
3.9.2 Defining the Graph Format 3-65
3.9.3 Definition of the Data to be Graphed 3-67
3.9.4 Easy Manipulation of the
Graphing Features 3-70
3.9.5 Saving the Session 3-71
3.9.6 Graphing Limitations 3-72
3.9.7 Graphing Related Problems 3-72
3.10 Learning Overview 3-73
3.11 Learning to use Report 3-78
3.12 Summary 3-84
4 USING JKSimMet
4.1 JKSimMet Description 4-2
4.1.1 JKSimMet Simulation Technique 4-3
4.1.2 JKSimMet Capabilities 4-3
4.1.3 JKSimMet Constraints 4-4
4.1.4 JKSimMet Expandability 4-5
4.2 Definition of Terms used in JKSimMet 4-6
4.3 The JKSimMet Cursor 4-7
4.4 The JKSimMet Menus and Toolbars 4-8
4.4.1 The Main JKSimMet Menu 4-9
4.4.2 The Functions Toolbar 4-9
4.4.3 The JKSimMet Tools Toolbar 4-11
4.5 JKSimMet Windows 4-12
4.5.1 The Session Window 4-12
4.5.2 The Project View Window 4-14
4.5.3 Equipment Data Windows 4-15
4.5.4 Port Data Windows 4-16
4.6 Building and Manipulating a Flowsheet 4-17
4.6.1 Loading a Project 4-17
4.6.2 Defining the Project Name 4-18
4.6.3 Defining the Flowsheet Name 4-19
4.6.4 Building the Flowsheet–Equipment Units 4-20
4.6.5 Building the Flowsheet–Connecting Ports 4-23
4.6.6 Flowsheet Related Problems 4-25
4.7 Editing the Flowsheet Data 4-26
4.7.1 The Equipment Data Window 4-26
4.7.2 Editing the Equipment Data 4-29
4.7.3 The Port Data Window 4-32
Page ii Contents Version 5.1 February 2003

Preface Contents
4.7.4 Editing the Port Data 4-34
4.7.5 The Feed Data Window 4-40
4.7.6 Editing the Feeder Data 4-41
4.7.7 The Water Feeder Data Window 4-41
4.7.8 Editing the Water Feeder Data 4-43
4.8 Annotating the Flowsheet 4-46
4.8.1 Adding Port Information Blocks 4-47
4.8.2 Adding Equipment Information Blocks 4-51
4.8.3 Adding Labels to the Flowsheet 4-53
4.9 User-Configured Graphing – The Graph Definition
Window 4-55
4.9.1 Define the Graph Format 4-55
4.9.2 Defining Data for Graphing 4-57
4.9.3 Viewing the Graph 4-62
4.10 Using Quick Graph 4-63
4.10.1 Opening the Quick Graph Window 4-63
4.10.2 The Quick Graph Toolbar 4-64
4.10.3 Features of Quick Graph 4-65
4.11 Using Overview 4-66
4.11.1 The Overview Window 4-66
4.11.2 Configuring an Overview Table 4-67
4.11.3 Recovery Mode 4-70
4.12 Printing in JKSimMet 4-72
4.13 Using Report 4-75
5 MODEL FITTING
5.1 Introduction to Model Fitting 5-2
5.2 Data Collection 5-3
5.3 Background 5-7
5.4 How the Model Fitting Program Works 5-8
5.5 A Simple Example 5-10
5.6 Learning Fitting 5-13
5.6.1 Preparation for Model Fitting 5-13
5.6.2 Start Model Fitting 5-14
5.6.3 Selecting Data 5-15
5.6.4 Setting up the Parameters 5-19
5.6.5 Master/Slave Fitting 5-21
5.6.6 Fit the Model Parameters 5-22
5.7 Checking the Fit 5-24
5.8 Presentation of Model Fitting Results 5-25
5.9 Problems Related to Model Fitting
and Possible Solutions 5-27
5.10 References 5-30
6 MASS BALANCING
6.1 Introduction to Mass Balancing 6-2
6.2 Data Collection 6-3
6.3 Background 6-4
6.4 How the Mass Balancing Program Works 6-7
6.5 A Simple Example 6-9
Version 5.1 February 2003 Contents Page iii

Contents Preface
6.6 Learning Mass Balancing 6-14
6.6.1 Preparation for Mass Balancing 6-14
6.6.2 Model Types for Mass Balancing 6-15
6.6.3 Selecting Data 6-15
6.6.4 Component 6-17
6.6.5 Water 6-20
6.6.6 Solution Controls 6-21
6.6.7 Carrying out the Mass Balance 6-22
6.7 Checking the Balance 6-24
6.8 Presentation of Mass Balancing Results 6-26
6.8.1 Overview 6-26
6.8.2 Printing the Mass Balance Results 6-28
6.8.3 Plotting Graphs 6-29
6.9 Problems Related to Mass Balancing and Possible
Solutions 6-32
6.9.1 The Middlings Problem 6-33
6.9.2 The Infinite Division Problem 6-34
6.10 Metallurgical Accounting 6-35
6.11 References 6-36
APPENDICES
A1 Introduction A-2
A2 Hydrocyclone (Model 200, 201) A-7
A3 Single Deck Screen (Model 230) A-21
A4 Efficiency Curve Models (210, 610, 211, 611, 203)
(General Classifier Models) A-31
A5 Efficiency Curve Variable d50c (Model 251) A-37
A6 Crusher (Model 400) A-41
A7 Rod Mill (Model 410) A-59
A8 Perfect Mixing Ball Mill (Model 420) A-69
A9 Autogenous Mill Model (Model 430)
and Semi –Autogenous Mill Model (Model 431) A-81
A10 Size Converter Model (Model 490) A-101
A11 Variable Rates SAG Model (Model 435) A-103
A12 High Pressure Grinding Rolls (Model 402) A-123
A13 Simple Degradation (Model 480) A-141
A14 Splitters (Models 810, 811, 812, 870) A-145
B ERROR MESSAGES
C JK BREAKAGE TESTING
All Trade Marks acknowledged
Page iv Contents Version 5.1 February 2003

Preface Acknowledgements
ACKNOWLEDGEMENTS
More than twenty-five years of development has gone into the
simulation models used in JKSimMet. This represents a huge
contribution by the students and staff of the Julius Kruttschnitt
Mineral Research Centre (JKMRC). There is not sufficient space
available to acknowledge all the contributors separately, and only a
few outstanding contributions are mentioned.
The founding Director of the JKMRC, Professor Alban Lynch, and
his co-worker, Dr T C Rao, developed the first practical models of
grinding and classification, and successfully applied them at Mount
Isa Mines. Professor Lynch and his successors Dr Don McKee and
Dr Tim Napier-Munn have presided over subsequent
developments.
Dr Bill Whiten is responsible for the generalized model structure,
many of the models, and the general purpose data-fitting routines.
The simulator structure has gone through several software
generations and hardware implementations. The original engine
was programmed by Dr Alex Kavetsky, who has also contributed a
great number of the models. The major contributors to the DOS
simulator are principally Mr David Wiseman, and also Dr Fred
Hess and Dr Thomas Kleine.
The original documentation was developed by the Centre for
Information Technology Research at the University of Queensland.
The testing and debugging of JKSimMet has mostly been done by
JKTech, headed by Dr Rob Morrison and assisted by Mr Chris
Bailey, Mr Dennis Noreen and Mr Philip Baguley.
Major thanks are due to the many sponsors who have contributed to
the AMIRA projects which have resulted in the development of
JKSimMet.
Special thanks are also due to the organizations listed below which
purchased pre-release copies and have helped by testing the
software in an industrial environment:
• ZC Mines Limited • Renison Limited
• Bougainville Copper Limited • Billiton Research B.V.
• Western Australian School of Mines (Kalgoorlie)
Version 4
Six years of JKSimMet marketing have lead to the licensing of more
than 150 sites world wide. Meanwhile, application and model
development continue at the JKMRC. The development of
Version 4 and revision of the manual has been the result of
contributions from the all the JKTech team, in particular Michal
Andrusiewicz and Phil Baguley.
Version 5.1 November 2001 Acknowledgements Page v

Acknowledgements Preface
Version 5.0
Version 5 is a complete rebuilding “from the ground up” of the
JKSimMet interface to bring it into Windows 95/98.
The major conceptual changes to the interface are due to Stephen
Treloar-Bradford. Detailed implementation has been by Phillip
Baguley and Phil Beak. The DLL engines were programmed by
Phillip Baguley and Michal Andrusiewicz.
The Help files were developed by Andrew Schroder.
Cathy Evans has developed the V5 documentation.
Ricardo Pascual developed the V4 to V5 conversion program.
Rob Morrison provided overall project leadership.
Version 5 provides a platform for future mineral process modelling
at the JKMRC.
Overall, the development of JKSimMet V5 represents a major
achievement for the development team and a major investment in
the future for JKTech
Special thanks are also due to the V5 beta testers in industry.
Version 5.1
Version 5.1 is an upgrade of Version 5.0 which operates in the
Windows 2000 environment.
Several extra models have been added to the extensive model library
and many operability improvements have been made. A series of
bug fixes is also included.
The evolution of V5.1 has been accomplished as a joint project
between the JKTech software group and the JKTech consulting
group.
Most of the changes have come from suggestions by many of the
current users, assembled and tested by the JKTech consultants and
coded by the JKTech software group.
Page vi Acknowledgements Version 5.1 November 2001

Preface About this Manual
ABOUT THIS MANUAL

This manual is intended for users at all levels of experience with the
system. It has been designed for novice users at both computing and
the use of mineral processing plant simulation. It provides a
reference section for more experienced users, and it offers advanced
information for those users who wish to fine tune their simulations
in order to maximize the benefit of their tests.
Depending on your experience you will wish to refer to different
sections of the manual.
If you have just bought the package and it is not yet installed on
your system:
• read Chapter 2 first, and then install JKSimMet on your
computer.
If you are new to computing or JKSimMet:

• work through the tutorial section in Chapter 3.
If you are familiar with JKSimMet simulation techniques:

• read Chapters 4, 5 and 6.
If you wish to fine tune JKSimMet to your own requirements:

• read Chapter 5.
Version 5.0 December 1999 About this Manual Page vii

About this Manual Preface
(Blank Page)
Page viii Version 5.0 December 1999

Overview Overview
CHAPTER 1
OVERVIEW
Version 5.1 November 2001 Chapter 1 Page 1-1

About JKSimMet Overview
1. OVERVIEW
1.1 About JKSimMet

JKSimMet is a mineral processing plant simulator which runs on
the Intel Pentium family of computers under Windows 95, 98, ME,
NT4 or 2000. It gives engineers the ability to design and optimize
any crushing or grinding circuit including stages of classification.
It allows engineers to:
• design a circuit on the graphics monitor
• enter model and plant data
• simulate the circuit
• graph and print the results.
JKSimMet performs steady state simulation of a range of

comminution and classification operations. Process models of the
following units are available:
• secondary and tertiary cone crushers
• jaw crushers
• gyratory crushers
• rolls crushers
• autogenous and semi-autogenous mills
• rod mill, ball mill
• HPGR crusher
• simple degradation
• vibrating screen
• DSM screen
• hydrocyclone classifier
• several general classifier efficiency curves
• several splitters.
New process models can readily be incorporated into JKSimMet by

JKTech. This is done by defining their characteristics as
steady-state models and creating an icon for each to represent them
on the screen.
JKSimMet is intended for use by plant engineers not necessarily
skilled in either modelling or computing. For that reason, it has
been written to operate in a user-friendly manner. Users select
options from menus or lists and build flowsheets on the screen.
This removes the need for specialized computer skills while
maintaining flexibility.
Page 1-2 Section 1.1 Version 5. 1 November 2001

Overview About JKSimMet
The main features of JKSimMet are:

• graphical user interface
• flowsheet specified interactively on the graphics screen
• models selected from a built-in library
• model parameters specified by the user
• range of data output displays and printed reports
• simple data transfer.
JKSimMet has been designed primarily as a powerful aid to an

engineer. The principal application of JKSimMet for many users
will be to carry out process analysis and optimisation of existing
circuits.
JKSimMet is also extremely useful for conducting conceptual
design studies, where the purpose is to assess the suitability of
different flowsheets to achieve a desired performance objective.
Limitations Provided that the data used in the process models are relevant to
the ore being studied, JKSimMet can be used to generate detailed
design information. Until experience is gained in detailed design
studies using JKSimMet, it is recommended that design tasks be
carried out in consultation with JKTech.
It is important at the outset to understand what JKSimMet will and

will not do. JKSimMet will predict the performance of a circuit
within the limitations of the data and the models selected.
JKSimMet will not determine of its own accord the best circuit, the
best operating conditions or the changes that are required to ensure
that a circuit operates efficiently. JKSimMet does not allow
process constraints to be specified.
Constraints The operator has an essential role in deciding the conditions to be
simulated and in critically assessing the simulation predictions.
This is a deliberate result of the design philosophy of JKSimMet,
which places considerable emphasis on the process experience and
knowledge of the operator.
This point is amplified at the beginning of Chapter 4, and the

reader is strongly advised to keep these points in mind when using
the system for simulation analysis.
Version 5. 1 November 2001 Section 1.1 Page 1-3

Equipment Requirements Overview
1.2 Equipment Requirements

For successful operation of JKSimMet you must have:
Computer Intel Pentium PC (or other fully compatible computer) with all of
System the following:
• Processor speed 400MHz minimum

• 128Mb memory minimum – 256Mb recommended
• CD-ROM Drive
• 1.4 Mbyte (3.5 inch) diskette drive
• 2 Gbyte or larger fixed disk drive (with 100Mbytes free space)
• A SVGA or fully compatible equivalent graphics controller
(minimum) – Recommended an XGA graphics controllerr
• a suitable monitor – 15 inch minimum
17 inch recommended.
Printer An MS Windows 95,98, ME, NT or 2000 compatible printer:
Operating MS Windows 95,98, ME, NT(4 sp5 or later) or 2000

System
Pointing Device Microsoft Mouse or functional equivalent.
Equipment A wide range of equipment combinations has been successfully

Tested tested but if you are in doubt JKTech will be pleased to comment
on a particular combination.

Overview Cautionary Tales
1.3 Cautionary Tales

Backup JKSimMet V5 is supplied on CD-ROM with an additional
JKSimMet installation program on a 3.5 floppy disk.
Diskette
A hardware key (Hard Lock) is required for operation.
It is recommended that you make a backup copy of the files on the

Diskette. If you do damage your one and only copy of a JKSimMet
diskette, you can acquire a new diskette from JKTech by notifying
them and quoting the version number of your copy of JKSimMet.
Read.Me Any modifications to procedures since the production of this

Print.Me manual are in a file called READ.ME. Print this file and read it
before going further.
Learn by JKSimMet is a program which is rich in capabilities and easy to

Example operate. The simplest way to become familiar with the techniques
of using JKSimMet and the capabilities it has to offer, is to follow
through a structured example. Such an example is provided with
the package. This example assumes no experience with JKSimMet
and leads you through a session exploring the use of the various
modelling and simulation features of the program. We recommend
that you spend some time working through the example in
Chapter 3 until you are confident that you can apply JKSimMet to
your own problems. The data analysis capabilities of JKSimMet
are supported by examples in Chapters 5 and 6.
Backup Work As you input each section of data (say a flowsheet or a data set) you
should save your work to the hard disk. Usually you will want to
overwrite your earlier version. If you do this regularly, then when,
not if, there is a power failure or other mishap, your work up to the
last save will be waiting for you on the hard disk; it will not have
been lost forever.
Once you are a proficient user of JKSimMet, you will be creating

and using mathematical models of your plant. These models are
stored on your fixed disk between sessions. It is possible, usually
through carelessness but occasionally through computer
malfunction, to lose information from the fixed disk. Therefore,
we recommend that you make a backup copy of the information
stored on your fixed disk frequently.
Backup Work You should use the backup facilities within JKSimMet to backup
Files simulator work sessions to a server or other archival storage such
as a Zip Disk.
Windows Backup Alternatively, Project Data Files(*.JKSM5) only need be backed

up.

Program Structure Overview
1.4 Program Structure

Program JKSimMet consists of the following software modules:
Structure
• Main Program
• Supporting DLL’s
• Program Database
• Project Databases
Process Models of the following units are supplied:

Models
• rod mill
• ball mill
• autogenous mill
• semi-autogenous mill
• cone crusher
• HPGR crusher
• two rolls crusher
• jaw crusher
• single deck screen
• DSM screen
• hydrocyclone
• rake classifier
• spiral classifier
• splitter
• combiner (sump, stockpile, bin)
• size converter
• degradation model
Custom Contact JKTech if you are interested in adding other models to

Models those listed above.
A developer’s kit is also available for model development.

Overview JKSimMet Support
1.5 JKSimMet Support
Documentation Three levels of documentation are supplied:
• user manual
• model documentation
• context sensitive Help files.
Installation and JKTech can provide assistance to install the system and can also
Training provide on-site training to match particular user needs.
Courses JKTech offers regular courses in simulation technology at various

locations around the world and on-line.
Extended Continuing backup support is provided by JKTech either through a

Backup Maintenance Agreement, telephone or facsimile contact, or through
visits by JKTech to site.
Email Help JKSimMet project files can be sent electronically to JKTech via the
Internet for assistance. Send files to jktech@jktech.com.au
Updates Updates and bug fixes will be supplied for one year from date of
installation/supply and are available under a maintenance contract
thereafter.
Restrictions A standard licence for the use of JKSimMet permits operation of

the software on a single workstation only. Extension of the licence
for additional workstations at a single site is available for a small
fee.
Distribution of copies of JKSimMet to other company sites is not

permitted. Additional copies for other sites are available at reduced
cost.
Hardware Key JKSimMet will not operate without a hardware key. The standard
key is suitable for a parallel port. Keys are also available to suit
PCMCIA or USB ports.

JKSimMet Support Overview
(Blank Page)

Installing JKSimMet Installing JKSimMet
CHAPTER 2
INSTALLING JKSimMet

Contents of the Package Installing JKSimMet
2. INSTALLING JKSimMet
2.1 Contents of the Package

Package The JKSimMet system comes as a package containing this manual,
Contents a CD, a floppy disk and two “Hardlock” keys
The manual contains information on the installation and

maintenance of the JKSimMet software, a tutorial guide for first-
time users and a comprehensive reference chapter.
Page 2-2 Section 2.1 Version 5.1 November 2001

Installing JKSimMet Computer Hardware/Software
2.2 Computer Hardware/Software

For successful operation of JKSimMet you must have:
Computer Intel Pentium PC or other fully compatible computer with all of the
System following:
• Processor speed 400MHz minimum

• 128Mb memory minimum (256Mb recommended)
• CD-ROM Drive
• 1.4 Mbyte (3.5 inch) diskette drive
• 2 Gbyte or larger fixed disk drive (with 100 Mbytes free space)
• A SVGA or fully compatible equivalent graphics controller
(minimum) – Recommended XGA
• a suitable monitor – 15 inch minimum
17 inch recommended.
Printer Any MS Windows 95, 98, ME, NT or 2000 compatible printer.
Operating MS Windows 95, 98, ME, NT(V4 sp5 or later) or 2000

System
Pointing Device Microsoft Mouse or functional equivalent.
Equipment A wide range of equipment combinations has been successfully

Tested tested but if you are in doubt JKTech will be pleased to comment
on a particular combination.
Version 5.1 November 2001 Section 2.4 Page 2-3

JKSimMet V5 Installation Installing JKSimMet
2.3 JKSimMet V5 Installation

JKSimMet V5 JKSimMet V5 is a standard Windows Program.
Installation
Step 1 Make a backup copy of any existing projects
Step 2 If you have JKSimMet V5 installed already on your
computer, go to:
Control Panel
Select Add/Remove, and
Select JKSimMet V5
Uninstall
Step 3 Insert CD-ROM in drive
Step 4 From the Windows Start Menu, select RUN and then
Browse to find Setup.exe on your CD Drive
Eg. D:\Setup.exe
Step 5 Press OK and follow the instructions on screen
Step 6 The installation procedure will prompt you for the
supplied floppy diskette and will copy your company
specific copy of JKSimMet to enable the software.
If you do not have an A: drive floppy disk, you can double click on
the self exploding zip file to install JKSimMet.exe in your
JKSimMet V5.1 directory.
If an update is provided by email, you can copy it to a floppy disk
or unzip as in the previous paragraph
Note: The install program will also ask to update your HTML help
file viewer. This will allow full use of JKSimMet V5 help.
Notes for Note 1: Your computer must be using NT4 with service pack 5 or
Windows NT or later or 2000.
2000 installation Note 2: As JKSimMet V5 requires several device drivers, you must
have full administrator privileges to install or uninstall JKSimMet.

Installing JKSimMet Making a Backup Copy
If you choose not If you choose not to use the default path (/Program Files/JKSimMet
to use the default V5.1) for installation, you will need to modify the UnZip path for
path for the JKSimMet V5.1.exe file.
installation
Modify this
line to your
install path
Non-English If you are installing in a non-English version of windows, the

versions of spelling of the install path may be different. If this is the case you
Windows must modify the UnZip path to the correct spelling as discussed
above.
2.4 Compatibility and Conversion Between

V4 and V5
A conversion utility is included to transfer User directories from
Version 4 into a series of flowsheets within one or more projects as
specified by the user.
These projects are then accessible to Version 5.
Note that Versions 2 to 4 used Ryan McFarland (IBM) ProFort
which is a 16-bit FORTRAN compiler.
Version 5 uses MS Power Station FORTRAN which is a 32-bit
compiler. (Now supported by COMPAQ/DEC).
There may be minor differences in calculated parameters as a result
of this change.
The converted project will also be slightly ambiguous regarding
data type in some cases because V2 to V4 used calculated data to
store the results of simulation, mass balancing or model fitting.
Version 5 has sufficient space to store several data types. Hence, it
would be prudent to re-run a simulation, balance or fit to guarantee
the integrity of the calculated data.

What Is New in Version 5 Installing JKSimMet
2.5 What Is New in Version 5.0

The short answer is just about everything.
The interface has been redesigned to take advantage of the features
of MS Windows 95.
Interaction within each of the modules (i.e. simulation, fit and
balance) has been standardised and has access to all of the data
presentation and transfer tools.
• Flowsheets now provide for automatic drawing of equipment
connections.
• Flowsheets are expandable to 4 “pages”
• Many flowsheets are accessible within a project
• A generalised Select function is provided to allow sub-
sections of any flow sheets to be simulated, fitted or
balanced. This supersedes the multi-circuit feature of V4.
• Data and flowsheets from other projects may be copied into
the current project
• Use of the Windows 95 operating system and a FORTRAN
90 compiler potentially removes the V4 limits on numbers of
models etc.
• The flowsheet can be annotated with Data Information blocks
which provide stream information as well as access to
equipment data. The previous annotation capability has been
replaced by labels.
• Project and flowsheet notes may be included as properties.
• A Quick Graph Facility is now available for each piece of
process equipment
• The Overview Tool has been generalised to present many
kinds of data
• A configurable Report tool allows a selection of data to be
printed, copied to clipboard and to a range of file types.
• Comprehensive copy and paste capabilities are provided to
assist transfer of data and results to other Windows
applications.
• Program configuration has been completely implemented
within a relational database.
• This will allow other JKSim** simulators to be incorporated
as JKSimMet modules.

Installing JKSimMet What Is New in Version 5
• There is also scope to include a series of “supplementary”

examples within the defined model types. However, caveats
about inappropriate use are still applicable.
• The database structure and DLL engines will allow for
seamless integration of models developed by others via a
developers kit and a compatible compiler.
• A number of Version 5 objects are also designed to be shared
with new JKTech products such as JKMetAccount and the
MLA Data Presentation program
• Last and by no means least, the V5 structure provides for
eventual expansion to a fully integrated dynamic simulator, at
some time in the future.

What Is New in Version 5 Installing JKSimMet
2.6 What Is New in Version 5.1
The major change in V5.1 is compatibility with Windows 2000.
Several new models including the HPGR, simple degradation and

an improved range of splitters have been added and several more
classifier icons included.
In addition, the file structure has changed so that .JKSM5 files are
considerably smaller and no longer grow with use. Compaction is
no longer required. This change in file structure has resulted in
much faster loading and saving.
Many of the user settings which were “forgotten” on file save and
load are now “remembered”. For example, the graph colours, the
lock status and % passing size are now stored with the file, as are
the default settings for data and error displays in port windows.
Almost all of the reported bugs have been fixed and as many as
possible of the feature improvements requested by users have been
implemented.

Learning JKSimMet Learning JKSimMet
CHAPTER 3
LEARNING JKSimMet

How JKSimMet Works Learning JKSimMet
3. LEARNING JKSimMet
Learning Learning JKSimMet is designed primarily as a tutorial exercise. It
JKSimMet is anticipated that the first time user of JKSimMet might spend two
to three hours working through this chapter step by step. In this
way the user will gain sufficient confidence and knowledge to
begin using the system in earnest.
Given the nature and design of JKSimMet, the user will very
quickly be able to learn the basic operating techniques. It is
assumed that the user already understands the techniques of mineral
processing simulation and also has some appreciation of the
standard features of the MS Windows 95/98/ME/NT/2000
interface.
3.1 How JKSimMet Works

About JKSimMet is a general-purpose computer software package for the
JKSimMet analysis and simulation of mineral processing operations. The
package is designed to service the diverse needs of plant and
development metallurgists, who need to apply modern process
analysis techniques to characterise plant behaviour and design
engineers, who require accurate process simulation models to
facilitate the evaluation of various plant designs.
JKSimMet integrates all tasks associated with optimisation, design

and simulation, including the storage and manipulation of models,
data and results, within one package. It is fully interactive and
operates with high-resolution colour graphics capabilities. These
graphics facilitate the display of detailed plant flowsheets and
accompanying information.
The engineer using JKSimMet proceeds through a series of tasks:
• building a flowsheet diagram of the processing plant on the
computer screen
• assigning characteristics to the various process units and
material flows of the simulation model
• simulating the flow of materials through the simulated plant
( Or a subsection of the plant).
• reviewing and presenting the results.
Once a model has been built the engineer can alter the design and
change the parameters as he sees fit until he arrives at a satisfactory
design or an optimum operating condition for an existing plant.

Learning JKSimMet How JKSimMet Works
The results may be graphed, printed in summary form and stored on

hard disk or archived to diskette. The results can also be
transferred to other suitable programs via the clipboard.
Building a Simulation is based on the ability to build a model that is
Simulation representative of a real system. The behaviour or characteristics of
Model the model must be similar to the characteristics of the real system.
In order to build the model the engineer must analyse the overall
plant and break it down into a number of sections (circuits), in such
a way that the circuits are easily understandable and identifiable.
The circuits are interconnected to form the total system.
The data structure within JKSimMet V5 consists of the following:

Project A project is the container in which the user
stores all of the data related to a particular
body of work. The project contains one or
more flowsheets and the associated equipment
unit and stream data.
Flowsheet A flowsheet is a graphical representation of a

complete processing plant or a component
section of that plant. The flowsheet can have
internal recirculating streams.
A flowsheet may be increased in size to
represent a large, complex circuit. Either the
complete flowsheet or selected sections of it
may be simulated, mass balanced or model
fitted.
Note that this capability to select items for
inclusion in simulation, modelling or mass-
balancing replaces the circuit-oriented
flowsheets required by the DOS versions of
JKSimMet.
Equipment Version 5 introduces a new concept. Each

and Ports flowsheet item is now a piece of equipment
which can have any number of ports. These
ports represent the connections to each piece
of equipment. The reason for this change is to
allow for future development of a dynamic
simulator. This approach also will allow for
pipes and conveyors to be modelled as pieces
of equipment.
Units and Streams still provide a convenient
way of thinking about flowsheets and for
practical purposes, the terms equipment and
ports mean the same things as units and
streams.

How JKSimMet Works Learning JKSimMet
Units A unit is any type of unit process such as a ball

mill or a hydrocyclone classifier. JKSimMet
allows you to select the appropriate unit from
an exhaustive list of processing unit types and
to display their pictorial representations
(icons) on the screen. These units are
identified within the system by a name which
the user specifies. You can specify the
orientation of the units (direction of flow
through the unit left to right or vice-versa) and
also the position of units on the flowsheet
diagram.
Streams A stream is a description of any flow of

material. The description is usually in terms
of solids flowrate, water flowrate and particle
size distributions (plus assays for mass
balancing if required). The stream connections
between units are made by drawing lines
connecting the appropriate feed and product
ports on the units. JKSimMet automatically
checks to ensure that the stream connections
are valid. Each stream or port is named by
JKSimMet as a combination of its equipment
name and port name. The user can edit the
equipment names as required but the port
names for each piece of equipment are fixed.
The unit models currently available for simulation include:

• Feeder • Autogenous mill
• Stockpile • Semi-autogenous mill
• Bin • Rod mill
• Pump sump • Ball mill
• Sump • Single deck screen
• Splitter • DSM Screen
• Gyratory crusher • Hydrocyclone
• Two rolls crusher • Spiral classifier
• Jaw crusher • Rake classifier
• HPGR crusher • Degradation model

Learning JKSimMet How JKSimMet Works
Specifying Once the flowsheet has been drawn the engineer must provide data
Flowsheet Data for each process unit and also provide raw data in the form of flows
and size distributions for the streams in the circuit. This is done by
stepping through the process units and the streams one-by-one,
adding circuit data and building up an annotated description of the
modelled processing circuit on the screen. The unit data for the
process equipment may come from previous experience, from a
design database or they may be derived from plant data. The
stream data can be entered in one of three size distribution formats,
depending on the preferences of the user. The engineer can review
or correct the data at any time after entering the data.
Flowsheet Once the flowsheet has been specified and the required unit and
Simulation stream data have been entered, the simulation can be run. The
results of the simulation are stored and can be displayed on the
screen or printed as required. The following options are available
for examining the results:
• view the detailed data in the equipment and port data

windows,
• view summary data for equipment and ports via data
information blocks,
• view summary data in overview tables,
• view the size distribution data plotted as graphs on the
screen or in printed form,
• generate configurable reports at summary or detailed level,
• copy-and-paste the data into other programs (eg.
MS Excel) via the clipboard
• print the results to a Windows compatible printer or to a
file.
Recorded data include:

• flowrates of solids and water
• percentage solids
• pulp densities
• full particle size distributions.
After analysis of the results, you can alter the flowsheet, adjust the
equipment parameters or port data and repeat the simulation
process until you obtain a satisfactory result.
Flowsheet A new capability in V5 is that a subset of the flowsheet may be
Selection selected for simulation, mass balancing or model fitting.

The Mouse Learning JKSimMet
3.2 The Mouse
The Mouse The standard two-button mouse is used as the pointing device in
JKSimMet. In this manual we refer to "left-click" and "right-click"
which simply means to press the left- or right-hand button on the
mouse.
The manual assumes that you are familiar with common mouse
techniques such as double-clicking and click-and-drag.
The Cursor In JKSimMet V5 the cursor (your position on the screen) is

indicated by an arrowhead. When the cursor is over an equipment
unit in the flowsheet window the cursor will change to indicate that
the drop-down menu can be accessed by right-clicking on this zone.
In data windows, the position of the active data cell (i.e. the cell
where anything that you type will appear) is indicated by a thick
grey border
Cursor The mouse can be used to move the cursor when working with
Movement JKSimMet. In the equipment and stream data windows the cursor
control keys (also known as the arrow keys) may also be used to
move the cursor from one data cell to the next.
Appearance As with all MS Windows programs, the preferences which the user
sets for the Windows desktop will provide colours and fonts for
many of the tools and menus within JKSimMet.
Keyboard Access Most of the functionality of JKSimMet can also be accessed from
the keyboard using standard MS Windows conventions.

Learning JKSimMet The JKSimMet Display
3.3 The JKSimMet Display
The JKSimMet V5 display uses windows to present the various

types of data on the JKSimMet desktop. These windows include
the following:
• flowsheet window,
• equipment and port data windows
• graph windows
• data overview window.
• the report window
Users may have as many windows open on the screen as they wish
at any one time. An XGA video card and a large monitor are
recommended for this strategy.
Many of the windows are divided into several distinct areas which
are accessed by selectable tabs. Each area is used to convey
specific types of information.
Note that most windows may be minimised for convenience.
However, some non-critical changes (eg. an equipment name
change) may require that a window be closed before other windows
are updated.

JKSimMet Startup Learning JKSimMet
3.4 JKSimMet Startup
JKSimMet The instructions for starting JKSimMet V5 are as follows:

Startup
Step 1 Right-click on the Windows Start button at the bottom
left-hand corner of the screen to bring up the Start menu.
Step 2 Move the cursor to select the Programs sub-menu.
Step 3 Move the cursor to highlight the JKSimMet V5.1 program
from the list displayed in this sub-menu and left-click to
launch the program. The JKSimMet logo is displayed
while the program is launching.
Having successfully launched the program you enter JKSimMet at

the main JKSimMet desktop window as shown below. From here,
the next step is typically to open a previously saved data set (note
that each data set is known as a project in V5) or to enter the data
for a new project. Section 3.5 describes the steps involved in
working with an existing project.
Alternatively, JKSimMet can be launched by selecting an existing
project file (extension .JKSM5) and double clicking it. This
launches JKSimMet with the chosen file as the active project.
The JKSimMet desktop window

Learning JKSimMet Working with an Existing Project
3.5 Working with an Existing Project

About this As a first exercise in the use of JKSimMet follow the instructions
Exercise in this section. They will show you how to:
• Load an existing demonstration project for a simple ball mill

and hydrocyclone circuit. This project was created by JKTech
and was installed with JKSimMet.
• Use the simulation tools in JKSimMet to simulate the action of
the circuit under predefined feed conditions.
• View the results of the simulation on the computer screen and
print selected results on the printer.
The files which define the flowsheet, process units and streams that
make up the demonstration circuit are already on your computer.
They were installed onto the hard drive during the JKSimMet
installation procedures. They can be recalled by following a few
simple steps outlined below.
Loading an Step 1 Left-click on the Open Project icon on the JKSimMet

existing project toolbar at the top left-hand corner of the JKSimMet
window. This will open the Project View window as
shown in the screen image below.
Open
Project

Working with an Existing Project Learning JKSimMet
Step 2 Left-click on the tab marked Saved in the Project View

window. This displays a list of all the existing project
files (along with a description of each project in the
Object Description box)
Step 3 Move the cursor to the red book of the project which
you want to load, in this case the Learner Flowsheets
project, and left-click, hold and drag it across to the
JKSimMet desktop to load the project. Note that when
you click on a project name, its file name, complete
with directory location appears in a strip at the bottom
of the Project View window.
Step 4 Left-click on the main window to make it the active
window.
3.5.1 Selection of a Flowsheet

Within each project the user can define one or more flowsheets to
represent the circuit(s) which he wants to investigate. Each
flowsheet can be expanded in size to make room for complex
flowsheets. We will work with a flowsheet called Example Ball
Mill – Cyclone simulation in the project Learner Flowsheets.
Follow the steps outlined below to select this flowsheet as the
active flowsheet.
Loading an Step 1 Left-click on the text box at the bottom right of the
existing JKSimMet flowsheet window to view a drop-down list
Flowsheet of the flowsheets which have been created in the
Learner project.

Step 2 Move the cursor down the list to highlight the name of
the flowsheet which you want to use (in this case
Example Ball Mill – Cyclone simulation) and left-click
on this to bring the chosen flowsheet into view on the
main screen.
Changing the Step 3 If the flowsheet you want to work with is not
size of the completely visible in the window you can change the
flowsheet height and width of the window by placing the cursor
window on the bottom, right corner of the flowsheet window
and left-clicking and dragging the window edge until it
is the required size.
Drop-down list
of flowsheets
in this project
3.5.2 Simulation
The Example Ball Mill – Cyclone simulation flowsheet already
contains all the stream data and parameters required to simulate this
circuit. We will use the JKSimMet simulation capabilities to
predict the product stream size distributions and capacity of the
simulated circuit, but first we will find out how to look at the
equipment unit data and port data.

Key to the The demonstration circuit consists of a ball mill and a nest of four
Demonstration hydrocyclones. These equipment units are connected by streams.
Circuit The streams enter and leave the equipment units through feed and
product ports.
Note that there are also two specialised units in this circuit, these
being the Feed and the Water Feeder. The Feed unit allows new
feed material to be introduced to a circuit as dry solids or a slurry.
The Water Feeder allows the addition of water to the circuit.
Feed Nest of four Water

unit cyclones Feeder
Examining The data windows for each equipment unit and its associated
equipment and streams can be accessed by placing the cursor over the unit and
port data right-clicking the mouse button to view the pop-up menu.
Left-clicking on the word Equipment on the pop-up menu brings
the equipment data window into view.
Left clicking on the name of a stream port in the pop-up menu (in
the cyclone example these choices are combiner, underflow or
overflow) brings the data window of that stream port into view.
Selectable tabs Note that the port and equipment data windows use selectable tabs
to provide access to the several types of data which are available
within each window. To view the available data left-click on each
tab in turn.

Arranging If there are several windows open on the JKSimMet desktop the
windows on the user has several options to organise the windows to suit their
desktop needs.
The options available can be seen by left-clicking on the icon at
the top, left-hand corner of the window which you want to move,
close etc. Clicking on this icon brings into view a drop-down
menu which allows the user to move, minimise or close the data
window by selecting the appropriate command.
Minimise window button Close

on open window. window
button
Left-click this icon to

view drop-down menu
to move, minimise or
close this window.
Move a window Select the word Move on the drop-down menu and then move the
mouse or use the keyboard arrow keys to move the window as
required. To stop moving the window left-click with the mouse or
press the Enter key on the keyboard.
Alternatively a window can be moved by simply left-clicking and
dragging on the window title bar to move the window to where
you want it.
Minimise/Restore To minimise a window select the word Minimise on the drop-
a window down menu or left-click on the minimise button at the top, right-
hand side of the title bar. This shrinks the window to a small title
bar at the bottom of the JKSimMet desktop area. To return the
window to its previous size and position left-click on the Restore
button at the top, right-hand side of the title bar.
Close a window Select the word Close on the drop-down menu or left-click the
Close button at the top, right-hand corner of the window or hold
the Ctrl key down and press the F4 key.

Left-click this icon to Minimise window button Close

view drop-down menu on open window. window
to move, minimise or button
close this window.
Restore window button

on minimised window
Resize a window The width and height of the flowsheet window can be adjusted by
selecting the word Size on the drop-down menu. The size of the
(Flowsheet window can then be adjusted by using the arrow keys or by left-
window only) clicking and dragging a corner of the window
Another alternative for arranging windows on the desktop is to use

the options available under the Window menu on the JKSimMet
menu bar. These options allow the user to arrange all of the
windows in one operation, the choices for arranging the open
windows being cascade, tile horizontal, tile vertical.. There is also
an option Arrange Icons, which organises the icons of any
minimised windows into rows at the bottom of the screen.
Concept: To simulate a closed circuit, JKSimMet uses an iterative procedure.

Convergence In the first iteration, an estimate (perhaps zero) of the circulating
load is used. This allows the calculation of a better estimate of the
circulating load to be used for the second iteration and so on. The
procedure is repeated until the difference between succeeding
estimates of the circulating load are less than a specified amount
(the convergence limit). The circuit is then said to have
converged.
The convergence value is shown by JKSimMet during simulation.

The tolerance limits can be changed by the user.

General Approach JKSimMet V5 uses a standardised approach for all of the

analysis tools – simulation, mass balancing and model
fitting. As shown in the Simulate window example below,
the tabbed window for each tool offers a Control tab to
define parameters and set the limits for the operation. It
also has a Select tab which allows the user to choose a
subset of the flowsheet components for simulation or
balancing etc. Each selection list can be named and saved,
allowing the user to analyse as many subsets as required.
This capability was only available within the mass
balancing module of earlier versions of JKSimMet. It
should remove the need for multiple circuits in all but the
largest multi-survey data sets. Once the Select list is
defined, a simulation can be run.
Running a Step 1 To simulate the example left-click on the Simulation icon.
Simulation This brings the Simulate window into view.
Step 2 A glance at the flowsheet shows which parts of the

flowsheet have been selected to be included in this
simulation as all of these items are outlined in blue on the
flowsheet. In this example every item on the flowsheet is
selected to be used in the simulation.
Step 3 Run the simulation by left-clicking on the Start button at
the bottom left of the Run Simulation tab area of the
Simulate window.
The simulation will now run iteratively through the circuit.
As each iteration in the simulation is completed the values
in the simulation window will be updated. Once the
execution of the simulation has finished it is possible to
assess the simulation results by looking at the values in the
simulation window. More detailed information can be
viewed via the port and equipment unit data windows. We
shall first look at techniques for examining the data on the
computer screen and then at printing the data.

3.5.3 Displaying the Simulation Results

The simulation has calculated the flows of through each of the
various equipment units of the circuit and their ports. The Run
Simulation tab has a section where the results of the simulation are
summarised. The detailed data for each piece of equipment and
port on the flowsheet can be examined individually by displaying
the appropriate data window on your screen, as described in
section 3.5.2.
Data Display The data windows contain all of the information that JKSimMet
uses to perform the simulation and also show the results of the
simulation. The port data windows list the raw and calculated
values for mass flows of water and solid and the size distribution
values while the equipment data windows show the model
parameters used for simulation together with any data that result
from the simulation (e.g. cyclone operating pressure).
Step 1 To examine all of the data for any equipment unit or

port in the circuit, move the cursor over the unit whose
data you wish to examine. Right-click on the
equipment unit to bring the pop-up menu into view (as
shown below) and then move the cursor to highlight the
required information (equipment or port name) on this
list and click the left mouse button. This will bring the
selected data window into view. In this example the
Cyclone equipment data window is shown. Note that
when a data window is the active window, the
equipment unit to which the data relate is highlighted in
red on the flowsheet.

Data window for

hydrocyclone
Step 2 There are several alternative methods to look at the port

data associated with each equipment unit. One method
mentioned previously is to return to the flowsheet,
right-click on the equipment icon of the unit which the
stream feeds into or flows out of and then left-click on
the name of the port whose data you want to examine.
The alternative method, which is useful if the
equipment data window is already open, is to left-click
on the Port Detail drop-down list at the top, centre of
the equipment data window and then to select the name
of the port whose data you want to view. Both of these
actions bring up the port data window. The cyclone
underflow data window is shown below as an example.
Another way to access the equipment data window only
works if the flowsheet is “locked”. If you have finished
editing the flowsheet, you may click on the Lock the
Flowsheet icon on the tool bar. The lock button will
stay depressed indicating that the flowsheet icons can
no longer be moved. This prevents “accidental”editing.
In this locked mode a double click on an equipment
icon will open its data window immediately.
Step 3 The port data window has three areas for the user to
examine. The major part of the window is the area
where the data are listed. Two selectable tabs allow the
user to view the mass flow data for water and solids

and their associated data and the size distribution data,
simply by left-clicking on the appropriate tab. Note that
a third tab is present here when component (e.g. assay)
data have been included in the flowsheet data. The
other areas of this window are the drop-down menus
for Format (sizing format), Data type and Error which
allow the user to choose how the data are presented.
The Set SDs button which, as its name implies, allows
the user to set the SD values for the data, will be
discussed in a later section.
Left click on the drop-down

lists to select the data format
you wish to view.
Left click on a tab to

view the associated data.
Concept: The JKSimMet user can view a variety of data in the stream data
Data Formats window by selecting the required format from the Format, Data
Type and Error drop-down sub-menus. The size distribution data
can be displayed in one of three formats - % retained at size,
cumulative % retained at size or cumulative % passing size. The
Data menu gives the user the option of displaying GSIM data
types (experimental and calculated data only) or SDs data types
(experimental data, calculated data, SDs and errors) or all data,
which as the name implies, displays all of the data types including
balanced and fitted data as separate columns.

Concept: Exp Data which the user has entered which are
Data Types (Experimental the results from sampling, sizing and assay.
Stream Data)
Bal Calculated data which are the output of the

(Mass-balanced data) mass-balancing procedure.
Fit Calculated data which are the output of the

(Model-fitted data) model-fitting procedure.
Sim Calculated data which are the output of a

(Simulated Data) simulation model.
SD An estimate (standard deviation) of the

accuracy of an experimental measurement
(see chapters 5 and 6 for details).
Errors The error is the difference between the

measured or experimental data and the
calculated data. Chapters 5 and 6 discuss
errors in detail.
Changing The user can change the width of the columns in which the data
column width are presented in both the port data and equipment data windows.
To change the width of a column move the cursor to the right-
hand edge of the cell at the top of the column whose width you
wish to change. When it is positioned over the border line, the
cursor will change from the usual arrowhead to a vertical line
with arrows on each side of it; left-click and drag with this cursor
to change the column width as required and release the mouse
button when the column width is to your satisfaction.

3.5.4 Printing the Simulation Results

When you are satisfied with your simulation, you can print the
results out on the printer. The printing facilities contain functions
that:
• print the raw and calculated data for a selected port, including
SDs and errors if selected on the window display
• print all details for a selected equipment unit
• print the flowsheet
• print an overview table
• print a graph of selected data
• print a user-configured report.
The user can print quick or generic graphs, an overview table of

data and a report once these have been created by the user. The
overview, report and graph plotting functions are comprehensive
and they are discussed separately from printing later in the manual.
The printing functions are invoked via the main JKSimMet menu at
the top of the JKSimMet desktop or from the Print button on the
active window. A Print Preview functionis available in most cases.
Reports The simulator can print reports in several formats, these are:
• equipment (a selection or individual)

• ports (a selection or individual)
• equipment feed streams (a selection or individual)
• overviews
• configured reports
Quick Text To print the contents of a port or equipment data window simply
Printing open the required data window and click on the Print Preview icon
on the JKSimMet toolbar. A Print Preview window will display the
data as they will be printed; clicking on the Print icon in this preview
window prints the page(s) immediately. Alternatively, the data
window contents can be printed immediately by clicking on the Print
icon in the data window.
Flowsheet Print The current flowsheet can be printed by selecting File on the
JKSimMet main menu, selecting the Print Flowsheet option and then
selecting the required option for colour or monochrome printing
from the sub-menu. Selecting Print to Clipboard sends a copy of the
screen image to the Windows clipboard from which it can be pasted
into other suitable applications such as MS Word or MS Paint.

Graph Print Quick or generic graphs can be printed via the Print icon on their
window or copied to the clipboard.
Printing Step 1 To print the simulation data, select each piece of

Simulation Data equipment and port in turn, open its data window and
click on the Print Preview icon. This will preview the
pages to be printed. Click the Print icon on the Print
Preview window toolbar to send the pages to the default
Windows printer. If you do not want to print a page,
close the Print Preview window by clicking its close
button.
Data Type Step 1 Select the data to be displayed from either GSIM
Selection (grinding simulation which shows measured and
calculated data), or SDs which also displays standard
deviations and errors or All Data which shows all of the
available data types.
You may also wish to keep a printed copy of the circuit

flowsheet. It is possible to print the flowsheet window as
follows:
Print Circuit Step 1 With the desired flowsheet as the active window, select
Flowsheet the Print Flowsheet option on the File menu of the
JKSimMet main menu. Then select the required option to
print to file or clipboard in colour or monochrome from
the four shown on the sub-menu.
There will be a short pause while JKSimMet translates
the screen data into a format suitable for the printer.
Report Printing Step 1 Click on the report icon on the tool bar.
Step 2 Click on the Print icon on the Report window to print the
default report.
For details on the Report feature refer to section 3.5.6.

3.5.5 Summarising the Results - Overview

The Overview feature gives you a powerful means of summarising
your data and checking it for adjustment problems. The overview
window displays a configurable list for presentation of data from
all selected streams. The overview window can display either
actual experimental or calculated data. Alternatively the overview
window can show calculated recovery data in cases where
component data (e.g. assays) have been entered.
Step 1 Left-click on the Overview Config icon on the main

JKSimMet toolbar to bring the overview window into
view.
An overview list named Simulation results overview
has already been prepared for this example.
Step 2 Resize the overview window by clicking and dragging

the bottom right-hand corner of the window. This
allows you to see all of the data summarised in the
overview window. Alternatively you can use the scroll
bar at the bottom of the overview window to view all of
the data. You may also need to make the columns
wider to see the data clearly.
A typical use of the overview window would be to
check that the % solids of all the simulated streams are
within acceptable operating range. Is this the case in
our example?
Note: The % passing and passing size are set as a Flowsheet
Property. These provide a very useful summary via the
overview table.

3.5.6 Summarising the Results - Report

The Report feature gives you a powerful means of summarising and
printing both the port and equipment data. The Report window
displays a list of all of the equipment units and ports on the current
flowsheet and the user can select from this list the items which are
to be included in the report printout. The report feature allows the
user to select experimental or calculated data with or without SD
values and/or error values. A typical use of the report feature would
be to print a standard set of data for inclusion in a technical
memorandum.
Step 1 Left-click on the Report icon on the main JKSimMet

toolbar to bring the Report window into view.
Ensure that the prepared example report named Report
Config Example is selected in the Report drop-down
list.
Step 2 Click on the Print Preview icon in the Report window

to see what the selected data will be look like when
printed. Experiment with the various options in the
Report window and use the Print Preview window to
see how each option changes the printed report format.

The Report Print Preview window

3.5.7 Exporting Data from JKSimMet

While JKSimMet provides a range of options for examining your
data, there may be occasions when it would be useful to be able to
use JKSimMet data in a report or a presentation. Version 5
provides a copying facility which allows the user to copy data from
the equipment and port windows to the Clipboard. These data can
then be pasted into any clipboard compatible application such as a
spreadsheet (e.g. MS Excel) or a word processor (e.g. MS Word).
Note that there are two types of Copy buttons on the equipment and
port data windows. These are:
Copy Selected Cells to Copies only the data cells which are
Clipboard currently selected to the Clipboard.
Copy Grid to Clipboard Copies all visible cells on the current

tab to the Clipboard, including row
and column labels.
Hint: If you wish to copy all of the tabs at once, use the print
preview button and then the Copy to clipboard button on the Print
Preview window.
(Also see information on exporting data via tab-delimited and
comma-delimited text files in Exporting data using Report in
section 3.10)
3.5.8 Finishing a JKSimMet Session

You have completed your simulation of the ball mill and cyclone
circuit and examined and printed both the flowsheet and the
simulation data. In the next exercise we will attempt to improve
the operation of the circuit by varying the parameters of some of
the components, and then running simulations to observe the
predicted effect.
Before doing this, end the JKSimMet session as explained below.
Note that JKSimMet will ask you if you wish to save the flowsheet
over the original copy of Example Ball Mill - Cyclone on the hard
drive. Normally you would save changes, but in this case we
suggest that you do not do so because it will change the nature of
the example for the next person who uses these exercises to learn
JKSimMet.

Ending the Step 1 To quit from JKSimMet move the cursor to the File
JKSimMet menu on the menu bar at the top of the screen and left-
Session click to view the drop-down File menu.
Step 2 Move the cursor down the File menu to select Exit.
Step 3 A pop-up window will ask you whether you want to
leave the session. Left-click on the Yes button.
Step 4 Another pop-up window will ask you whether you want
to save the last changes to the file. In this case left-click
on the No button so that the Learner project file on the
hard drive remains unchanged for the next user.
In future if you want to save changes you have made to

your own project file before exiting from JKSimMet,
left-click on the Yes button to save the file.
Save As If you do not want to overwrite the Learner project,
select Save As from the File drop-down menu. A
Save As window will appear as shown below. This
allows the user to save the file under any chosen name
and in any chosen directory. The JKSimMet files are
identified by the five-letter filename extension jksm5.

Learning JKSimMet Making Changes to an Existing Flowsheet
3.6 Making Changes to an Existing

Flowsheet
About this Now that you have successfully simulated the ball mill and cyclone
Section demonstration circuit supplied with JKSimMet, this exercise will
extend your knowledge by showing you how to:
• change the standard data provided with a test, in an attempt to
improve the performance of the circuit under changing
conditions
• re-simulate the circuit
• view the results of the altered simulation and plot selected
results as a graph on the screen or using overview or on the
printer.
The objective is to optimise the performance of the circuit by

changing key parameters of the units and streams. The selection of
these parameters is the engineer's job and you may well have your
own ideas and wish to experiment. However, we have decided for
this exercise to vary:
• cyclone conditions to achieve a finer product
• throughput to compensate for a change in ore hardness.
This should have the effect of changing the performance of the

grinding circuit that you are going to simulate.
Note that there are two ways of changing the test circuit
performance; you can change the parameters for the existing circuit
components, as we are doing in this exercise, or you can replace or
add components. We will see how to do the latter in section 3.7.
3.6.1 Selecting the Flowsheet to Use

In this and the following sections you will perform many of the
same steps as in section 3.5 using a demonstration test. We will
assume that you are starting a fresh session with JKSimMet and
need to start the program and load the Learner Flowsheets project
and the flowsheet named Example Ball Mill – Cyclone.
We begin by starting JKSimMet, loading the Learner Flowsheets

and flowsheet named Example Ball Mill – Cyclone.
Step 1 Start the JKSimMet program and load the
demonstration project Learner Flowsheets, following
the same procedure as you did in section 3.5.

Making Changes to an Existing Flowsheet Learning JKSimMet
Step 2 Select the flowsheet Example Ball Mill – Cyclone in

the drop-down list in the JKSimMet main window,
following the same procedure as you did in section
3.5.1.
Step 3 Open the equipment data window for the Feed using
the procedure outlined in section 3.3.6. Alternatively,
lock the flowsheet using the Lock icon on the toolbar
and double click on each piece of equipment when you
wish to view the data window for it or its ports.
The Feed is a special equipment unit which represents
the flow of new material into a circuit. The Feed
equipment data window allows us to examine the feed
stream data, both mass flow and size distribution data.
It layout is the same as that found in the port data
windows which contain stream data.
The Feed equipment data window

Step 4 Click on the Overview Config icon on the main

JKSimMet toolbar to view the overview window.
Make sure that the pre-defined Simulation Result
Overview is selected on the drop-down list.
Step 5 Use the Print icon on the toolbar to print the overview
window. This provides a printed record of the base
results for the flowrates, % solids and other data from
the original simulation.
Step 6 Click on the flowsheet window to make this the active
window.
3.6.2 Altering Operating Conditions
One of the powerful tools which JKSimMet provides for the user is
the ability to adjust the data for the components of the test circuit.
While it is difficult and costly to experiment with real equipment,
the JKSimMet simulator allows the engineer to experiment with a
wide range of changes and to view the predicted results of these
changes.
Understanding the power of this adjustment method is important
and this section proceeds by:
• showing you how to make changes and re-simulate
• providing exercises for you to practise
• familiarising you with some short-cuts and additional useful
techniques.
The general technique is to decide the changes you want to make,
select the component whose parameters you want to change, make
changes to the parameters, re-simulate and observe the results.
You then have the choice of making further changes, undoing the
changes and trying some other ideas or accepting the changes and
saving the file on disk as a permanent record.
The parameters are characteristics of the equipment models and
their ports which can be altered. In a real plant we can alter most
equipment parameters (with varying degrees of difficulty and with
varying degrees of expense!). A few stream parameters, such as the
mass flowrate and feed size distribution can also be varied.
Simulation allows us to vary any of the parameters which affect the
process performance such as ball mill size and ore hardness with
great ease.

The exercises in this section will investigate what happens when
you change the following parameters:
• the number of parallel hydrocyclones, and their key
variables such as vortex finder and spigot sizes
• ore work index
• feed size distribution
• cyclone feed density.
You are welcome to experiment with changing other parameters of
other components but we suggest that you follow the exercise until
you are confident that you understand JKSimMet.
Concept: Note that in the data windows some of the data values are
Changing Data displayed in blue characters and some in black.
Fields
Blue text on a white background indicates that
Blue
the user can change the displayed data. To
change the data, highlight the old value by
double-clicking on it, type in the new value
and press Enter to register the change.
Black Black text on a grey background indicates that

the data cannot be changed by the user. These
are result fields which are controlled by the
JKSimMet system.
Step 1 Open the hydrocyclone equipment data window (by

placing the cursor over the cyclone icon on the
flowsheet, right-clicking to view the drop-down menu
and selecting the word Equipment).
The hydrocyclone equipment data window

Step 2 Using the mouse or cursor control keys, move the

highlight to the data entry box whose data you wish to
change (in this example the Parallel data entry box).
Step 3 Double-click the left mouse button to highlight the
number you wish to change (in this case the number of
cyclones) and then type in the new value of 3.
Step 4 Left-click on the Simulation icon at the top of the
screen. This brings the Simulate window into view.
Step 5 Left-click on the Start button in the Simulate window to
start the simulation.
Step 6 The simulation will begin and you will see the iteration
counter increase until the simulation converges.
Step 7 Click on the overview window to bring it into view and
examine the results of this simulation with three
cyclones. Now compare the circuit performance against
your previous printout. Is it better or worse? (with
respect to, say, cyclone overflow P80 or water split to
underflow)
Steps 2 and 3 can be repeated before simulating to change other

parameters of the hydrocyclone. Steps 1 to 4 can be repeated to
change parameters for several components.
Concept: Water JKSimMet allows for water addition to the feed port of an
Addition to equipment unit by connecting a Water Feeder unit. The water
Equipment addition can be specified in tonnes per hour or as the amount
Units required to achieve a given feed density or simply as that
determined from the densities of the combined feed streams (i.e. no
water added). The water addition control method is specified in
the Water Feeder equipment window using the drop-down list
labelled Model.
Cyclone Step 1 Bring the cyclone equipment window into view and
Variation change the number of parallel cyclones back to 4.
Exercises
Step 2 Change the vortex finder diameter from 0.365m to
0.390m and run the simulation. Note the cyclone
pressure drop (by looking in the Performance Data
table of the cyclone equipment window).
Step 3 Reset the vortex finder diameter to 0.365m.

Step 4 Change the spigot (Apex) diameter from 0.203m to

0.190m. Run the simulation again and observe the
cyclone pressure drop.
Step 5 Reset the spigot diameter to 0.203m.
Ball Mill Step 1 Bring the ball mill product port data window into view
Variation and note the product 80% passing size.
Exercises
Step 2 Bring the ball mill equipment data window into view
and then select the work index for the simulated mill and
increase the value of the index by 2.0.
Step 3 Run the simulation again and observe the increase in
ball mill product size (which is displayed in the ball mill
product port data window).
Step 4 Left click on the Simulate window to make it the active
window. Left-click on the Control tab and then left-
click on the Start Condition drop-down list and select
Experimental Data.
Step 5 Now view the circuit feed stream data by right-clicking
on the Feed unit and selecting the Equipment option.
Change the value of TPH solids for the feed, run the
circuit simulation and observe the mill product stream
80% passing size. Repeat these steps until the original
product size is achieved.
Cyclone Feed One of the easiest operating parameters to change in an actual

Density plant is the pulp density of the cyclone feed. This exercise
Exercise examines the effect on the grinding product of changing the
cyclone feed density.
Step 1 Place the cursor on the Water Feeder icon which is

connected to the cyclone feed port on the flowsheet and
right-click to view the drop-down menu. Move the
cursor to highlight the Equipment option and left-click.
The data window for the Water Feeder unit will appear.
Step 2 Move the cursor to the Model drop-down list and left-
click. Move the cursor to highlight the Water Feeder –
Required % solids option and left-click to select this
option.

Step 3 Left click on the Required % Solids data cell to make it

the active cell, type in the value 60.0 and press Enter.
Step 4 Run a simulation and observe the effect of this change in
cyclone feed density on the streams in the circuit.
Feed Ore type variations or changes to a crushing plant often cause

Characteristic alterations in the mill feed size distribution. This exercise
Variation examines the effect of a feed size change on the grinding product.
Exercises
Step 1 Bring the circuit feed stream data window into view by
right-clicking on the Feed icon and selecting the
Equipment option on the drop-down list.
Step 2 Left-click on the Sizing format drop-down list, move
the cursor to highlight % Retained and left-click on
this to make this the active sizing format.
Step 3 Left-click on the tab labelled Size Distribution to view
the sizing data. Use the cursor or mouse to input the
following new size distribution. Start at Size 1 16mm
and input in the Exp column the following values; 0.5,
3, 8.5, 19, 17, 11, 8, 7, 5, 3.5, 2, 1.8, 1.5, 1.4, 1.3, 1.2,
1.1 and 1.0. JKSimMet will supply the last value of
6.2 at size 19.
Step 4 Run a simulation of the circuit and examine the
cyclone operating conditions and product size.
3.6.3 Saving the Session
Once you have made changes to the test circuit data, you should
remember that the changes have only been made to the copy held in
the computer's memory. To record the changes for posterity, you
must also make sure that the files on the hard drive have been
updated. This is done by saving the test to the hard drive.
It is good practice to save your work at regular intervals while you
are making changes. This will protect your work against power
failure, computer malfunction or mistakes that you will inevitably
make from time to time.

Saving the To save the session as it is now, perform the following steps:
Session
Step 1 Left-click on the File menu on the main JKSimMet
menu bar.
Step 2 Move the cursor to highlight the Save As option and
left-click to open the Save As window.
Step 3 Type the new filename in the File name box and select
the directory in which you want to save the file. If
required, you can create a new folder for storing
JKSimMet files by clicking on the Create New Folder
button.
Step 4 Once the filename and its directory have been entered,
click on the Save button to save the file.

3.6.4 Graphing Your Results

JKSimMet has a graphing facility which you can use to create
graphs of your results on the display screen and to print these
graphs.
The facility has been designed so that users can produce graphs
very simply using a selection of standard layouts in the Quick graph
feature, while the Generic Graph Configuration window provides
the flexibility for the user to develop customised layouts.
The Generic Graph Configuration window allows the user to draw
graphs of:
• size distributions of all raw and calculated data for the streams
in a circuit,
• equipment parameters such as efficiency curves for the raw
and calculated data for classifying units in a circuit or
appearance functions for ball mills,
Up to 15 curves can be drawn on a single graph and the user can

have open on the screen as many graph windows as required. The
flexibility which the Generic Graph Configuration provides also
brings a certain amount of complexity and we shall avoid this here
by first describing Quick graphing with the standard layouts. A
tutorial on the full graphing features is given in section 3.8
(Learning Graphing). As an introduction to graphing we will look
initially at the basic graphs which the user can create with a few
clicks of the mouse.
About this From the Example Ball Mill – Cyclone flowsheet, you will create a
Exercise graph of size distribution data by:
• selecting the circuit data to be graphed

• using the Quick graph facility.
The graph will be displayed on the screen.

The sizing format for this graph will be selected from the available
default graph formats. A drop-down list allows the user to change
the sizing format to % retained, cumulative % retained, or
cumulative % passing. Another drop-down list in the window
allows the user to select either the experimental data, calculated
data or the absolute error to be plotted on the graph. By using the
buttons on the graph window you can add or remove gridlines as
required.
Drawing a Step 1 Place the cursor over the cyclone unit on the flowsheet
Graph and right-click to view the drop-down menu..
Version 5.0 December 1999 Section 3.6 Page 3-35

Step 2 Move the cursor to select the word Graph from the
drop-down menu. JKSimMet will open a window
which graphs the stream data for the feed and products
streams of the selected unit, as shown below.
Buttons to Drop-down Drop-down list to

add gridlines list to select select Experimental
to graph format of size data, Calculated data
plot or absolute error.
Plot single data

set button
Step 3 The graph which is displayed in the window is the

default format of cumulative % passing size for the
calculated data.
Step 4 Add gridlines to the graph by left-clicking on both the
x-axis and y-axis gridline buttons. Your graph should
now look like this.
Step 5 The final feature of this basic graph is that the user can
select any port attached to the unit for its data to be
plotted individually. Left-click on the Show Single
Port button at the top left corner of the graph window to
view only one data set on the graph and then select the
required port from the drop-down list of port names
(Single Port Selection list). Note that this drop-down
list of port names is inactive until the single data set
option has been selected.
Page 3-36 Section 3.6 Version 5.0 December 1999

Concept: Once you have set up the graph to your satisfaction you can print
Printing a the graph window. Whether the graph is printed in colour depends
Graph on whether or not the printer connected to your computer can print
in colour.
Printing a Step 1 Use the Printer Setup option in the File menu to set the
Graph orientation of the paper to landscape or portrait as
required.
Step 2 To print the graph click on the Print icon on the Quick
Graph window. This will print the graph immediately.
Step 3 Quit from JKSimMet by selecting Exit from the File
menu on the main JKSimMet menu. When asked
whether you want to save any changes to your file
respond with no in order to keep the original example
for future users.

Creating a New Project Learning JKSimMet
3.7 Creating a New Project

About this In this section you will build a JKSimMet project from scratch, just
Section as you would do with a real project. The techniques covered in this
Chapter are the initial steps in setting up a project and flowsheet
which are common to all of the JKSimMet mass-balance, model-
fitting and simulation tools.
The first step in every new project is to build the flowsheet. Then
some of the data required for the equipment and streams of the new
circuit will be entered by you, the user, and some will be copied
from an existing project. The techniques available to you for
examining the data such as graphing and printing, will also be
described in this section.
This section will show you how to:
• create a new project and define new project and flowsheet

names,
• build a flowsheet,
• re-use component data (such as for the ball mill unit) from
previously created projects,
• define data for equipment units and streams,
• run a simulation and view the results for the new test you have
created.
3.7.1 Starting a New Project

This exercise begins with the creation of a new project following
the steps outlined below.
Concept: A project consists of one or more flowsheets. It is only possible to

Projects work on one project at a time (although each project may contain
several flowsheets). If you already have a project open and you
create a new project, the new project will overwrite in memory the
currently open project.
All of the projects that you create will be saved on the hard drive
and will be quite separate from the Learner Flowsheets project.
Step 1 Start JKSimMet and left-click on the Open Project icon in
the toolbar. This will bring the Project View window on
to the screen with the Saved tab active.
Step 2 Left-click on the New tab to make this the active tab.

Learning JKSimMet Creating a New Project
Step 3 Click on the red Default Project icon and drag it across on
to the JKSimMet flowsheet window. This will load the
Default Project which is a blank project, for you to work
on.
Version 5.1 February 2003 Section 3.7 Page 3-39

3.7.2 Define Flowsheet Name

The flowsheet window in this version of JKSimMet can
accommodate much larger circuits than was the case in previous
versions. Users can now draw a flowsheet which is larger than the
screen. Scroll bars are used to move around the flowsheet window.
In mass balance, model fit and simulation modes the user can
select a subset of any of the units and streams for analysis.
Each flowsheet must be given a name so that the user can select
the required flowsheet for display. In this case we are only creating
a simple flowsheet with a single circuit, but it is still advisable to
name the flowsheet.
Define Flowsheet Step 1 Left-click on the JKSimMet flowsheet window to make
Name this the active window and then right-click on any blank
area of this window.
Step 2 On the pop-up menu which appears, move the cursor to
highlight the word Flowsheet and then move the cursor to
highlight Properties on the sub-menu which appears and
left-click to select this option. This will bring into view
the Flowsheet Definition window.
Step 3 In the box labelled Title in the Flowsheet Definition

window type in your own title for the flowsheet. The user
can also type other details such as any comments on the
flowsheet in the appropriate spaces in the Flowsheet
Definition window.
.Step 4 While the Flowsheet Definition window is open you
should also take the opportunity to set the % passing size
values which are used in the port data displays.
Step 5 Close the Flowsheet Definition window by left-clicking
on the Close icon in the window title bar. Note that the
name of the flowsheet now appears in the drop-down list
box at the bottom, right-hand corner of the flowsheet
window
Page 3-40 Section 3.7 Version 5.1 February 2003

3.7.3 Drawing a New Flowsheet

To draw a new circuit directly on to a blank flowsheet window you
will need to follow these steps:
• select the units that make up your circuit and place their icons
(pictures that represent the units) on the flowsheet (make sure
that they are positioned so that it will be easy to connect the
streams between them),
• connect the appropriate feed and product ports of the units
with streams that represent the flow of material between the
units,
• add feeders to carry the input material into the circuit,
• connect water addition points to the circuit.
Each piece of equipment on the flowsheet has a default name

which can be edited by the user. Naming the components of the
flowsheet is recommended as this makes it easier to identify the
data later, for example when you want to define the operating
parameters of an equipment unit or identify it in a report.
Concept: JKSimMet identifies all components of a circuit by the names that

Unit Naming you give to them. The program does not enforce any conventions
Conventions in naming and you may select any name you wish. You may call
the ball mill Bert if you wish, but you will no doubt find that
naming a ball mill, Ball Mill or some abbreviation thereof, while
somewhat less interesting, is in practice easier to remember.
JKSimMet will not forget what Bert is, but you probably will!
You now have a blank flowsheet window on the screen in front of you and you can
begin to draw in a new circuit. You must position the process equipment before
connecting the ports of the new circuit.
Create New Step 1 To create a new equipment unit on the flowsheet first
Equipment Units left-click on the Project View window to make it the
on the Flowsheet active window and then left-click on the tab labelled
New to make it the active tab. Note that once a project
has been loaded there is only one item in the New list
in the Project view window – Default Equipment .
Step 2 Double-click with the left mouse button on the Default

Equipment book icon to “open” the book and display
the list of equipment categories which are available to
you.
Step 3 To view a list of the units which are available in each
equipment category simply left-click on the plus-sign
which is next to the category name. In this case, left-

click on the Mill category to show the list of mills
available.
Default Equipment book

has been “opened” to
show the list of equipment
categories.
Step 4 Left-click on the icon of the equipment unit which you

want to add to the flowsheet and drag it on to the
flowsheet. In this case, click and drag the Rod Mill
icon to the flowsheet, placing it in the position you
want it to appear and releasing the mouse button to
leave the unit in the required position.
Positioning Equipment units may be moved around the flowsheet window

A Unit whenever you want to move them, providing that the flowsheet is
not locked. Simply place the cursor over the icon of the unit you
wish to move, left-click and drag the equipment icon to its new
position and release the mouse button to leave the icon in place. If
there are streams attached to the unit they will remain attached
after moving it.
Changing In order to make flowsheet layout uncluttered, the orientation of

Feed equipment units can be changed so that the feed end is facing left
Direction or right as required. To change the feed direction move the cursor
to the unit you wish to change and right-click to view the drop-
down menu. Move the cursor to highlight the word Flip and left-
click to make the unit change from left-hand feed to right-hand
feed or vice-versa. While it is possible to Flip units which have
streams attached, it is better to plan the orientation of the units
before you connect them together with streams or you may end up
with some very convoluted pipework.
Deleting a Unit An equipment unit can be deleted by placing the cursor over the
unit on the flowsheet and right-clicking to view the drop-down
menu. Select the Delete option from the menu and the unit (and
any attached streams) will be deleted from the flowsheet.

Concept: Re-using equipment data that have been created for a previous
Re-using data project is a convenient short-cut. It allows the engineer to quickly
construct similar flowsheets based on the same components.
Use Existing Step 1 To use equipment units which have been used in a
Equipment Units previous project first left-click on the Project View
on the Flowsheet window to make it the active window and then left-
click on the tab labelled Saved to make it the active tab.
This brings into view a list of the projects which have
been saved in the current directory on the hard disk. If
the project which you want to access is in another
directory, click on the Browse Directories button and
select the required directory in the Select Directory
window.
Step 2 Double-click with the left mouse button on the book

icon of the project whose data you wish to re-use. This
will display the list of flowsheets which are the
components of the project. In this case we will look at
the project called Learner Flowsheets.
Step 3 Left-click on the plus sign to the left of the flowsheet

where the data you wish to re-use are located. This will
reveal a list of the equipment units which are part of the
flowsheet. In this case left-click on the plus sign for the
Example Ball Mill Cyclone simulation flowsheet.
Step 4 Move the cursor to the icon of the equipment unit

whose data you wish to re-use and left-click and drag
the unit icon onto your current flowsheet. For the
example you are working on, click and drag the
Primary Mill and then the Cyclones units to the
flowsheet you are building.
The first stage of building the flowsheet is complete and your

flowsheet should look similar to the one shown below.

The Learner Flowsheets Example Ball Mill Cyclone circuit is a

large, single-stage ball mill treating a coarse feed and producing a
relatively coarse product. Another common circuit configuration is
to use a rod mill followed by a ball mill to produce a finer product.
The first part of this exercise will investigate the use of this
arrangement. Because the ball mill is very large, it is necessary to
configure the circuit with three rod mills in parallel.
In reality, this is not a practical configuration without the use of a
feed sump. However, for simplicity we will not draw a feed sump
on the flowsheet at this stage.
3.7.4 Create Connecting Streams

The next step is to create streams to join the equipment units you
have placed on the flowsheet.
The combiner and product ports of each unit are represented on the
equipment icons by a short grey line which resembles a short length
of pipe with a flange at the end. Up to three streams can connect to
a combiner port. Only one stream can connect to each product port.
If an equipment unit has more than one product (for example, a
cyclone has two products) there will be a separate product port for
each product stream on the unit icon. The hydrocyclone icon is
shown below as an example.
Cyclone product
(overflow) port with
no stream connected.
Cyclone combiner port
with one stream connected.
Cyclone product
(underflow) port with
no stream connected.

Connecting Step 1 To begin to draw in a stream to connect a combiner and

Ports a product port, first position the cursor over the
combiner port of a unit.
Step 2 When the cursor has changed into a hand grasping a

spanner with the word JOIN in black text above it, left-
click the mouse button. The word above the cursor will
change to PROD to tell the user that the first
connection has been made and to make the second
connection by joining the stream to a product port.
Step 3 Move the cursor to the product port of the unit you
wish to join.
Step 4 When the cursor is in the correct position to join the

streams the cursor will change to a mirror image of
itself, with the word PROD now in white text. At this
position left-click the mouse button to make the
second connection. The simulator will draw in the
connecting stream on the flowsheet.
In the example flowsheet that you are building the units should be
connected as shown in the picture below. Repeat steps 1 to 4 above
to connect all of the units as shown. Note that your streams may
follow slightly different paths, depending on the order in which you
make the connections and the relative positions of the units on the
flowsheet.

Errors in JKSimMet will not allow you to draw connecting streams which
Connecting could not exist in a real plant. For example, JKSimMet does not
Streams allow you to draw connecting streams from one combiner port to
another combiner port or from one product port to another when
you draw in the circuit diagram.
Deleting If the user makes a mistake when drawing connecting streams the
Connecting stream can be deleted as follows:
Streams
Step 1 To delete a stream place the cursor over the equipment
unit from which the stream emanates as a product and
right-click to view the pop-up menu.
Step 2 Move the cursor to highlight the Delete option and to

view its sub-menu which lists all of the items which can
be deleted
Step 3 Move the cursor along the list in the Delete sub-menu to
select the port name whose stream you wish to delete.
Note that if you choose the combiner port from the
Delete sub-menu all streams connected to that port will
be deleted.
Concept: Each equipment unit has a three-stream combiner at its feed port
Unit Feed (hence the name combiner used to denote the feed port). If there is
Ports more than one stream entering the unit, the combiner port data
window displays the data for the combined feed streams.
Concept: Each equipment unit has one, two or three product streams,
Unit Product depending on what type of unit it is. On the flowsheet, each
Streams product stream which leaves a unit is denoted by a product port
(shown as a short grey line which resembles a short length of pipe
with a flange at the end). Only one product stream flows from each
product port.

3.7.5 Adding a Circuit Feed Stream

The next step in building the flowsheet is to define a feed stream to
the circuit. In JKSimMet V5 the source of new material to feed
into a flowsheet is a special unit called the Feed. The Feed allows
the user to enter the stream data which define the feed material,
such as mass flows and size distribution.
Adding a New Step 1 Left-click on the Saved tab in the Project View window
Feed to a to view the Saved Equipment list. Double left click on
Flowsheet the Learner Flowsheets Template.
Step 2 Left-click on the plus sign of the Example Ball Mill-
Cyclone Simulation circuit.
Step 3 Left-click and drag the Feed icon on to the flowsheet
and place it near to the feed end of the Rod Mill.
Step 4 Left-click on the flowsheet to make this the active
window.
Step 5 Draw in a connecting stream between the Feed unit
product port and the Rod Mill unit combiner port.
3.7.6 Adding Water to the Circuit

The flowsheet diagram is now almost complete. The final task in
drawing our circuit flowsheet is to make provision for water to be
added to the rod mill and the cyclone feed.
Concept: In JKSimMet V5 all water additions are made by means of a

Water special type of unit called a Water Feeder. Water may only be
Addition added to the feed port of an equipment unit. The water addition
can be specified as either tonnes per hour of new water or
controlled by the required percent solids of the unit feed stream.
The choice of options is controlled by selecting the appropriate
model in the Water Feeder equipment data window.
Adding Water Step 1 Left-click on the New tab in the Project View window
to a Flowsheet to view the Default Equipment list. If only the Default
Equipment icon is visible, double-click on the closed
book icon to view the list.
Step 2 Left-click on the plus sign of the Feed category icon to

view the list of feed of feed options available.

Step 3 Left-click and drag the Water Feeder icon on to the

flowsheet and place it near to the feed end of the Rod
Mill.
Step 4 Left-click on the flowsheet to make this the active

window.
Step 5 Right click on the Water Feeder icon and select

Equipment from the Drop Down list.
Step 6 Enter an appropriate % solids value in the Water

Feeder equipment window
Step 7 Draw in a connecting stream between the Water Feeder

product port and the Rod Mill unit feed port.
Step 8 Repeat Steps 3 to 7, placing the second Water Feeder

icon near the cyclone and connecting it to the cyclone
feed port.
Step 9 It would be wise to record your work at this stage.

Right-click on a blank area of the flowsheet, move the
cursor to select Project and then select Save from the
sub-menu.- or select File and then Save from the menu.
The circuit flowsheet is now complete and should now look like
the flowsheet shown below. At this stage it is advisable to Lock the
flowsheet by clicking on the Lock button on the JKSimMet toolbar.
If required, the user can add various information such as stream
name labels or equipment unit information blocks to the flowsheet.
The techniques for annotating the flowsheet in this way will be
discussed in the next section.

Concept: Locking a flowsheet prevents the equipment units on the flowsheet

Locking the from being moved accidentally. It is advisable to lock a flowsheet
Flowsheet once you have finished drawing it, particularly large complex
flowsheets, because if a unit is moved accidentally whilst trying to
access data the flowsheet is redrawn and this may take several
seconds for complex diagrams. Locking a flowsheet also allows
users to access the equipment data window by double-clicking on
the equipment icon on the flowsheet.
Concept: JKSimMet V5 automatically creates names for all of the ports on

Port Naming the flowsheet. Each port name is created by identifying which unit
Conventions it is attached to and describing whether it is a feed or product port
for that unit. For example, if the user has a nest of cyclones named
Deslime Cyclones, their feed port will automatically be named
Deslime Cyclone Combiner. The product ports are given the
descriptors which are appropriate for the particular item of
equipment. For example, cyclone product ports are overflow and
underflow and flotation product ports are concentrate and tails.

3.7.7 Adding Information Blocks and Labels

to the Flowsheet
Displaying Data You can easily put information about the ports and equipment units
on the Flowsheet on your new flowsheet. This is done by adding Information Blocks
to the flowsheet. This is a very useful feature as it allows the user to
examine the circuit performance in terms of port data and equipment
data in pictorial form on the flowsheet.
Concept: Each of the units and ports on the flowsheet can be annotated with
Information an Information Block which can display data for that that item on
Blocks the flowsheet. For equipment units the information block displays
two items of data while for ports up to four items of data can be
displayed. The user can select which data items are displayed in
the information block. The information block can be placed in any
position the user chooses on the flowsheet screen.
Firstly you will place information blocks on the flowsheet for some
key ports.
Adding a Port Step 1 Make the flowsheet window the active window.
Information Block
To the Flowsheet Step 2 Left-click on the Information Block Configuration
button on the main JKSimMet toolbar. This opens the
Configure/Assign Information Blocks and Labels
window as shown below.
The Ports tab for configuring Port Information Blocks
Step 3 Left-click on the selectable tab labelled Ports to

configure the information blocks for the port data.
Step 4 Check that the box marked Allow Dual Data Types is
empty. This will allow you to place four different data
items in the information block. If this box has a tick in
it you can place two data items in the information block
and view two types of data (e.g. experimental and
simulated data) for them both.

and view two types of data (e.g. experimental and

simulated data) for them both.
Step 5 Decide which four data items from the Configuration

list you want displayed in the port information block
and then left-click on each in turn to place them in the
block. For this example select Solids (t/h), % Solids,
Vol.Flowrate and % Passing X. If you make a mistake
or want to change any of the selected data items simply
click on the Clear button below the list and repeat the
selection process. Note that % - X mm and Y Passing
Size are set from the Flowsheet properties window
accessed via the tool bar icon or a left click on the
flowsheet.
Step 6 From the data type drop-down list select the type of
data which you want to display in the information
block. In this case select Sim to display simulated data.
Step 7 Once you have the required configuration for the
information block left-click on the Apply button to
apply your selection to the information block. Note
that this action places an information block legend on
the flowsheet.
Step 8 From the list of ports at the left of the window select
the port for which you want to add an information
block. For this example, select the Ball Mill Combiner.
Step 9 Left-click on the Add New Block button to place the
information block on the flowsheet. The new block
appears behind and slightly to the side of the Port
Legend block. Note that the information block has the
name of the port across the top of it. This will help to
identify which port the data relate to if the information
block is not placed directly next to the port on the
flowsheet.
Step 10 Repeat steps 3 to 8 for any other ports for which you
want to display an information block.
The user can also add an information block for each equipment unit
on the flowsheet. This allows the user to observe the effect of any
changes to the circuit on unit parameters such as cyclone operating
pressure. For the example which you are working on here, an
information block for the cyclones would be useful.

Adding an Step 1 With the Configure/Assign Information Blocks and

Equipment Unit Labels window as the active window, left-click on the
Information Block selectable tab labelled Equipment to configure the
information blocks for the equipment unit data.
Step 2 From the list of units at the left of the window select
the equipment unit for which you want to add an
information block. For this example, select the Primary
Cyclones unit. The list of unit parameters in the
Configuration section of the window will change to
reflect the type of unit which has been selected, as
shown below.
The Equipment tab for adding Equipment Information Blocks
Step 3 Decide which two data items from the Configuration

list you want displayed in the unit information block
and then left-click on each in turn to place them in the
block. For this example scroll down the list and select
Cal Operating Pressure and D50c Cal. If you make a
mistake or want to change any of the selected data
items simply click on the Clear button below the list
and repeat the selection process.
Step 4 Once you have the required configuration for the
information block left-click on the Apply button to
apply your selection to the information block for the
selected unit.
Step 5 Left-click on the Add New Block button to place the
information block on the flowsheet. Click and drag on
the information block to place it where you want it on
the flowsheet. Note that the information block has the
name of the unit across the top of it. This will help to
identify which unit the data relate to if the information

block is not placed directly next to the unit on the

flowsheet.
Step 6 Repeat steps 2 to 5 for any other units for which you
want to display an information block.
The final option for annotating the flowsheet is to add one or more
Labels. This allows the user to type in their own text in a text box
which can be formatted in a range of colours and styles.
Adding a Label Step 1 With the Configure/Assign Information Blocks and

to the Flowsheet Labels window as the active window, left-click on the
selectable tab titled Labels to set up a label on the
flowsheet.
Step 2 In the box marked Text type the text you want to
display on the flowsheet. Note that as you type the
Preview box shows how the label will look on the
flowsheet.
Step 3 Select the required text justification by clicking on the

radio button in the Text Alignment box. View the
results of your selection in the Preview box.
Step 4 Select whether word wrap and/or borders are required
for the text box.
Step 5 If you want to use a different background colour for the
label click on the Background Colour box to view the
palette of colours from which you can select a new
colour.
Step 6 If the height and width of the label set by the Autosize
function are not suitable for your label click on the
Autosize On box to switch the Autosize function off.
Then enter the required size (in millimetres) of the label
in the boxes marked Height and Width.

Step 7 When you are happy with the format of your text box as
shown in the Preview, click on the Add Label button to
place the label on the flowsheet. Click and drag the
label to the required position. Note that once a label
has been placed on the flowsheet its text and format
cannot be edited.
Step 8 If you want to delete a label simply double-click on it to
remove it permanently from the flowsheet.
The Labels tab for adding Text Labels to the Flowsheet
3.7.8 Entering Data

Having completed your circuit diagram the next step is to supply
data for each component of the circuit. This can be done in two
ways:
Entering The user can enter new data using the
new data keyboard or by copying and pasting data from
a spreadsheet.
Re-using The user can re-use the data for a unit created
the data from in a previous project by dragging onto the
existing projects current flowsheet the icon of the unit from the
existing project that is stored on the
computer's hard disk.
Once imported the data can be modified as
required.
We have already seen how to re-use equipment unit data by using

the icons for an existing ball mill and cyclones when drawing the

circuit flowsheet for My RM-BM-Cyc Circuit. In the next section

you will learn how to enter new data into the default equipment
unit used on the flowsheet.
3.7.9 Define Data for Rod Mill

The only equipment unit in the new circuit without data is the rod
mill. You will use the keyboard to enter a new set of data for the
rod mill. The data to be entered are listed below and are also
shown in the Rod Mill unit data windows opposite.
UNIT DATA FOR FLOWSHEET My RM-BM.CYC
ROD MILL
Data which can ROD MILL

be entered Model Lynch/Kavetsky
Number of Rod Mills 3
Data for Simulated Mill
Internal Mill Diameter (m) 3.40
Internal Mill Length (m) 4.90
Fraction Critical Speed .650
Load Fraction .350
Ore Work Index 15.0
Data from Original Mill

Rod Mill Constant 2079
Internal Mill Diameter (m) 3.40
Internal Mill Length (m) 4.90
Fraction Critical Speed 0.650
Load Fraction 0.350
Ore Work Index 14.1
Feed 90% passing size (mm) 11.5
Selection Function Data

Function is constant below XC (mm) 7.43
Intercept of function at Size 0 IN -3.6
Slope of function with Size SL 0.500
Calculated Calculated Data

During Change in breakage stages 1.53
Simulation Number of breakage stages 7.30

Equipment Step 1 Place the cursor over the Rod Mill icon on the
Unit Data flowsheet and right-click to view the drop-down menu.
Entry
Step 2 Move the cursor down the drop-down menu to select
the Equipment option.
Step 3 The unit data window for the Rod Mill appears on the
screen, ready for you to enter the data listed above.
Note that there are already data in the window. These
data are typical values for a rod mill which have been
selected as default data for this unit. You will replace
these data with the values listed previously.
Note: Notice that there are more data elements than
will fit in the unit data window. As discussed
previously you can view the various groups of data by
left-clicking on the appropriate selectable tab.
Select tab to view

this data group
Step 4 First change the name of the Rod Mill to Rod Mills
No. 21,22,23 by clicking and dragging across the
existing name to highlight it, typing in the new name
and then pressing Enter. Note that the new name
appears in the title bar of the rod mill data window as
soon as you press Enter.
Step 5 Now change the number of parallel units to three by
double-clicking on the number in the cell labelled
Parallel and typing the number 3.
Step 6 Enter the data for the simulated and original mill in the
data cells with blue text which are visible under the tab
named Scaling. Left-click on a data cell to make it the
active cell and then use the arrow keys to move the
active cell as required.
Note: It is possible to overwrite any of the values that
appear in blue.

Step 7 Left-click on the tab named Selection function and

Calculated Data and type in the appropriate data from
the list.
Step 8 Click on the Simulation icon on the main JKSimMet
toolbar to bring the simulation window into view.
Step 9 Click on the Start button on the Run Simulation tab to
simulate the circuit.
Step 10 Check the results and save the file if you are happy with
the results.
Step 11 Print out equipment and port data as a base case for the
exercises in the next section.
3.7.10 Examining Data

Before we move on to the rod mill circuit exercises it is worthwhile
to summarise the techniques which are available to the user for
examining the large amount of data which exist in the flowsheet.
Equipment Unit The equipment and port data windows are the source of the most
And Port detailed data about these items. The user can have as many of these
Data Windows windows open on the JKSimMet desktop as he wishes. To make
the desktop less cluttered, use the Minimise button to close the
windows while allowing easy access to them. The windows will
return to their original size and position when the Maximise button
is clicked.
In port data windows, the user can choose which data types to
display (experimental, simulated etc.) by selecting the appropriate
item from the Data drop-down list. Similarly the user can choose to
view the size distribution data in one of three formats and can
choose the error format by selecting the required type from the
Format or Error drop-down lists respectively.
Quick Graph The Quick Graph feature provides a quick and easy method to
check for errors or discontinuities in sizing data by plotting a graph
of cumulative percent passing or cumulative percent retained vs.
size.
Tool window The JKSimMet tool window (Mass Balance, Model Fit or Simulate
window as appropriate) provides a summary of stream data showing
the results which have been calculated by running the balance, fit or
simulate tool.

Flowsheet print The flowsheet (streams and units) can be printed via the print icon.
Selecting Print Flowsheet from the file menu allows the flowsheet
to be printed or sent to the clipboard from where it can be pasted
into MSPaint for editing or to any clipboard aware application.
3.7.11 Rod Mill Circuit Exercises

It is apparent that a more realistic circuit can be made with some
further changes to the circuit data. These are:
• reduce the number of rod mills to one
• alter the % solids in two places to allow for an addition of water.
Single Rod Mill Reduce the number of rod mills from three to one. Add the finer
Exercise feed cyclone parameters and scale the new feed rate, ball mill size
and cyclones to suit one rod mill.
Step 1 Make the Rod Mill equipment data window the active
window.
Change Number Step 2 Change the number of rod mills to 1 and press Enter to
of Rod Mills register your change
Step 3 Position the cursor over the Water Feeder icon which is
connected to the rod mill feed port and right-click to
activate the drop-down menu.
Step 4 Move the cursor to select the Equipment option to bring
the Water Feeder unit data window into view.
Set Rod Mill Step 5 Left-click on the Model drop-down list and move the
Feed Density cursor to select the Water Feeder – Required % Solids
option
Step 6 In the Operating Conditions area of the data window
overtype the 'Required % solids' field with the new
value of 75.
Step 7 Press Enter to register your changes.
Step 8 Left-click on the flowsheet window to make it the

active window.
Step 9 Position the cursor over the Water Feeder icon which is
connected to the cyclone feed port and right-click to
activate the drop-down menu.
Set Cyclone Step 10 Repeat Steps 4 to 7 for the cyclone feed water addition,
Feed Density setting the required % solids to a new value (try 60).
Step 11 Simulate and examine the results.

Cyclone Feed Note that the cyclone feed and product are now MUCH finer than
Size Exercise before. This causes a problem with the simulation of the existing
circuit because the cyclone model is NOT valid for large variations
in feed size. A second set of cyclone model parameters is given
below for you to try out. As an exercise, enter the data into the
correct windows and run the simulation again. Examine the circuit
data to see how the different cyclone parameters affect the circuit
performance.
CYCLONE DATA FOR FLOWSHEET My RM-BM CYC
Data which can HYDROCYCLONE

be entered Model Nageswararao
Operating Variables
Number of Cyclones 3
Cyclone Diameter (m) .660
Inlet Diameter (m) .280
Vortex Finder Diameter (m) .300
Spigot (Apex) Diameter (m) .175
Cylinder Length (m) .487
Cone Angle (degrees) 15.0
Model Constants
KD0 (D50) .000104
KQ0 (Capacity) 595.5
KV1 (Volume Split) (m) 7.25
KW1 (Water Split) 9.57
alpha (Efficiency Curve) 2.01
beta (Efficiency Curve) 0.00
Calculated Calculated Data

During Water split to O/F (%) 80.93
Simulation Corrected D50 (mm) .2019
Operating Press. (kPa) 161.4
Additional Follow the same general sequence to:

Exercises
• scale the new feed rate to produce the same product size,
• adjust the size of the ball mill instead,
• check the effects of a new set of cyclone parameters,
• add a sump to the flowsheet,
and anything else that may be of interest to you.

For a quick summary of each, copy the Simulate tab to the
clipboard and paste each result summary in sequence into a suitable
spreadsheet for comparison of results.

Learning Simulation Learning JKSimMet
3.8 Learning Simulation

Simulation within JKSimMet V5.0 is controlled via its own
window (or tabbed dialogue). Which is accessed by clicking on the
Simulate icon on the JKSimMet tools toolbar
The Simulate window has three selectable tabs which provide

access to the three data areas in the window. These are:
• Control
• Select, and
• Run Simulation
The Control tab in the Simulate window
Control tab The Control tab allows the user to set the parameters for the
simulation. For the most part, the default values for the
parameters should be appropriate. However, for flowsheets with
very large flows, the convergence limit can be reduced to
increase the “accuracy” of what goes in equalling what comes
out.
A choice of spline or linear size interpolation is available. The

spline interpolation is well suited to grinding data while for
sharply classified size distributions (which sometimes occur in
crushing circuits), linear interpolation may be useful.

Learning JKSimMet Learning Simulation
Select tab This tool is a more general version of the select list used in the
Mbal module of Version 4. The standard operating condition
will be to select all equipment and streams. However, it is often
useful to work with a subset of the flowsheet. To do this, the user
defines a new select list as follows:
Step 1 Click on the New button to create a new select list. If

you wish, you may give the list a name by typing a
name into the Name text box. This name helps to
differentiate this list from the other lists.
Step 2 Select only the equipment and streams which are part
of the circuit of interest by placing a tick in the box
next to the name of each in the select list. Ensure that
all other select boxes are empty.
The Select tab in the Simulate window
For example, if you are working with a rod mill - ball mill circuit
and wish to simulate and fit the rod mill only, do the following:
• create a new list by clicking on the New button,

• select the feed, water addition and rod mill,
• select the connecting streams.
Now run the simulation or fit as required.
Using Subsets When working with a subset of a flowsheet which does not
of a Flowsheet contain a Feed unit, you must select the stream (or streams)
which is (or are) are the feed to your chosen sub-circuit.
Renaming In the Select list the stream names appear as Stream 1, Stream 2
Streams in the etc. rather than the descriptive names which are visible in the
Select list port data windows. If you wish to give a stream a more
meaningful name in the Select list, right click on its name and
select Rename from the pop-up menu which appears. Type the
new stream name into the text box and click on OK to confirm
the change. Note that these names are only used in the Select list.

Learning Simulation Learning JKSimMet
The Select tab in the Simulate window
Run Simulation This is the working tab which allows the user to start and stop a
simulation. It also provides a summary of port data for those
equipment ports which have been selected for inclusion in the
simulation.
The Run Simulation tab also displays the Convergence value and
the number of iterations which the simulation algorithm has gone
through. These values are updated while the simulation is
proceeding.
Configure the To configure the summary table on the Run Simulation tab, click
Run Simulation on each data column header in turn and select the required data
data summary from the drop-down list of port data which appears. If you want to
change the % Passing Size X or the X% Passing Size values, open
the Flowsheet Properties window (using the View option on the
JKSimMet main menu) and type in the desired value. You will
need to close and then reopen the Simulate tab to apply the new
% Passing Size values.
If you want to view the updated summary data values after each
iteration as the simulation is proceeding, ensure that the Simulation
Updates box on the Control tab has a tick in it. This feature allows
the user to check the data for unrealistic values (e.g. cyclone
underflow percent solids of 90%) and to stop the simulation if
necessary. If the Simulation Updates box is not ticked, the
summary data are not displayed until the simulation is complete
Exporting the The Copy to Clipboard button which is between the Start and Stop
simulation data buttons, copies the simulation data summary to the clipboard. This
summary feature can be used to easily compare several alternative
simulations by copying the data summary and then pasting it into a
clipboard compatible spreadsheet such as MS Excel for
comparison.

Learning JKSimMet Learning Graphing
3.9 Learning Graphing

About this The JKSimMet graphing module can plot graphs of simulation data
Section or other types of data, including some equipment related data, on
the computer screen or on the printer.
The data can either be plotted simply using the JKSimMet Quick
Graph feature to choose the appearance of the graph as in
section 3.6.4 or the full graphing facilities can be used to configure
the plot to the user’s requirements. This gives you the ability to
prepare sophisticated graphs suitable for publication and
presentation.
In this section you will follow a prepared example that will guide
you through the creation of a graph. The example is set up for
simulated sizing curves for all streams in the Example Ball Mill
Cyclone flowsheet.
The steps you will follow are:
• definition of the overall format of the graph including labelling
of axes, tick marks and so on,
• definition of the data sets to be plotted and of the method for
drawing curves,
• assembly of a graph from the definitions of data and format,
• note that while annotation of the graph is not available, an
automated legend facility has been added.
• production of the final graphs on the screen and printer.
Graph The Graph Definition window allows the user to define the format
Definition of the graph and to select which data sets are plotted on the graph,
using three selectable tabs to access the data fields.
Format tab Define the overall features of the whole graph,

including the titles to be used for the graph and
its axes, the ranges of the axes, scaling and
modification and the format of the number
labels on the graph axes.
Data tabs Define the sets of data values to be graphed,
their range, and the shape and colour of
symbols to be drawn at the data points.
JKSimMet can plot up to 15 data sets on a
single graph.

Learning Graphing Learning JKSimMet
It is a time consuming procedure to produce a final graph that looks

exactly right. You will discover that you may refine your original
definitions several times before you are satisfied. Reproducing
original definitions from scratch also takes time. The Format tab of
the Graph Definition window allows the user to set up a suite of
formats which can then be recalled and applied to any data set.
Types of Data Up to fifteen curves can be drawn on a single graph. The types
that can be of data that can be used to produce curves are:
Graphed
• Graphs of sizings of all raw and calculated data for the streams
on a flowsheet.
• Efficiency curves for the raw and calculated data for all the
classification devices on a flowsheet.
• Selected functions used in the mathematical models for all of
the equipment units in a project.
The Port Data and Equipment Data sections of the Graph

Definition window both contain fifteen columns, each of which
describes one curve. Thus the user can configure a named Graph
Data Set which plots up to fifteen items, either all port data, all
equipment data or a mixture of the two where this is appropriate.

3.9.1 Drawing a Graph

About this The aim of this tutorial example is to create a single graph of
Example calculated sizing data for the Example Ball Mill - Cyclone
flowsheet, and in the process, to learn a stepwise procedure for
using JKSimMet's graphing facilities.
The example proceeds through the following steps:

• identifying the data sets to be graphed, and defining the
representation of the data on the screen (Port Data tab)
• defining the appearance of the overall graph (Format tab)
• viewing the graph and progressively refining the layout
• display of the final graph.
• optionally, add a legend to the graph.
Before starting the graphing example, we suggest that you save the
Learner project under a new name, for example Graph Demo. This
will avoid corrupting the Learner Flowsheets file for future
JKSimMet learners.
Step 1 Open the project Learner flowsheets and load Example

Ball Mill - Cyclone flowsheet.
Step 2 Save the Learner project under a new name using the
Save As option under the File menu.
Step 3 Left-click the Generic Graph Config button on the
JKSimMet toolbar to bring into view the Graph
Definition window.
3.9.2 Defining the Graph Format

The Format tab on the Graph Definition window provides various
options for the user to define the overall appearance of the graph.
These include:
• labels for the graph and for the X and Y axes
• ranges, scaling and modification for the axes
• format of the numbers at the tick marks along the axes.
By creating named Format definitions users can save time when

creating graphs in the future by re-using these previously defined
graph formats.

Defining the For the tutorial example you will set up the graph format by
graph format following the instructions below:
Step 1 Left-click on the New Format button at the top, right

corner of the Graph Definition window, type the name
of your graph format into the Name box and press enter
to place the name into the Graph Format drop-down
list. We will use Cum % Passing as the name in our
example.
Labels Step 2 In the Labels section of the Format tab enter an

appropriate label for the Y-axis and press Enter.
Leaving this field blank means that no axis label is
required.
Step 3 Double-click on the Font button to set the format for

the text of the axis label. Repeat this step for the Font
Size.
Font and Font Size not available in version 5.1.
Step 4 Repeat Steps 2 and 3 of this section for the X-axis label
and for the graph title.
Axes and Data Within the Axes and Data Interpretation area of the Format tab do
Interpretation the following:
Range Step 5 In the columns marked Min and Max type in the
minimum and maximum data values required for the
graph axes (i.e. the range) for both the X-axis and
Y-axis. The values are .01 and 100 for the X-axis and 0
and 100 for the Y-axis.
Scale Factor Step 6 Set the scale factor as required; 1 is the usual value and
this is used for our example.
Plotting Scale Step 7 Double-click in the Plot Style cell to view the drop-
down list and select the required axis format from the
list. In this case select Logarithmic for the X-axis and
Linear for the Y-axis.
Grid On Step 8 If gridlines are required for the X-axis or Y-axis place a
tick in the appropriate box in the Grid On column.
Number Step 9 Move the highlight to the number format column and
Formats double-click to view the available options on the
drop-down list. Select the required format from the list.
In the tutorial example use Decimal for both the X-axis
and Y-axis.

The Format tab should now look like the example below.
Having defined the graph format you are now ready to define which
data are plotted on the graph.
3.9.3 Definition of the Data to be Graphed

About this The next step in creating a graph is to identify the data which are to
Section be plotted and to define how the line and points which represent the
data are to appear. This is done through the Port Data and
Equipment Data tab sections of the Graph Definition window.
This section requires you to specify:
• the data set to be graphed (this is done by choosing the item type
and then selecting one item from a list of those available),
• the range of data to be graphed, that is the minimum and
maximum values that are to appear,

• the curve characteristics in terms of
- interpolation method between points
- solid line or no line between points
- character used to represent each point.
Each definition of a data set to be plotted on a graph is named by

the user and can be recalled and re-used within JKSimMet.
Note that the items which can be plotted on a graph include

equipment unit data such as classifier efficiency curves, ball mill
appearance functions, as well as the size distribution of the streams.
In our tutorial example, we will plot size distribution data for the
ports.
Invoking Data Step 1 Select the Port Data tab at the top of the Graph
Definition Definition window.
Step 2 To define a new data set, left-click on the button

marked New, then type the name of your data set into
the Name box and press Enter.
Item Selection Step 3 Position the cursor in column 1 of the row labelled Port
and double-click (or left-click and then press Enter) to
view the drop-down list of port names. Move the
highlight to the port data which you want to plot and
double-click to select it.
Step 4 Once a port name is selected for plotting JKSimMet

will enter a range of default values for the plotting
format. The user can edit these as required.
Step 5 Move the highlight to the Format row and double-click.

This brings into view the drop-down list of available
graph plotting formats. Select the Format option from
the drop-down list.
For the tutorial example select the Cum % Passing

option.

Data Type Step 6 Move the highlight to the Data row and double-click to
view the drop-down list of data options.
Select simulated data (Sim) for this plot.
Graphical Note that you can have either a point or a line to represent a data
Representation set. It is not necessary to have both. When a single data type has
been chosen for plotting (e.g. Exp or Fit) both the line and point
marker represent this data. However, when the paired data types
have been chosen for plotting (e.g. Exp & Sim, Exp & Fit or Exp &
Bal) the point markers represent the experimental data and the line
represents the second item of the data pair (Fit, Sim or Bal as
appropriate). This feature is useful for comparing the calculated
data with the experimental data.
Line Type Step 7 Position the highlight over the appropriate cell in the
Line row, and double-click to view the list of available
line types.
Select the required option from the Line drop-down list

displayed, and press ENTER.
Symbol at Points Step 8 Move to the Point row and double click to view the list
of symbols which can be used to represent the data
points. This defines the symbol that is displayed to
mark the coordinate points on each curve within the
graph.

Select the required symbol from the list.
Colour Step 9 Move to the Colour row and double click to view the
list of colours which can be used to represent the data
points and lines. Select the required colour from the
list.
Spline Step 10 The user can choose to use spline interpolation for the
Interpolation curve which is drawn for each data set. To use spline
interpolation left click on the spline box to place a tick
in it.
Graph Over Step 11 Move the highlight to Min and Max rows and set the
Range minimum and maximum plotting range values (on the
x-axis) for each curve as required.
Steps 3 to 11 can be repeated to select up to 14

additional data sets to be drawn on the same graph.
3.9.4 Easy Manipulation of the Graphing

Features
Now that you have a general understanding of the function and
operation of the data and format definitions, it is easier to
understand that the production of a quality graph may require
several iterations to refine the appearance of the graph by adjusting
settings through the format and data definitions.
The typical procedure for fine-tuning graphs is:

• set up a format definition,
• display the graph defined by the data and format definitions
already completed in section 3.8.2 (Defining the Graph Format)
and section 3.8.3 (Definition of the Data to be Graphed),
• change the format definition items which are not to your
satisfaction,
• display the graph again,
• repeat this define and display sequence until you are satisfied
with the appearance of the graph.
Step 1 Click on the Generic Graph Config icon on the main

JKSimMet toolbar to bring the Graph Definition
window into view.

Step 2 Click on the View/Refresh Graph button. JKSimMet

will display the graph defined by the data and format
definitions built earlier. Note that you can change the
size of the graph window to make it easier to see the
graph. Your graph should look similar to the one shown
below.
Step 3 Use the Display X Axis Grid and Display X Axis Grid
buttons on the graph window to add or remove
gridlines. Similarly the legend can be added or removed
by clicking on the Display Legend button on the graph
window. Note that the position of the legend cannot be
changed.
Step 3 Return to the Graph Definition window by clicking on
the Edit Graph Definition button on the graph window.
Select the Format tab and change the label settings.
Step 4 Click on the View/Refresh Graph button to view the
adjusted graph.
This procedure can be repeated until you are satisfied with the
resulting graph.
3.9.5 Saving the Session

Saving the data It is often a good idea to save the project during graphing, in case
something untoward happens to all that information you have just
entered.

3.9.6 Graphing Limitations

One Data Source A graph can contain data from only one flowsheet (the current
Limitation flowsheet). However, you can set up a dummy circuit on a
flowsheet and import key results (such as a product size
distributions) from several other flowsheets. The dummy circuit
can just consist of the equipment units to whose ports the required
streams are attached.
Note also that a single flowsheet may contain many independent
simulation circuits.
3.9.7 Graphing Related Problems

If there are any problems an error message will appear on the
screen. There are three levels of problems - refer to section 4.18
(Errors) if you are not familiar with them.

Learning JKSimMet Learning Overview
3.10 Learning Overview

About The JKSimMet overview module provides a flexible and powerful
Overview tool for users to summarise, review and report results of mass
balancing, model fitting and simulation work.
The overview screen is fully configurable by the user, and can
detail data attributes (e.g. volumetric flowrate) for any or all of the
streams on a flowsheet. There is no limit on the number of
overviews which can be created by the user for a particular
flowsheet. One useful aspect of the overview facility is the ability
to create any number of overview displays and to have more than
one overview window open on the JKSimMet desktop at any time.
These overviews can be readily printed, and so provide the ideal
means to produce results in a format suitable for reports or
presentations.
In this section, you are guided through the procedure to set up a
new overview display. The example is for display of simulation
data in the Example Ball Mill-Cyclone simulation. The steps you
will follow are:
• creation of a new overview display
• selection of streams
• selection of data to be displayed
• selection of type of data to be displayed
• display recovery and stream data values
• printing the new overview.
Create a New Step 1 Left-click on the Overview Config button on the main
Overview JKSimMet toolbar to bring an overview window into
view. As you can see, the overview window opens with
the default setting which displays four columns of data
for all of the streams in the current flowsheet.
New Overview Delete Overview

Select List button Select List button

Learning Overview Learning JKSimMet
Step 2 Left-click on the New Overview Select List icon at the

top of the overview window to create a new overview
list.
Step 3 Highlight the default name in the Name text box, type
in a new name for your overview (Summary No.2 is
used in the example) and press Enter. Your chosen
overview name will now appear in the drop-down list at
the top, left corner of the overview window. Also note
that the name of the current overview selection appears
in the title bar of the overview window.
Deleting Step 4 The user can remove streams from the overview list by
Streams from simply placing the cursor anywhere in the appropriate
the Overview row and then clicking on the Delete Row icon to
delete the row. In this example, remove the last stream
from the list (Cyc Feed Water Add).
Change column Step 5 If a column is too narrow for you to read the text in it,
and window size place the cursor over the right border line in the title
cell at the top of the column and click and drag the
column border to the required width. If the Overview
window is too small to view all of the data, click and
drag the bottom, right corner of the window to change
the window size as required.
Adding Streams Step 6 If you want to add a stream to the list (for example if
to the Overview you delete a stream by mistake) click on the Insert Row
icon to add a new row to the bottom of the overview
list.
Step 7 In this new row, place the cursor on the cell in the
Equipment column and press Enter to view a drop-
down list of the equipment units in the flowsheet.
Select the equipment unit to which the required stream
is connected and press Enter to place your selection in
the cell.
Step 8 Move the cursor to the Port column and press Enter to
view a list of ports associated with the equipment unit.
Select the name of the port by which the required
stream enters or leaves the equipment unit.
Selecting Stream You will now select the stream data to be displayed in the
Data for Display overview.

Step 9 Place the highlight in the title cell at the top of the
column whose data you wish to change. Press Enter to
view a drop-down list of the types of stream data which
are available for display. Select the type of data you
want to include in the overview and press Enter to
place this choice in the table. In this example, select
TPH Solids for the first column.
Note that if you are using Mass Balance and have entered
component data you may select Components from the list of data to
be displayed in the overview. If you choose Components as the
type of data to be displayed, you must then select the component
you want displayed from your list of components. This is done by
selecting the required component from a drop-down list which
becomes available in the cell below the title cell in the Components
column. This second row of the data selection cells is blank if any
other type of data is selected for display.
Select Data Type Step 10 To select the data type place the highlight in the title
cell in the third cell down from the top of the column
whose data you wish to change. Press Enter to view a
drop-down list of the types of data which can be
displayed, including Experimental data, the various
forms of calculated data and data SDs. Select the type
of data you want to include in the overview and press
Enter to place this choice in the table. In this example,
select Sim (simulated data) for the first column.
The other options - Experimental, Standard Deviation, and Error,

are very useful for model fitting and mass balancing.

Learning Overview Learning JKSimMet
As an exercise, set up the overview as shown below. Note that this

window and some of the columns have been resized (as described
previously) to make it easier to see all of the data.
Clearing a To clear display data from a column, place the highlight on the top
Column cell in the column to be cleared, press ENTER to view the drop-
down list and select None.
Displaying A useful feature of the overview facility is the ability to switch

Recovery between actual data and recovery information.
Information
To view the recovery data, place a tick in the box labelled
Recovery by left-clicking on the box. The overview window will
now display stream data as a percentage of the stream chosen for
the recovery basis, in this case, MILL FEED.
The stream used for the recovery basis can be selected by placing
the cursor over the name of the stream in the overview list and
right-clicking. A pop-up window will ask you whether you want to
make the selected stream the reference for the recovery

calculations. Click on Yes to make the stream the basis for the
recovery calculations. Note that this stream is now listed in bold
text in the overview table to denote that all recoveries are
calculated with respect to this stream.
Printing To print the overview display follow these steps:

Overview
Step 1 With the Overview window as the active window, click
on the Print Preview button on the overview window.
This brings into view the Print Preview window.
Step 2 If necessary, change the orientation of the page to fit

the overview data table by selecting the appropriate
choice from the Orientation drop-down list.
Step 3 When the preview is to your satisfaction, click on the

Print button at the top, right-hand corner of the Print
Preview window to print it.
Exporting You may transfer an overview to the clipboard using the Copy to
overview data Clipboard and Copy Grid to Clipboard icons on the overview
window. The Copy to Clipboard icon copies only the data cells
selected by the user to the clipboard while the Copy Grid to
Clipboard copies the title cells and all of the data cells to the
clipboard.
Alternatively, the overview data can be exported to the clipboard in

its printed format (as shown in the Print Preview window) via the
Copy to Clipboard button in the Print Preview window. Other
buttons in the Print Preview window allow the user to save the
printed form of the overview table as a tab-delimited, comma-
delimited or text file.

Learning to use Report Learning JKSimMet
3.11 Learning to use Report

About The JKSimMet Report feature provides a flexible tool for users to
Report print the results of mass-balancing, model fitting and simulation
work.
The printed report is fully configurable by the user, and can present
selected data for any or all of the ports or equipment on a flowsheet.
There is no limit on the number of reports which can be created by
the user for each flowsheet. One useful aspect of the report tool is
the ability to create any number of report configurations which can
be used to generate printed outputs as required.
Each report can be readily viewed in a print preview window and
then printed and thus provides the ideal mechanism for producing
results in a format suitable for reports or presentations. The data in
the reports can also be exported from JKSimMet in a range of
formats (e.g. tab-delimited or comma-delimited text files) using the
options available in the report Print Preview window.
In this section, you are guided through the procedure to set up a
new report configuration. The example is for printing a selection
of simulation data in the Example Ball Mill-Cyclone simulation.
The steps you will follow are:
• selection of port and equipment data for the report
• selection of data types to be printed
• viewing the report via the print preview feature
• printing the report.
Create a New Step 1 Left-click on the Report button on the main JKSimMet
Report toolbar to bring the Report window into view. As you
can see there is a default set of selections made for the
report.
Name of Create New

current report Report button

Learning JKSimMet Learning to use Report
Step 2 To create a new report configuration click on the Create

New Report button in the Report window. This brings
into view a grid which lists all of the ports and
equipment items on the current flowsheet. Note that
none of the items in the grid are currently selected.
Select All Items Unselect All

button Items button
Step 3 To name the new report format double-click in the

Name box to highlight the default name of the report
configuration and then type in a new name for the
report (the name Cyclone Data will be used here). Press
Enter to confirm the name change.
Selecting Data Step 4 Select whether the report will print port data only or
for the Report equipment data only or both port and equipment data
by selecting the appropriate choice on the Print What
drop-down list. In this case choose the option Both.
Step 5 Select the equipment and port items whose data you
want to be printed in this report by clicking on the box
next to the name of each to place a tick in the box. If
you place a tick in the wrong box simply click on it
again to delete the tick. Note that each equipment item
and each port can be selected individually. For our
example, select the Cyclone and Cyclone Feed Water
Add equipment data and the Primary Mill product and
Cyclone combiner, overflow and underflow port data
for inclusion in the report.
Note that a Select All Items and an Unselect All Items

buttons have been provided on the Report window
toolbar to help users in selecting data for the report.

Selecting Data Step 6 Next select the type of data to be listed in the report by
Types for the placing a tick in the box next to the name of the
Report required data types in the Data types to print area of the
Report window. In this case only tick the simulated
data (Sim) box.
Selecting Error Step 7 When working on fitting or mass-balancing data, the

data for inclusion user can choose to include the data error in a report by
in a report placing a tick in the Error box in the Error Type area of
the Report window. The user can then select from the
adjacent drop-down list the particular error that is to be
included in the report. In this case the error is not
relevant so leave the Error box clear.
Selecting Port Step 8 If you have included port data in your selected items, as
data is the case here, you can choose to print the Totals data
and/or the size distribution data for the ports by placing
a tick in the appropriate boxes in the Port data to print
area of the Report window. Note that if Component
data have been entered, these can also be selected for
inclusion in the report here.
The Report window should now look like the picture shown below.
Previewing a Step 9 Once you have configured the report to your

report printout satisfaction, click on the Print Preview button to view
the report as it will be printed.
Step 10 The Print Preview window opens at Page 1 of the

printout with the Zoom setting at 25% of normal size.
Change the Zoom setting to 100% by selecting this
value from the Zoom drop-down list and also resize the
Print Preview window to view the entire page width.

Step 11 Use the Next Page and Previous Page buttons on the
Print Preview window toolbar to view all of the pages
in the report and check that they show the required
data.
Printing the Step 12 To print the report simply click on the Print button on
report the Print Preview window toolbar. Alternatively the
report can be printed directly from the Report window
by clicking on the Print button on that window’s
toolbar.
Preparing a The Report window has a box marked Summary.

Summary report When this box is ticked, the Report feature uses a
summary mode to present the port and equipment data
in the printed report in a different format. The user can
choose to use whichever mode suits their requirements.
In the case of the port data, Summary mode prints all of

the data of a given type (e.g. Experimental) for all ports
in one table. Each data type selected is printed as a
separate table, with all ports listed in each table. This
compares with the normal report mode which prints the
data for each stream on a separate page, with all data
types for each stream being listed on this one page for
each stream.
This difference between the Summary and normal

mode is illustrated in the Print Preview windows shown
below.

Print Preview Window showing Summary report data format
Print Preview Window showing normal report data format

Exporting data A useful feature of the Report Print Preview window is the ability
using Report to export data in report form from the simulator in a variety of
formats. Four buttons on the Print Preview window toolbar
provide the following data export features:
Copy data to Clipboard for pasting into other applications.
Save the data as a tab-delimited file (suitable for importing into a

spreadsheet such as MS Excel).
Saves the data as a comma-delimited file (suitable for importing

into a spreadsheet such as MS Excel or a word processing
application such as MS Word).
Saves the data as a text file.
These data export options allow the user to transfer data to other
applications for preparation of presentations and reports.

Summary Learning JKSimMet
3.12 Summary
By working through this section on Learning JKSimMet, you have
learned to:
• run a supplied demonstration simulation
• display and/or print the results of simulations
• change some of the simulation data
• re-simulate
• build your own flowsheet, import some of its data from a
previous circuit and input new data.
You have also learnt how to plot graphs from the simulation
results.
In this way, you have learnt all the basic techniques necessary to
use JKSimMet. Additional advanced techniques for model-fitting
and for the maintenance of your system are covered in subsequent
sections.

JKSimMet Reference Using JKSimMet
CHAPTER 4
JKSimMet----
REFERENCE

Using JKSimMet JKSimMet Reference
4. USING JKSimMet
Contents of This chapter covers all the basic operational features of JKSimMet.
this Section While Chapter 3 is a tutorial, Chapter 4 is structured as a reference
section. Section 4.1 (JKSimMet Description) contains an overview
of JKSimMet. Section 4.2 contains some important definitions of
key terms. Section 4.4 (Menus and Toolbars) describes the
operating structure and its conventions while Section 4.5 describes
the various types of windows used to display information in
JKSimMet.
Sections 4.6 to 4.8 contain the information on building and

annotating a circuit flowsheet. Sections 4.8 to 4.11 discuss the
options available for presenting data by graphing and summary
tables.
4.1 JKSimMet Description

About the JKSimMet is a computer software package designed to facilitate
Package the simulation of mineral processing plant operations. Its
development follows 30 years experience in the modelling and
simulation of minerals processing at the Julius Kruttschnitt Mineral
Research Centre.
JKSimMet is designed for use by mineral processing engineers who

may not be skilled in either computing or modelling. It enhances
an engineer's capability to design and simulate all aspects of
crushing and grinding circuits, including classification stages.
JKSimMet allows engineers to:
• design a circuit on the computer screen
• enter model and plant data
• fit model parameters to that data
• run a simulation of the circuit
• present the data and results as flowsheets, text or graphs to print
or export to file or to the clipboard..
Version 5 of JKSimMet is a user-friendly system which uses the

MS Windows interface, with features such as switching between
applications, import and export of data and figures via copy and
paste functions and drop-down menus for quick editing and data
manipulation now available to the user. In this version there is a
common structure for all of the analysis tools (simulate, model fit
and mass balance) and the engineer uses the same flowsheet and
follows the same data entry procedures for all of the analysis
modes.

4.1.1 JKSimMet Simulation Technique

Process Models JKSimMet performs steady state simulation of a range of
comminution and classification operations. Units for which
process models are available in JKSimMet include:
• Stockpile • Rod mill

• Bin • Ball mill
• Pump sump • Ball mill (air swept)
• Sump • Screen, one deck
• Splitter • DSM screen
• Gyratory crusher • Hydrocyclone
• Two rolls crusher • Spiral classifier
• Jaw crusher • Rake classifier
• Autogenous mill • O-Sepa classifier
• SAG mill • General air classifier
• HPGR • Simple Degradation
Model These units may be combined in both simple and complex

Descriptions flowsheet circuits to enable the engineer to simulate the operations
of plants or subsections of plants. Simulations may be controlled
through the specification of model parameters, the selection of
necessary process mathematical models, and the specification of
operating data such as sizings and equipment sizes.
The algorithms for each model are outlined in Appendix A.
4.1.2 JKSimMet Capabilities

Simulation In addition to the simulation capabilities discussed above,
Capabilities JKSimMet encompasses all the functions necessary for the
engineer to use and maintain a number of data sets.
JKSimMet provides process engineers and metallurgists with a

powerful tool for conceptual design, tuning and monitoring process
plants and their elemental circuits and units. It enables an almost
infinite number and variety of circuit designs to be simulated so
that the optimal design for the task and expected range of variation
of input and flow conditions may be arrived at, or at least
approximated, before expensive experiments with real plant are
undertaken. Once operating, a plant can be modelled with
JKSimMet to allow monitoring and fine tuning functions to be
undertaken on an ongoing basis without interruption of the
production.
With the model-fitting tool the JKSimMet models can also be
tuned to more specific user operating conditions; such that the
simulation can more nearly approximate real plant conditions.
Having said all this, however, JKSimMet does not and cannot

Using JKSimMet JKSimMet Reference
replace the process engineer. It facilitates the simulation of circuit
and plant designs; it does not design. Like any tool, the standard of
the work that it does is, in the final analysis, directly related to the
skill of the craftsman that uses it.
4.1.3 JKSimMet Constraints

System While JKSimMet is a powerful and flexible system there are,
Constraints necessarily, some constraints. These are:
Size distribution There is a maximum of 30 size fractions in
the size distribution for any one stream.
Number of There is no defined limit to the number of

Flowsheets flowsheets which may be included in a
project. However, the database will become
very large and may cause slower systems to
slow down perceptibly.
Model Fitting In Version 5

Constraints • only one flowsheet can be simulated or
fitted at a time.
• up to 10 primary parameters (masters)
may be selected
• a further 10 can be “slaved” to each
primary parameter.
• up to 10 ports and 10 pieces of
equipment can be selected to provide an
objective function for model fitting.
Note: The database structure introduced in

Version 5 will allow for a substantial
increase in these capabilities in future
releases.
Number and For a list of the available models refer to

Type of Models section 4.1.1 (JKSimMet Simulation
Technique). The user can add new models
with the optional software developers kit
(see section 4.1.4). However, JKTech
welcomes suggested new models which will
be considered for subsequent releases of
JKSimMet. JKTech can also develop
custom models for an individual client.
Mass Balancing The JKMBal algorithm can process up to 50

ports with data and 30 pieces of equipment.

4.1.4 JKSimMet Expandability

Package JKSimMet is a self-contained package providing within itself all
Expandability the features required to build, execute and maintain a library of data
sets.
JKSimMet is supplied with process models for those units listed in

section 4.1.1 (JKSimMet Simulation Technique). While these
models cover many of the typical processes encountered in
comminution processing, JKSimMet has been designed to facilitate
the incorporation of new models. While the user cannot add new
models to the system, recommendations to JKTech will be
considered for inclusion in later releases. The user can, however,
through the use of model-fitting, modify the models currently in the
system by, for example, setting new regression equation constants.
For sophisticated users a software developers kit (SDK) is available

as an option. Use of the SDK requires knowledge of a suitable
computer language such as MS C, or PowerStation FORTRAN.
The SDK includes an editor which allows user-designed model
tabbed dialogs to be added to JKSimMet.
Additional multi-component modules are planned. These will be

add ons at additional cost.

Definition of Terms JKSimMet Reference
4.2 Definition of Terms used in JKSimMet

JKSimMet A number of the terms and names used within the JKSimMet
Components system have a specific meaning which it is important to understand.
These terms are defined here to avoid ambiguity.
Project JKSimMet is organised and based upon the

concept of a project. A project can be
considered as a portfolio in which the user
stores one or more flowsheets and their
related data.
Flowsheet A flowsheet consists of one or many process

circuit diagrams and related data. The
flowsheet may contain one item of process
equipment or many. Complex multi-stage
circuits or many circuits in parallel are
acceptable. The generalised select tool
allows these to be considered one at a time
or together.
Equipment The process equipment is a component of

the circuit. Each equipment item consists
of:
• an icon on the flowsheet diagram
• a data window which details the process
model and its model parameters.
Ports A port is a model of a flow of solids and/or

water into or out of an item of equipment.
Each equipment unit has one input port to
which up to three input connectors can be
attached and one, two or three output ports,
depending on the particular type of
equipment. Only one connector can be
attached to each output port. For the models
in JKSimMet, the stream characteristics of
interest are density, size distribution and
solids and water flow rates. A port consists
of:
• an input or output port attached to an
equipment unit on the flowsheet
• a data window which contains the port
data (solids and water flows, size
distribution and assays (as appropriate).

JKSimMet Reference JKSimMet Cursor
4.3 The JKSimMet Cursor
The cursor which indicates your position on the screen takes several forms in
JKSimMet, depending on what operation the user is performing.
The arrowhead This shape is the usual form of the cursor for pointing in all
cursor JKSimMet data windows, graph windows etc.
The Arrowhead The arrowhead cursor with crosshairs appears when the cursor is
with crosshair positioned over an equipment unit on the flowsheet. The change in
cursor shape of the cursor indicates that the user can either move the
equipment unit by left-clicking and dragging it on the flowsheet or
can access the drop-down menu for that unit by clicking the right-
hand mouse button. Note that equipment cannot be moved if the
flowsheet is locked (see 4.4)
The spanner The arrowhead cursor changes to the spanner in hand cursor when
cursor it is positioned over a feed or product port to which a stream can be
connected. The orientation of the spanner and the word next to it
changes to guide the user during the stream connection process.
Note that if a port already has its maximum number of streams
connected, the cursor will not change to the spanner when it is
positioned over the port connection point.
If you decide not to continue with a stream connection, press

escape to return to the arrow cursor.

The JKSimMet Interface JKSimMet Reference
4.4 The JKSimMet Menus and Toolbars

JKSimMet V5 has been developed to run under the
MS Windows 95/98/ME/NT/2000/XP operating systems and
makes use of the windows interface to provide easy and flexible
access to the large amount of data stored in the JKSimMet
software. A typical JKSimMet screen is shown below with various
components of the screen labelled.
Main Balance-ModelFit- Functions

Menu Simulate toolbar toolbar
Status bar Session window
The various components of the JKSimMet menus and toolbars are

described in detail in the following section and also in the
comprehensive JKSimMet online help system.

JKSimMet Reference The JKSimMet Interface
4.4.1 The Main JKSimMet Menu

The Main Menu of the JKSimMet interface follows the standard
Windows menu layout, with a selection of drop-down submenus
which allow the user to access a range of commands. Each
submenu is accessed by clicking on the appropriate word on the
Main menu bar.
The File submenu New opens the Project View window so that the user can load a
new project.
Open opens the Project View window so that the user can load a
project.
Close shuts the current Project. Opening a second (or a new)
project also closes the current project after offering an option to
Save the current project.
Save saves the flowsheet and all the data associated with the units
and streams as a data file. These data files are managed
automatically by JKSimMet.
Save As allow the user to save a copy of the current project under a
new name and/or in a new directory. The default file name
extension is .jksm5.
Print displays a Print Preview window of the active window,
allowing the user to print the active window if required.
Printer Setup allows the user to select a printer and specify the
number of copies printed etc. in the standard way.
Print Preview allows the selected window to be displayed on
screen as it would appear in the printed version. An option to copy
the printed format to the clipboard is also offered by most print
preview screens.
Print Flowsheet provides options for the user to print the
flowsheet to file or the clipboard in colour or monochrome.
Exit closes JKSimMet. The user is prompted to save the current
project if the project has not been saved recently.
4.4.2 The Functions Toolbar

Many of the functions which are available in the drop-down menus
of the main JKSimMet menu can be accessed via the icon buttons
on the Functions Toolbar.
Note that, if required, this toolbar can be moved to a more

convenient place on the screen by simply clicking and dragging it.
Similarly, the shape of the toolbar can be adjusted to your personal
preference by dragging its edge.
The buttons on the menu perform the following tasks:

The JKSimMet Interface JKSimMet Reference
The first five buttons on the Functions toolbar provide shortcuts to
the standard New, File Open, Project Open, Save and Print options
which also appear in the File menu of the main JKSimMet menu.
These buttons open the Project Definition window and Flowsheet

Definition window respectively. These windows allow users to
enter names and descriptions of the active project and active
flowsheet.
The Information Block Configuration button brings into view the

Configure/Assign Information Blocks and Labels window. This
provides several options for displaying data and information on the
flowsheet and is discussed in more detail in section 4.8.
The Generic Graph Config button is a shortcut to bring the Graph

Definition window into view. This window, which allows the user
to configure a graph to their own requirements, is discussed in
detail in section 4.9.
Clicking on the Overview Config button opens a new Overview

window which the user can configure to display a range of port
data from the current flowsheet. More than one overview window
can be open at a time. The configuration procedure is described
later.
The Report button is a shortcut to bring into view the Report

window. This window provides the facility to select any of the port
and equipment data for printing (see section 4.12)
As its name suggests, the Toggle Tool Bar button toggles the
JKSimMet Tool toolbar on and off (i.e. makes it visible or not).
The Run button allows the user to run Simulate or Model Fit or
Mass Balance – whichever is currently active. If none is active, the
button has no effect.
The Lock the Flowsheet button does just that, locking the
flowsheet and preventing items on the flowsheet from being
accidentally moved while trying to access data on the flowsheet.
This is particularly useful when large, detailed flowsheets are being
used as it minimises the time spent waiting for the screen to be
redrawn if the user accidentally moves one item of equipment.
Users can still change data while the flowsheet is locked. While the
flowsheet is locked, double clicking on a piece of equipment will
open its window.
The Flowsheet Size drop-down list allows the user to set the size of
the flowsheet at 1x1 or 2x2 panels, depending on the users
requirements.

JKSimMet Reference The JKSimMet Interface
4.4.3 The JKSimMet Tools Toolbar

The JKSimMet tools toolbar allows the user to select which of the
three available JKSimMet tools is to be used for analysis of the
data.
To select mass balance, model fit or simulate mode, simply click

on the appropriate button. Note that these buttons toggle from on
to off. Pressing another button (or the same one twice) will close
the current tool.
The Run Mass Balance button brings the Mass Balance window
into view. This window allows the user to select equipment and
ports to be included in the mass balancing procedure. (Mass
balancing is discussed in detail in Chapter 6).
The Run Model Fit button brings the Model Fit window into view.
This window allows the user to select equipment and ports from
the flowsheet to be included in the model fitting procedure. For
detailed information about the model fitting tool see Chapter 5.
The Run Simulation button brings the Simulate window into view.
This window allows the user to select equipment and ports to be
included in the simulation procedure. The simulation tool is
discussed in more detail in section 3.8.

JKSimMet Windows JKSimMet Reference
4.5 JKSimMet Windows

Version 5 of JKSimMet makes full use of the windows interface to
allow users to view whichever data they choose on the screen at
any one time by simply opening the required windows. This
section describes briefly each of the main window types which
make up the JKSimMet interface.
4.5.1 The Session Window

The session window is the driving seat of JKSimMet. In this
window the user creates the flowsheets for analysis with the mass
balance, model fit or simulate tools.
After starting the JKSimMet program a blank session window is
visible on the JKSimMet desktop, as shown below.
The Session Window at JKSimMet Startup
The user has two options at this point – to create a new project or to
load an existing (i.e. previously saved) project. To do either, the
user must first bring the Project View window into view by
clicking on the Open Project icon on the toolbar.
To create a new project the user drags the Default Project on the
New tab of the Project View window onto the session window.
This loads a blank project in which the user can create one or more
flowsheets, using the equipment from the Default Equipment file
on the New tab of the Project View window or existing equipment
from project listed on the Saved tab. The procedure for creating a
flowsheet will be discussed in more detail in the following sections.

JKSimMet Reference JKSimMet Windows
Alternatively, the user can load a previously saved project from the
list which is visible on the Saved tab of the Project View window.
This will also be covered in more detail in the following sections.
Once a blank project or an existing project has been loaded in the
session window the JKSimMet Toolbar is available, giving access
to the mass balancing, model fit and simulate tools. Note that the
toolbars can be moved and resized as required by the user.
The Session Window after a Project has been Loaded

4.5.2 The Project View Window

The Project View window gives the user access to previously saved
projects, to the Default Project (a blank project) and also to the list
of all of the equipment units which are available for use when
adding equipment to a flowsheet.
The default equipment list is shown in the picture of the Project
View window below. Individual equipment units are accessed by
double clicking on the Default Equipment book on the New tab and
then on the appropriate book which contains the unit you are
seeking. Once the required equipment unit icon is visible, the user
can drag the icon onto the flowsheet in the session window in order
to add it to the circuit. (Note that the Default Equipment is not
available until a project has been loaded into the session window.)
Previously saved projects can be accessed by clicking on the Saved

tab to view a list of all of these projects. If the required project has
been saved in another directory (other than the default directory
C:\Program Files\JKSimMet V5.1\User) the Browse Directories
button allows the user to make this directory the active one and to
view its list of files in the Saved tab. Note that when the Saved tab
is selected, the current directory name appears at the bottom of the
Project View window. Also, only files whose name includes the
.jksm5 extension will appear in lists in the Project View window.
To make a saved project the active project, simply drag the required
project from the Project View window to the session window. If a
project is already loaded in the session window, JKSimMet will
warn you that loading this project will overwrite the current project.

JKSimMet Reference JKSimMet Windows
4.5.3 Equipment Data Windows

The data for each equipment unit can be viewed in the Equipment data
window. The equipment data window for each unit is accessed by
placing the cursor over the equipment unit on the flowsheet and right-
clicking to view the drop-down menu. Selecting the word Equipment
on the drop-down menu brings the equipment data window into view.
User-defined name Number of Names of ports

for unit (also used parallel units attached to this
in window title bar) equipment unit
Buttons to
print data
Model type
selected from
drop-down list
Buttons to
copy and
paste data
Data area of the window (the actual Selectable tabs give

contents and format varies according to access to the various
equipment type and model selected). data types for the unit
Alternatively, when the flowsheet is locked, double-clicking on the

equipment icon brings the equipment data window into view. Once
the window is open the user can view or edit the equipment data as
required.
Note that while the contents and format of the data area of the window
varies between equipment types and also the model chosen, the
general layout of the window (Name text box, Model list etc.) is
common to all equipment units. The data layouts for all of the
equipment and model types are detailed in Appendix A.
Click on a port name to open its data window.
Hint: If you wish to see the information on all tabs in the data window
at once, click on the printer icon on the tool bar to activate Print
Preview.

4.5.4 Port Data Windows

The data for each port can be accessed in the port data window.
The port data windows can be opened by two methods; the first
option, if the relevant equipment data window is open, is to click
on the port name at the top, right-hand corner of this window. The
second route is to select the port name from the drop-down menu
which appears when the user right-clicks on the flowsheet icon of
the unit to which the port is attached.
Drop-down list Drop-down list to Drop-down list to

for selecting size select type of data select type of error
distribution data to be displayed. to be displayed.
format.
Button to open Set

SDs pop-up window
for defining data
standard deviations.
Buttons to
copy and
paste data.
Selectable tabs to
access the mass flow,
sizing and assay data
associated with the
port.
The layout of the port data window is the same for all ports. Note
that the name of the port shown in the window title bar is defined
by JKSimMet, based on the name of the unit to which the port is
attached and the appropriate name for the port according to its
location on the equipment unit (eg. feed, underflow or overflow for
cyclones or feed and product for ball mills). In the example above,
the data window belongs to the Underflow port of the Primary
Cyclones, so its name is Primary Cyclones Underflow.
The data contained in the port data window are discussed in detail
in Section 4.7.4 on entering data.

JKSimMet Reference Building and Manipulating a Flowsheet
4.6 Building and Manipulating a

Flowsheet
In JKSimMet V5 each flowsheet is stored as a sub-unit of a project.
Therefore, to work with an existing flowsheet the user must first
load the appropriate project into the session window or
alternatively, to set up a new flowsheet the user must first load the
blank Default Project into the session window.
4.6.1 Loading a Project

The first step in working with a flowsheet is to load the project in
which the flowsheet is stored. This is done by opening the Project
View window and dragging the project onto the session window, as
described in section 4.5.1.
In the example used here, the Default Project is being loaded so
that the user can create a new project and set up a new flowsheet.
If a project is dragged from the Project View window on to a
session window where a project is already open, the user will be
reminded that the project being loaded will overwrite the current
project (in RAM-not the copy on disk) and be given the
opportunity to save the open project before continuing.
An alternative method is to select File Open from the menu bar.

Building and Manipulating a Flowsheet JKSimMet Reference
4.6.2 Defining the Project Name

Whenever a file is saved, the file name is also the Project Name
which is used to distinguish it from all the other projects in the
Saved tab list of the Project View window.
If you wish to save a copy of the project under a different name,
use the Save As option on the File menu of the main JKSimMet
menu. Selecting Save As opens the Save As window which allows
the user to type in the chosen name for the file and to save it in any
chosen directory. The filename will be given the extension .jksm5
which identifies it as a JKSimMet V5 file.
You may also rename these files from Windows but it is a good
idea to keep the .jksm5 file extension.
The user can also enter more detailed information about the project
in the Project Definition window which is accessed by clicking on
the Project Properties button. The default port selection may also
be set from this window.

The Project Definition window lists the name of the project and has
text boxes for details such as the who set up the project, when the
project was last saved and the number of flowsheets in the project.
The user can edit the Done By, Done For and Comments text for
the project. The text entered in the comments box appears in the
Object Description section of the Project View window and can be
useful in identifying a project in the list. Once all the required
changes have been made in the Project Definition window, it is
closed by clicking on the close button in its title bar.
Note that it is not possible to edit the title of the project in the
Project Definition window. The Project Name or Title is locked to
the File Name.
There are two other methods to bring the Project Definition
window into view. One is to select the Properties option in the
View menu on the main JKSimMet menu. The final method is to
right-click on a blank area of the flowsheet and to select Project
and then Properties from the pop-up menus which appear.
4.6.3 Defining the Flowsheet Name

Since a project can contain more than one flowsheet it is useful to
give each flowsheet a name to make finding it easier. Once a
flowsheet has been named, its name appears in the drop-down list
at the bottom, right-hand side of the session window. To define the
flowsheet name, click on the Flowsheet Properties button on the
toolbar to open the Flowsheet Definition window. Alternatively,
right-click on a blank area of the flowsheet and select Flowsheet
then Properties from the pop-up menus which appear.
To change the name of the flowsheet simply highlight the text in

the Title box, type in the new name and press Enter to register the
name. The flowsheet name will appear in the drop-down list at the
bottom, right-hand corner of the session window.
The user can also edit the Comments text for the flowsheet. These
comments appear in the Object Description section of the Project

View window and can be helpful in identifying flowsheets when
there is a large number of projects in the Saved file list.
The final items which the user can edit in the Flowsheet Definition
window are the values for the percentage passing size data for the
stream size distributions. Changing the values here changes the
values in all port data windows. These values appear in the port
Information Blocks when these are used to annotate the flowsheet.
When all the required changes have been made, the Flowsheet
Definition window is closed by clicking on the close button in its
title bar.
4.6.4 Building the Flowsheet -

Equipment Units
When the Default Project has been loaded, the user is presented
with a blank flowsheet. The first step in entering the data for the
project is to build the flowsheet. This procedure is the same for all
of the analysis modes which JKSimMet provides (mass balance,
model fit and simulate).
JKSimMet uses an equipment unit to represent each unit process
on a flowsheet. For the purposes of flowsheet construction, the
equipment unit is made up of:
• a name (defined by the user)
• an equipment unit type, including an icon
• a data window containing equipment dimensions and model
parameters.
The first step in building the flowsheet is to place the appropriate

equipment icons on the flowsheet . The user has two options when
adding an equipment unit to a flowsheet. These are to select a new
item of equipment from the Default Equipment list in the New tab
of the Project View window or to copy an existing equipment unit
by selecting it from the list of Saved items in the Project View
window. The list of equipment which is available in JKSimMet is
shown below in the same form as it appears in the Project View
window.

List of Equipment available in JKSimMet
The default equipment has typical values for the equipment

dimensions, model parameters etc. as its default data. Re-using an
existing equipment unit can save time entering the data for an item
of equipment if a previously saved unit has suitable data associated
with it.
Adding a piece To add an item of equipment to the flowsheet open the Project
of equipment to View window and select an equipment unit from the list in the New
the flowsheet or Saved tab as required. (Equipment in the New tab contains
default parameter values and that in the Saved tab contains the
values entered by the user for that particular item.) Click on the
icon of the equipment unit and drag it onto the flowsheet.

Adding equipment You may double click on an existing project to reveal its
or flowsheets from flowsheets and then double click on each flowsheet to reveal its
another project equipment. The equipment can be dragged and dropped into a new
flowsheet. You may also drag a complete flowsheet from a saved
project into the current project.
Editing an Once an equipment unit icon has been placed on the flowsheet the
equipment unit user can edit or manipulate it in several ways.
on the flowsheet
Move To move a unit to a different position on the flowsheet place the

cursor over the unit and hold the left mouse button down while you
drag the equipment unit to its new position. When the unit is in the
required position release the mouse button to place the unit. Any
streams which are attached to the ports on the equipment will
remain attached after moving it.
Lock To lock a unit in place on the flowsheet click on the Lock button on
the main JKSimMet Functions toolbar. This prevents accidental
movement of the equipment unit when the user is working on other
items on the flowsheet. Locking the flowsheet is particularly useful
when working with large, complex flowsheets since accidentally
moving a unit requires the flowsheet to be redrawn, a process
which can take several seconds.
Equipment Most of the options for editing an equipment unit which are
Properties available to the user are presented in a pop-up menu which appears
when the cursor is placed over the equipment unit and the right
mouse button is clicked. Note that the options listed in the menu
act on the equipment unit to which the pop-up menu is attached
(and on its associated ports). The format of the pop-up menu is the
same for all equipment units, except that the names of the ports
change according to the type of unit (e.g. a ball mill would have
only Combiner and Product ports listed, while the cyclone in the
example below has Combiner, Underflow and Overflow).

The pop-up menu gives the user access to the following

actions:
Add Opens the Project View window to allow the user to
add another equipment unit to the flowsheet.
Delete Select the Delete option from the pop-up menu. This
will open up a pop up sub-menu which offers a choice
of deleting the equipment or its ports. Deleting the
equipment also deletes its connected streams.
Equipment Opens the equipment unit data window. The user can
examine and edit the equipment unit data as necessary.
Combiner Opens the Combiner port data window. This allows the
user to view or edit the stream data for that port.
Underflow Opens the Underflow port data window.
Overflow Opens the Overflow port data window.
Graph Opens the Quick Graph window which allows the user
to view a standard suite of size distribution data plots
for the ports which are associated with the equipment
unit.
Flip Changes the orientation of the equipment unit. This
option flips the equipment unit so that the feed end of
the unit changes from right to left or vice-versa.
Help Opens the JKSimMet Online Help files. The help
system is context sensitive and will open at the
appropriate section of the help files.
4.6.5 Building the Flowsheet -

Connecting Ports
The flow of material (solids and/or water) between the equipment
units on the flowsheet is represented by streams which connect the
feed and product ports on the equipment units. Material enters and
leaves each equipment unit via these ports.
A port is a model of a flow of particles and/or water into or out of
an equipment unit. For the purposes of flowsheet construction a
port is made up of:
• an input or output point on an equipment unit.
• a data window with size distribution, solids SG and solids and
water flowrates data

Feed and A unit can have only one feed port to which up to three input slurry
Product Ports streams and one water addition can be connected. This feed port is
called a combiner to highlight the fact that its data represent the
combined streams if two or three streams are connected to this port.
The number of product ports on an equipment unit depends on

what type of unit it is; for example a ball mill has one product port,
a hydrocyclone has two product ports. Each product port
represents one stream discharging from the equipment unit and
therefore only one stream can connect to a product port.
Note that there are some specialised equipment units which do not
have a feed port. These are the Feed unit which is a source of new
feed (dry solids or solids and water) to a circuit and the Water
Feeder which is a source of water additions to a circuit.
One stream attached to Three streams

the Overflow product attached to the
port . feed port
One stream attached to

the Underflow product
port .
The flow of material between the equipment units is created on the flowsheet by
connecting the feed and product ports of the appropriate equipment units.
Connecting Ports To connect a product port to a feed port the user places the cursor
over the product port of the equipment unit first. When the cursor
changes to a hand grasping a spanner with the word JOIN next to it,
left click to start the connection process. The word next to the
cursor will change to FEED (or PRODUCT if you are connecting feed
to product) in black text to tell you to what type of port you need
to connect. Position the cursor over the port to which you want to
connect the stream and when the cursor changes so that the spanner
changes orientation and the word FEED (or PRODUCT) is now in
white text, left click to make the connection. A connecting stream
will be drawn on the flowsheet as soon as both ends are connected
to the correct ports.
Note that JKSimMet will not allow the user to connect a feed port to another feed port.
Similarly, it will not allow a product port to be connected to another product port.

4.6.6 Flowsheet Related Problems

As we have already mentioned in passing, JKSimMet detects many
of the possible errors during the building of flowsheets and
provides an on-screen error message. If you require a fuller
explanation of the error the error number provides the key to the
error messages section of the documentation. Refer to Appendix B.
Having gained an appreciation of what error has been made and
how it has occurred it is usually a simple matter to return to the
offending stage in the setting up of the circuit or project and redo it.
Getting the circuit design right depends on the skill of the design
engineer.
Note that the auto stream drawing is computationally intensive.

Allowing reasonable space between pieces of equipment will let
the streams draw more quickly.
Lock Stream Due to the large amount of computation required for automatic
Redraw stream drawing, editing a complex flowsheet can become quite
time consuming. To minimuse this problem, the Lock Stream
Redraw option available on the View drop down menu should be
set. When this option is active, stream redrawing is disabled so
that as many equipment item moves as required can be made.
When all the equipment items are in place, the Lock Streams
Redraw must be switched off to allow the streams to be drawn.

Editing the Flowsheet Data JKSimMet Reference
4.7 Editing the Flowsheet Data

Overview Once the flowsheet has been configured with equipment units and
their ports have been connected to form a circuit, the next step is to
edit the equipment unit and port data. The data for these items are
accessed by opening the equipment unit or port data window as
required and typing the data into the appropriate places in the
window.
Data Entry There is a convention that the fields in the data window which are
Conventions available for data entry have a white background. This helps the
user to see at a glance which fields can be edited. The text fields
and those which have a drop-down list for selection of a field entry
have black text on a white background. Those fields which require
a number to be entered are displayed as blue text on a white
background. These conventions apply to both the equipment and
port data windows.
Note that the exact appearance and colours of each window will
also depend on how your MS Windows desktop is set up.
4.7.1 The Equipment Data Window

Each equipment unit on the flowsheet has a data window associated
with it. This data window contains all of the information about the
equipment which JKSimMet requires to perform model-fitting and
simulation tasks.
Opening an An equipment unit data window can be opened in two ways. The
equipment data first method is to place the cursor over the icon of the equipment
window unit on the flowsheet and right-click to bring the drop-down menu
into view. Then move the cursor to select the Equipment option
from the menu and left-click. The second method can be used to
open an equipment unit data window when the flowsheet is locked.
In this case, double-clicking on the icon of the equipment unit
opens its data window.
Equipment data The basic layout of the equipment unit data window is the same for
window layout all types of equipment; the common interface features and those
which vary between equipment types are discussed below.

JKSimMet Reference Editing the Flowsheet Data
The features which are common to all equipment unit data

windows are shown in the picture of a typical data window below.
Title bar Port buttons Print buttons
Name box
Copy and
Model drop- paste buttons
down list
Number of
parallel units
Selectable
Equipment tabs
data area
A Typical Equipment Data Window
The common features found in all equipment data windows are as

follows:
Title bar The title bar displays the name of the equipment
unit.
Name box The user can enter a name for the equipment unit in
this box. Note that this name will be used to identify
the equipment in various other tables in JKSimMet
and will also be used to create names for the ports
which are attached to the unit. For example, if you
call your ball mill Bert its ports will be called Bert
Combiner and Bert Discharge. It is advisable to use
names which you can recognise easily.
Port buttons The names of the ports which are attached to the
equipment unit are listed here. Clicking on the name
of a port opens its data window.
Model box Clicking on the model name in the box brings into
view a drop-down list of the JKSimMet models
which are available for the equipment type. The
user can select the required model by highlighting its
name on the drop-down menu and left-clicking. The
models listed here vary from one equipment type to
another.

Parallel Units The number of parallel units represented by the
equipment unit icon is entered in this box.
Data transfer The four buttons in this area of the equipment unit
data window allow the user to transfer data to and
from JKSimMet and other programs by copying and
pasting data to and from the clipboard. The buttons
perform slightly different functions as follows:
Copy Selected Cells Copies only the data cells

to Clipboard which are currently selected
to the Clipboard.
Paste Clipboard to Pastes data from the
Selected Cells Clipboard to the currently
selected cells
Copy Grid to Copies all visible cells on
Clipboard the current tab to the
Clipboard, including row
and column labels.
Paste Clipboard Pastes data from the
to Grid Clipboard to the data cells.
Data on Clipboard must
correspond exactly to the
data cells.
Print buttons The Print Preview button displays the print preview
window which shows the data as they will appear
when printed. This print preview window is often a
useful means of viewing the data from several tabs
at one time. The print preview window also provides
several options to export the data to text file in a
range of formats. The Print button immediately
prints the equipment data.
Data area The lower section of the equipment data window
contains the area where data such as equipment
dimensions and model parameters are entered. The
contents of this section of the data window vary
from one equipment unit type to the next. The
cyclone data window will be examined to illustrate
the features of this data area.
Selectable These tabs provide access to the groups of data
tabs which describe the equipment unit. The number of
tabs varies from one to seven, depending on the
equipment unit and model type. In the cyclone data
window there are three tabs which give access to the
Operating Conditions, Model Parameters and
Performance Data.

4.7.2 Editing the Equipment Data

When a piece of equipment has been added to the flowsheet from
the Default Equipment list, its data will be set to the JKSimMet
default values for that particular type of equipment. The user can
edit these values as required, replacing them with values which
represent the actual equipment they want to model or simulate.
Once they are familiar with JKSimMet each user will develop their
own data entry routine. This section describes a step by step
procedure for data entry as a guide for users.
The equipment window for a cyclone will be used to illustrate the
data entry procedures. The cyclone data window shown below is
the default equipment hydrocyclone.
Changing the Each piece of equipment can be given a name chosen by the user.
Equipment name To rename an equipment unit left-click on the text in the Name box
to highlight it. Then type in the required name for the equipment
and press Enter to register the change.
The equipment name serves several purposes; it appears in the title

bar of the equipment data window and is used to identify the
equipment in other tables such as the Overview window and the
Model Fit and Simulate dialogue windows. The equipment name is
also used to create the names of the ports which are associated with
the unit. For example, if you name a cyclone Primary Cyclone the
ports will be called Primary Cyclone Combiner, Primary Cyclone
Overflow and Primary Cyclone Product.
Defining the The equipment icon on the flowsheet can represent one unit of
Number of equipment or several units operating in parallel. The user defines
Parallel Units the number of units operating in parallel by left-clicking on the
number in the Parallel Units box to highlight it, typing the required
number in the box and pressing Enter.

Selecting the Each equipment type has one or more process models associated
Equipment Model with it which JKSimMet uses in the Model Fit and Simulation
procedures. The user can select which model is used to represent
the equipment in the process by left-clicking on the drop-down list
labelled Model and highlighting the required model to select it.
Note that the contents of the data area of the equipment data
window will change according to which model is selected.
Accessing the When a model type has been selected, the contents of the data area
Equipment data of the equipment data window will change to display the
appropriate data for that type of model. There is often too much
information to be displayed in the available space so JKSimMet
uses selectable tabs in the data area to provide access to groups of
data. To view each group of data the user clicks on the selectable
tab to bring it into view.
If you want to view all of the equipment data at the same time a
useful technique is to use the Print Preview window to display the
entire contents of the equipment unit data window. To view the
Print Preview window simply click on the Print Preview button at
the top, right corner of the equipment data window. The window
can be resized and the Zoom set to 100% to make the text easier to
read. When you have finished looking at the data close the Print
Preview window.
Editing the There are two methods to enter numerical data for an equipment
Equipment data unit. One option is to type the data into the appropriate data fields
by typing data in the data area of the window. To do this, use the cursor to select
the cell (denoted by the grey border around the cell), type the new
value and press Enter to accept this value. If you make a mistake in
data entry you can revert to the previous value by pressing the Esc
key but this will only work if the Enter key has not been pressed.
Note that if you enter a value which is outside the normal range for
any data item a warning message will be displayed to tell you that
the value is outside the normal range and asking whether the user
wants to use this value or have it clipped to the maximum value of
the normal range.
If you want to know what maximum and minimum values define

the normal range for a data item double click on the cell for that
item and the Parameter Detail information window will be
displayed. This details the maximum and minimum acceptable

values for the item and lists other information about the item which
is not relevant here.
A typical Parameter Detail window
Entering The second method available for entering data in an equipment data
Equipment data window is to copy and paste the data. The values can be copied
using copy and from the data window of another unit of the same type or from an
paste Excel spreadsheet. The data are pasted into the appropriate cells in
the data window by selecting those cells and then clicking on the
Paste Clipboard to Selected Cells button.
Out of range data Note that, as before, if you paste a value which is outside the
normal range for any data item a warning message will be
displayed. If in your view, the value is reasonable, answer Yes to
the warning message and your value will be used.
However, when you use an out of range parameter, you should
check your simulation results for reasonableness even more
carefully than usual.

4.7.3 The Port Data Window

Each port on the flowsheet has a data window associated with it.
This data window contains all of the information about the material
flowing through the port which JKSimMet requires to perform
mass balancing, model-fitting and simulation tasks.
Opening a port A port data window can be opened in two ways. The first method
data window is to place the cursor over the icon of the equipment unit on the
flowsheet and right-click to bring the drop-down menu into view.
Then move the cursor to select the name of the port whose data you
want to view from the menu and left-click. The second method can
be used to open a port data window when the equipment data
window is the active window. In this case, clicking on the name of
the appropriate port from the list on the equipment data window
opens the port data window.
Port data The layout of the port data window is the same for all ports. The
window layout only feature which varies is the number of columns in the data area
of the window.
Title bar Data type drop-

down list Error drop-
Format down list
drop-down
Printing
buttons
Set SDs Copy and

button paste buttons
Selectable
tabs
Port data
area
A Typical Port Data Window
The common features found in all port data windows are as

follows:
Title bar The title bar displays the name of the port. The
name is created by JKSimMet using the name of the
equipment unit to which the port is attached and a
name that identifies which port on that unit is being
examined. In the example above the data window is
the underflow port of the Primary Cyclones so the
name of the port is Primary Cyclones Underflow.

Format list Clicking on the format box brings into view a drop-
down list of the sizing data formats which are
available. These are % Retained, Cumulative %
Retained and Cumulative % Passing. The user can
select the required format by highlighting its name
on the drop-down menu and left-clicking.
Data list The Data drop-down list allows the user to select
which data types are displayed in the data area of the
port data window. The number of columns in the
data area varies depending on the data types
selected.
Data transfer The four buttons in this area of the equipment unit
data window allow the user to transfer data to and
from JKSimMet and other programs by copying and

to the Clipboard.
selected cells
and column labels.
data cells.
Data area The lower section of the port data window contains
the area where data such as mass flows and size
distribution data are displayed.
Selectable These three tabs provide access to the groups of data
tabs which describe the flow of material through the port.
The tabs are labelled Totals, Size Distribution and
Components.

4.7.4 Editing the Port Data

When a piece of equipment has been added to the flowsheet from
the Default Equipment list, its port data will be set to zero. The
user can edit these values, replacing them with values which
represent the material flows they want to analyse. Once they are
familiar with JKSimMet each user will develop their own data
entry routine. This section describes a step by step procedure for
data entry as a guide for users.
The port data window for a cyclone underflow of a Default
Equipment cyclone which has just been added to the flowsheet is
shown below. The data cells are blank except for the solids SG
value which is set to the default value of 2.70. Note that if a Default
Equipment unit is added to an existing flowsheet the solids SG
value for the port data is automatically set to the same value as the
flowsheet feed.
Default Port You may set the default size format, data format and error format
Format from the Project Properties window.
Selecting the If the data which describe the material flowing through the port
Format for includes sizing data you can select the format for this data to be
sizing data displayed on the Size Distribution tab using the Format drop-down
list. Click on the Format box to view the list of options, move the
cursor to highlight the required format and click on it to select it.
The available options are % Retained, Cumulative % Retained and
Cumulative % Passing size

Selecting the The user can select the types of data which are displayed in the data
Data types area of the port data window. To do this click on the Data box,
for display move the cursor to highlight the required data group and click on it
to select it. The available choices are:
GSIM Displays two columns of data – Exp (experimental) and
one other which is either Sim (simulated) or Fit (model
fitted) or Bal (mass balanced), depending on which
JKSimMet analysis mode is currently active.
SD’s Displays the two columns as for GSIM, together with a
column for experimental data standard deviations (SDs)
and another for calculated Error.
All Data Displays all of the data types which are available in
JKSimMet – Exp, SD, Sim, Fit, Bal, and Error.
Selecting the The Error column in the data area of the port data window can
Error type display the absolute (Abs), percentage (Pct) or weighted (Wtd)
error for the simulated (Sim), fitted (Fit) or Balanced (Bal) data as
required. The user selects the required error type from the Error
drop-down list.
Accessing the With mass flow, sizing and component data there is too much
Port data information to be displayed in the available space in the data area
so JKSimMet uses selectable tabs to provide access to groups of
data. In the case of port data windows the data is grouped as
Totals, Size Distribution and Components. To view each group of
data the user clicks on the selectable tab to bring its data into view.
If you want to view all of the port data at one time a useful
technique is to use the Print Preview window to display the entire
contents of the port data window. To view the Print Preview
window simply click on the Print Preview at the top, right area of
the port data window. The window can be resized and the Zoom
set to 100% to make the text easier to read. When you have
finished examining the data close the Print Preview window.
Editing the There are two methods to enter numerical data for a port. One
Port data by option is to type the data into the appropriate data fields in the data
typing data area of the window. To do this, use the cursor to select the cell
(denoted by the grey border around the cell), type the new value
and press Enter to accept this value. If you make a mistake in data
entry you can revert to the previous value by pressing the Esc key
but this will only work if the Enter key has not been pressed.
Entering The second method available for entering data in a port data
Port data using window is to copy and paste the data. The values can be copied
copy and paste from the data window of another port or from an Excel
spreadsheet. The data are pasted into the appropriate cells in the
data window by selecting those cells and then clicking on the Paste
Clipboard to Selected Cells button.

The Totals The Totals tab contains the mass flow data for solids and water
data tab through the port. If experimental values are available for these data
they are entered in the appropriate data cells. Note that if a solids
mass flow and solids SG have been entered, only one of the other
data items is required and the remainder will be calculated by
JKSimMet. For example if you enter the TPH solids and the
% Solids, JKSimMet will calculate the TPH Water, Pulp Density
and Vol. Flow. The user must ensure that the Solids SG is correct.
A Port Data Window with the Totals tab displayed
The size for the % Passing x mm and the percentage for the x %
passes size data items can be set in one of two ways. If you want
the values to be applied only to this port, double-click on the label
of the item you want to change. This brings into view an Enter New
Value window in which the required value is entered.
If you want to change the size for the % Passing x mm and/or the
percentage for the x % passes size data items values for all ports,
right click on a blank area of the flowsheet to view the pop-up
menu and select Flowsheet and then Properties to bring the
Flowsheet Definition window into view. The size for the % Passing
x mm and the percentage for the x % passes size data items can be
entered in the appropriate boxes in this window. (See section 4.6.3
for more information on the Flowsheet Definition window).

The Size The Size Distribution tab contains the sizing data for the solids
Distribution flowing through the port. If experimental data are available for
data tab these data they are entered in the appropriate data cells. The first
step is to enter the sizes to which the data relate. The size values
are in millimetres. Note that if the required size distribution is
defined for the first equipment unit placed on a flowsheet, any
further unit placed on the flowsheet will automatically use these
size data in the port data windows.
There are several options for entering the size data. The first option
is to use the √2 button on the port data window to place a √2 size
series in the Size column. The first step is to zero the size data by
typing a zero in the Top Size box and pressing Enter. As the
warning message will tell you, doing this will delete all size and
sizing data. Then type the new top size in the Top Size box and
click on the √2 button. JKSimMet places a √2 size series of 30
values from the user-defined top size down to zero. To truncate the
size list simply type a zero where required in the column. The user
can also edit individual values in the list as required.
Alternatively, any or all of the size values can be entered by typing

the values or copying and pasting them from another port data
window. A useful shortcut is to store the most commonly used
sizing series in an Excel spreadsheet so that these data can be
copied and pasted whenever required.
A Port Data Window with the Size Distribution tab displayed
The Top Size must be chosen so that no material is retained at this

size. Note that the sizes must be entered in descending order of
size. If you try to enter a size which is larger than the size in the
data cell above it, JKSimMet will not accept the value.
The experimental sizing data should be entered next. Note that the
size distribution data are constrained such that their total is 100%.
If you try to enter a value which causes the total to be greater than

100% one of two things will happen; either the incorrect value is
not accepted and the value in that data cell is unchanged or the
value is accepted but the amount of material in the finest size
fraction with material in is reduced to maintain the total at 100%.
If any problems occur with entering the sizing data check that the
data already entered are correct. JKSimMet will calculate the
amount of material in the pan or sub-mesh fraction to make the
total 100%. If the value calculated by JKSimMet is not the same as
the value in your data, check the data which has been entered for
keying errors.
The Components If the user has defined a list of components to be used in mass
tab balancing in the Mass Balance window then the Components tab in
each port data window will be configured to accept data. In this
case the user can enter component data such as assay data for solids
flowing through the port. If experimental values are available for
these data they are entered in the appropriate data cells. Note that
the component data are only used in mass balancing in JKSimMet.
A Port Data Window with the Components tab displayed
If no component list has been defined by the user the Components

tab will not contain any data cells.

The Set SD’s Estimates of the accuracy of the experimental data can be provided
button by entering data standard deviations (SDs) for the data. To do this,
make the appropriate selectable tab active and selects SD’s in the
Data drop-down list so that the SD values can be seen in the data
area. . There are two methods for the user to enter SD values for
the data. The first method is simply to type in the required SD
values in each data cell in turn. The second method uses the Set
SD’s button to apply a selected SD model to all of the data on that
tab. In most cases users will use the two methods to enter SDs by
applying an SD model to all of the data and then fine tuning some
SDs by typing new values in.
To apply an SD model click on the Set SD’s button to bring the

Select SD Values window into view.
The Select SD Values window lists a wide range of options for

setting SD models. Select an option by clicking on it and then click
on OK to close this window and return to the port data window.
The Whiten error model is useful for sizings in grinding circuits
(other than SAG feed) and acceptable for assays (at percent levels)
in mass balancing. The SD model is a generalised two term error
model ie it uses a fixed and a proportional term to estimate assay
errors. These issues are also discussed in Chapters 5 and 6.

4.7.5 The Feed Data Window

The Feed unit is a specialised equipment item which is the source
of feed additions to a flowsheet. The feed material can be dry solids
or solids plus water. As can be seen below, the Feed data window
is very similar to the standard port data windows.
Opening the A Feed data window can be opened in two ways. The first method
Feeder data is to place the cursor over the Feed icon on the flowsheet and right-
window click to bring the drop-down menu into view. Then move the
cursor to select the word Equipment from the menu and left-click.
The second method can be used to open the Feed data window
when the flowsheet is locked. In this case, double-clicking on the
feeder icon opens its data window.
The Feed data window has one feature in common with a standard
equipment data window – the Name box where the user can define
a name for the feeder. The remaining parts of the Feed data window
are the same as a standard port data window with Totals, Size
Distribution and Components tabs to access various groups of data.
Note that the Feed has only one port, a product port. As it is the
source of new material to be added to the circuit it does not have a
feed port.

4.7.6 Editing the Feeder Data

The data entry procedure for the Feed follows the same pattern as
for the port data windows. The user should enter a name for the
Feed in the name box and then enter the mass flow and sizing data
which describe the feed material on the appropriate tabs. (See
sections 4.7.3 and 4.7.4 for more detailed information on entering
data in port data windows).
4.7.7 The Water Feeder Data Window

The Water Feeder is a specialised equipment item which is the
source of water additions to a flowsheet. Note that the Water
Feeder has only one port, a product port. As it is the source of new
water to be added to the circuit it does not have a feed port. Water
feeders can only be connected to the feed port of an equipment
unit.
Opening Water A water feeder data window can be opened in two ways. The first
Feeder window method is to place the cursor over the water feeder icon on the
flowsheet and right-click to bring the drop-down menu into view.
Then move the cursor to select the word Equipment from the menu
and left-click. The second method can be used to open the water
feeder data window when the flowsheet is locked. In this case,
double-clicking on the water feeder icon opens its data window.
Water Feeder The layout of the water feeder data window is shown in the picture
window layout of the window below. As can be seen, some of the elements found
on the equipment unit data windows appear here, such as the Name
box and Model drop-down list. However, the layouts of the
Operating Conditions tabs are unique to the water feeder data
window.
Data tab for Water

Addition model

The features found in the water feeder data window are as follows:
Title bar The title bar displays the name of the water feeder.
Name box The user can enter a name for the water feeder in
this box. Note that this name will be used to identify
the equipment in various other tables in JKSimMet
so it is advisable to use names which you can
recognise easily.
Model box Clicking on the model name in the box brings into
view a drop-down list of the three JKSimMet
models which are available for the water additions to
a circuit. The user can select the required model by
highlighting its name on the drop-down menu and
left-clicking.
Parallel Units The number of parallel units represented by the
water feeder icon is entered in this box. For most
purposes this value can be left as 1.
Data transfer The four buttons in this area of the water feeder data
window allow the user to transfer data to and from
JKSimMet and other programs by copying and

to the Clipboard.
selected cells
and column labels.
data cells.
Data area The lower section of the water feeder data window
contains the area where data about the water
addition are entered. The contents of the section
varies between the three water addition models
which are available.

4.7.8 Editing the Water Feeder Data

Data entry for the water feeder is a simple procedure. As a first step
the water feeder can be named by the user by typing the required
name in the Name box and pressing Enter. The chosen name is
used to identify the water feeder in various tables in JKSimMet and
it makes sense to choose a name which describes the water addition
point e.g. Cyclone feed water addition. The next step in the data
entry procedure is to select the required water addition model.
Selecting the The water feeder has three water addition models associated with it
Water Feeder which JKSimMet uses in the Mass Balance, Model Fit and
Model Simulation procedures. The user can select which model is used to
represent the water addition to the circuit by left-clicking on the
drop-down list labelled Model and highlighting the required model
to select it. Note that the contents of the data area of the equipment
data window will change according to which model is selected.
The water addition models are described below.
Feed Streams When this model is selected the water feeder does not add any
model water to the equipment unit to which it is attached. The water
content of the feed to the equipment to which the water feeder is
connected, is controlled by the water contents of its feed streams
only. There are no data to be entered by the user on the Operating
Conditions tab for this model.
Water Feeder data window with Feed Streams model selected

Required % Solids When this model is selected JKSimMet adjusts the water addition
model to obtain the required percent solids in the equipment feed. The
user must enter the value of the required percent solids on the
Operating Conditions tab.
This model is useful in simulations, where the user can select the
required percent solids for a feed port, e.g. a cyclone feed, and
JKSimMet adjusts the cyclone feed water to cope with any changes
in cyclone feed mass flows which are caused by other changes to
the flowsheet.
Water feeder data window with Required % solids model selected

Water Addition In this model the water addition is fixed at the value set by the user.
model The user must enter the value of the required water addition in the
New Water Addition box on the Operating Conditions tab.
This model is useful in mass balancing and model fitting where the
user often has measured water addition data to be incorporated in
the flowsheet. If the flowsheet data are being mass balanced the
user can also enter standard deviation (SD) values for the water
addition.
After a mass balance, the “calc” result needs to be copied manually
to “Exp” for use in simulation and model fitting.

Annotating the Flowsheet JKSimMet Reference
4.8 Annotating the Flowsheet

Overview JKSimMet allows you to annotate the flowsheet with three types of
information – equipment unit data or port data in Information
Blocks and user-defined text in Labels. These features are
illustrated in the flowsheet shown below.
Label with text

entered by user
Port data
information block
Equipment data
information block
Access All of the annotation features are accessed through the

Configure/Assign Information Blocks and Labels window. This
window is brought into view by clicking on the Configure/Assign
Information Blocks and Labels button on the JKSimMet toolbar.
The Ports tab of the Configure/Assign Information Blocks

and Labels window
Each type of annotation is accessed by clicking on the appropriate

selectable tab in the Configure/Assign Information Blocks and
Labels window to bring its configuration table into view.

JKSimMet Reference Annotating the Flowsheet
4.8.1 Adding Port Information Blocks

Each feed and product port can be annotated with its own
information block. This block shows the name of the port to which
the data apply and displays up to four items of data for that port.
The user can select from a standard list the data items which appear
in the information block. Note that the four items selected appear in
all of the port information blocks on the flowsheet. In other words,
the user cannot vary the types of port data displayed from one port
information block to the next.
A Typical Port Information Block
Access the Ports Left click on the Configure/Assign Information Blocks and Labels
Information Block button on the JKSimMet toolbar to bring the Configure/Assign
Configuration tab Information Blocks and Labels window into view. Click on the tab
labelled Port to make this the active tab.
List of ports for

List of port data
which information
items, up to four of
blocks can be
which can be
displayed
selected for display
in the information
blocks.
Drop-down list of
data types to be
displayed.
Selecting the port The first step in adding a port information block is to decide
data for display whether to display one type of data (e.g. Experimental data only or
Simulated data only) or to view two data types (e.g. Experimental
and Simulated) together.
Note that ore feeder and water feed data can be accessed via the
equipment table – (Section 4.8.2)

One data type The default setting is for one type of data to be displayed. This
means that the user can view the chosen data (e.g. experimental)
for up to four different data items (e.g. TPH solids, % solids, Vol.
Flowrate and % Passing size). The user can select the data type to
be displayed from the drop-down list that appears in the lower part
of the Configuration area. The available choices are Exp, SD, Sim,
Fit, Bal, Calc Bal SD and Error.
Select required
data type from
drop-down list
The next step in the configuration is to select up to four items for

display from the list of port data items. To select an item in the list
simply click on it. As an item is selected it will be placed in the
information block and at the same time it is removed from the
configuration list. If you make a mistake when selecting the data
items simply click on the Clear button at the bottom right corner of
the information block window. This will clear the entire contents
of the information block so that you can reconfigure its contents.
Add an Once you have configured the contents of the information block to
information your satisfaction, click on the Apply button. This creates an
block legend information block legend which shows the data type selected in the
information block title bar and lists the names of the data items in
the appropriate boxes.
A Typical Port Information Block Legend (One data type)
Names of data item to be Name of data type

displayed in each box. to be displayed.

Placing an To place the information block for a port on the flowsheet select
information block the name of the port from the list at the left side of the window and
on the flowsheet then click on the Add New Block button. The information block
will appear on the flowsheet behind the legend information block
and may be dragged to the required position. Note that the name of
the port to which the data apply is displayed in the title bar at the
top of the information block.
A Typical Port Information Block (One data type)
Name of port Data values (legend

information block
shows which data
items are displayed
Primary BM Combiner information block

has just been added to the flowsheet and
needs to be dragged to its correct position
Adding Port information blocks to the flowsheet
Deleting an To delete the information block from the flowsheet simply click on
information the Close button at the top, right corner of the information block.
block Note that when an information block is deleted it does not reappear
immediately in the list in the Configure/Assign Information Block
and Labels window. To make the deleted port appear in the list
close and then reopen the Configure/Assign Information Block and
Labels window.

The alternative to viewing one data type for four data items in an information block is to
view two data types for two data items. In other words the user can choose to display,
for example, experimental and fitted data for two items such as TPH solids and %
solids.
Displaying Dual To view two data types for two data items in the information block
Data Types in the user must click on the box labelled Allow Dual Data Types to
information place a tick in the box. The Configuration area of the
blocks Configure/Assign Information Block and Labels window will
change to display two drop-down lists from which to choose the
data type, as shown below.
With the Allow Dual

Data Types box
ticked, two drop-
down lists appear for
selecting data types
The data type and data item selection procedures are the same as
discussed previously but in the dual data type case the user must
choose two data types (one from each drop-down list) and can only
select two data items to display.
When dual data type information blocks are being used, the title bar
of the legend information block shows the names of the two data
types selected for display as shown below.
Typical Port Information Block Legend

and Information Block for Dual Data Types

4.8.2 Adding Equipment Information Blocks

Each equipment unit can be annotated with its own information
blocks. Each information block can display one or two items of
data for that equipment unit. The user selects the data items which
appear in the information block from a standard list. Since the data
to be displayed varies from one equipment type to the next, the user
must configure the information block for each unit individually.
Note that more than one information block can be configured for
each equipment unit.
Access the Left click on the Configure/Assign Information Blocks and Labels
Equipment button on the JKSimMet toolbar to bring the Configure/Assign
Information Block Information Blocks and Labels window into view. Click on the tab
Configuration tab labelled Equipment to make this the active tab. Note that the
interfaces of the Port and Equipment tabs are similar; both have a
list of the things for which an information block can be displayed
on the left of the window and an information block configuration
area at the right side of the window.
The Equipment tab of the Configure/Assign Information Blocks
and Labels window
List of equipment Equipment unit

units on flowsheet information block
will display one or
two data items
When an equipment
unit is selected, the
data items available
for display are listed
here
Selecting the The first step in adding an equipment unit information block is to
equipment unit select the required equipment unit from the list at the left of the
for display Configure/Assign Information Blocks and Labels window. Left-
click on the name of the unit to select it.
Selecting the Once a unit has been selected, a list of the data items for that
equipment data equipment unit type is displayed in the Configuration area of the
for display window. The user can select one to two items from this list for
display in the information block. To select a data item simply click
on its name and the data item will appear in the information block
above the list. To change the selected data items the user must use
the Clear button to remove all selected items from the information
block and to select the required ones from the list again.

Add an equipment Once you have configured the contents of the information block to
unit information your satisfaction, click on the Apply button to confirm the
block selection. Click on the Add New Block button to place the
equipment unit information block on the flowsheet. This creates an
information block which shows the names of the data items and
their values and also shows the name of the equipment unit in the
information block title bar.
A Typical Equipment Information Block
Name of equipment unit

Data values
Names of equipment data

items displayed
The information block can be dragged to the required position on

the flowsheet. If you want to display more data for an equipment
unit on the flowsheet a second (or third or more) information block
can be configured for the unit and added to the flowsheet by
repeating the standard procedure described above.
List of cyclone data items displayed, ready

Two information blocks to configure a second information block.
configured for ball mill.
Deleting an To delete the information block from the flowsheet simply click on
information the Close button at the top, right corner of the information block.
block
Water Feeder The Water Feeder equipment unit is a specialised form of the
equipment unit equipment unit. The data items which can be displayed in its
information information block include information about the experimental and
blocks calculated water additions and the SD and weighted error of the
water addition.

4.8.3 Adding Labels to the Flowsheet

The flowsheet can be annotated with labels in which the user can
type text. The user can add as many labels as required to the
flowsheet and the format of each label can be configured from a
range of formatting options (e.g. background colour, with/without
border). Note that once a label has been placed on the flowsheet it
cannot be edited.
Access the Label Left click on the Configure/Assign Information Blocks and Labels
Configuration tab button on the JKSimMet toolbar to bring the Configure/Assign
Information Blocks and Labels window into view. Click on the
Labels tab to make this the active tab.
The Labels tab of the Configure/Assign Information Blocks

and Labels window
Type label Change the label

text here background colour
by double clicking
here
Select format
from these
options Preview of label
is displayed here
Enter the label To enter the text which you want to display in the flowsheet label
text double click the default text in the Label Text box to highlight it
and then type in the required text. As you type, the text appears in
the Preview area of the window. The position of the text in the box
can be adjusted by using the Enter key to add blank lines and the
space bar to add extra spaces as required.
Format the label The user can select the alignment of the text from the choices in the
Text Alignment area of the window.
The Label Properties area allows the user to wrap text in the label
by clicking in the Word Wrap On box to place a tick in the box.
Similarly the user can place a border around the label by ticking the
Label Border On box.
The user can use the Autosize function to set the height and width
of the label box automatically. Alternatively, if the Autosize box is
not selected the user can type the required dimensions of the text
box into the Height and Width boxes which are situated above the
Preview area of the tab.

Select the label The user can change the default background colour of the label by
background colour double clicking on the Label Background Colour panel of the
window. This brings up the colour palette from which the user can
select an existing colour or create a custom colour for the label.
Add the label to Once you have configured the label to your satisfaction, click on
the flowsheet the Add Label button to place the label on the flowsheet. The label
can be dragged to the required position on the flowsheet. Note that
once the label has been placed on the flowsheet its format and
contents cannot be edited or changed in any way
The Preview area shows Click on this button to add the

how the label will appear label to the flowsheet once you
on the flowsheet. have finished formatting it.
Delete a label A label can be deleted from the flowsheet by double-clicking

from the anywhere on the label.
flowsheet

JKSimMet Reference Graphing in JKSimMet
4.9 User-Configured Graphing – the Graph

Definition Window
Overview JKSimMet allows you to graph a wide range of data. The user has a
choice of graphing tools – the Generic Graph Config tool which
allows each user to configure graphs to their requirements and the
Quick Graph tool which uses a JKSimMet-defined format to
quickly produce a size distribution graph. The features of the user
configured graphing are discussed in detail below, while Quick
Graph is detailed in section 4.10
The user-configured graphing system is accessed by left-clicking on

the Generic Graph Config button on the main JKSimMet toolbar.
This opens the Graph Definition window. Note that when the
Graph Definition window is opened for the first time in a project, a
Graph window displaying the default data is also opened. This
default graph window can be closed while the user configures the
required format and data definitions.
4.9.1 Define the Graph Format

Creating a By creating named Format definitions users can save time when
Graph Format creating graphs in the future by re-using these previously defined
graph formats.
To create a new format, left click on the New Format button at the
top of the Graph Definition window. The format is then configured
in the Labels and Axes and Data Interpretation section of the
Format tab.
The Graph Definition window with the Format tab selected

Graphing in JKSimMet JKSimMet Reference
Labels Labels for the graph as a whole and for the X and Y axes are
specified by typing in the text for the labels and using the Font and
Font Size drop-down lists to format them as required. To type text
into a label, double-click on the existing text to highlight it and
then type the replacement text. The text can then be set to the
required typeface and size by selecting the required items from the
Font and Font Size drop-down lists.
Axes and Data The axes and data interpretation section of the Format tab defines
Interpretation the ranges and scales of the axes.
The components of the data interpretation section are:

Min and Max Defines the value at the origin (Min) and the
maximum value (Max) for each axis. To
change the value, highlight the existing
number and then type the new value in its
place.
Caution: Watch out for zero points which
cannot exist with logarithmic scales.
Scale Factor Can be used to scale the axes, for example
from millimetres to metres or from metric to
imperial. The usual value is 1.0. To change
the value, highlight the existing number and
then type the new value.
Plot Style Allows the user to choose the axis format as
either linear or logarithmic. The plot style is
changed by double clicking on the Plot Style
box to bring a drop-down list into view.
The required option is selected from the list by

highlighting it and then left-clicking.
Grid On JKSimMet will add grid lines to the X or Y

axes if a tick is placed in the appropriate box
by clicking on it. Gridlines can be removed by
clicking on the box again to remove the tick.
Number Format The format of the numbers at the tick marks
can be changed by selecting the required
format from the drop-down list in this column.
The choices are Decimal, Scientific (Nx10n) or
Engineering.

Re-using an Re-using previously defined graph formats saves time re-entering

existing Graph labels etc. when configuring graphs.
Format
To use an existing format, left click on the Graph Format box at top
of the Graph Definition window. This brings into view a drop-
down list of all the graph formats which have been defined in the
current project. Move the cursor to highlight the required format
and left-click to make this the current format.
The Graph Definition window with the drop-down list

of user-defined Graph Formats visible.
Select other
existing user-
defined formats
from this list.
4.9.2 Defining Data for Graphing

The user must define which data are to be plotted on the graph.
This is done by defining named Graph Data Sets using the Port
Data and Equipment Data tab sections of the Graph Definition
window. A Data Set can contain port data only, equipment data
only or a mixture of port and equipment data as appropriate. A
maximum of 15 items can be plotted on each graph.

The default
graph data set is
displayed here
The Graph Definition window with the Port Data tab selected.
Creating a Each definition of a data set to be plotted on a graph is named by

Graph Data Set the user and can be recalled and re-used within the JKSimMet
project. By creating named Graph Data Sets users can save time
when creating graphs by re-using these previously defined data
sets.
To create a new data set, left click on the New Data button at top
of the Graph Definition window. The data set is then configured in
the Data Selection sections of the Port Data and Equipment Data
tabs.
Note that the items which can be plotted on a graph include
equipment unit data such as classifier efficiency curves, ball mill
appearance functions, as well as the size distribution of the streams.
For the sake of simplicity, the Port and Equipment Data tabs are
discussed separately here.
Port Data
The various data cells in the Data Selection area of the Port Data
tab are discussed below. Each column in the Data Selection area is
used to configure the data presentation for one port. Note that the
user can select an individual port more than once in the Data
Selection area. For example, if the user wanted to present the
experimental data for a port with green dots and the simulated data
with a blue line, it would be necessary to configure this format in
two separate columns.

Port Selection The first row of the Data Selection area is labelled Port and it is in
this row that the user defines the name of the port whose data are to
be plotted on the graph. Double click on the Port cell to view a list
of the port names on the current flowsheet. Move the highlight to
select the required port and press Enter to make the selection.
Note that once a port name has been selected, JKSimMet places a
standard set of choices in the formatting cells in that column. The
user can edit these if required.
To remove a port from the selection to be graphed and clear all the
other selections in its column, double-click on the Port cell and
select None from the drop-down list of port names.
Format The Format defines which type of plot is presented for the port.
Double-clicking on the Format cell brings into view the drop-down
list of available graph plotting formats.
Move the highlight to the required format and left-click to select

that format.
Data Move the highlight to the Data row and double-click to view the
drop-down list of data types which can be selected for graphing.
If the single data type options are selected (Exp, Sim, Fit or Bal),
both the line and point markers for these data represent the chosen
data type. However, when the paired data types are selected for
plotting (e.g. Exp & Sim), the data point markers represent the
experimental data and the line represents the second item of the
data pair (Fit, Sim or Bal as appropriate). This feature is useful for
comparing the calculated data with the experimental data.
Line The Line option allows the user to choose the style of line which
will be used to represent the data. The choices are accessed by
double-clicking on the Line row cell and selecting the required line
style from the drop-down list. Note that the user can choose to
have no line plotted by selecting the option None on the list.

Point JKSimMet places a marker at every data point on the graph. The
user can select the style of marker to be used for the port from a list
of point marker styles. The choices are accessed by double-clicking
on the Point row cell and selecting the required marker style from
the drop-down list. Note that the user can choose to have no point
marker plotted by selecting the option None on the list.
Colour The user can choose what colour is used to display the line and
point markers on the graph. To view the list of available colours,
double-click on the Colour cell. Move the highlight the required
colour and left-click to select it.
Spline The user can choose to use spline interpolation for the curve which
is drawn between the data markers for each port. To use spline
interpolation left-click on the spline box to place a tick in it.
X Min and X Max The user must define the minimum and maximum plotting range
values (along the X axis) for the data. These values are typed into
the appropriate cells
Equipment Data
Many of the formatting cells on the Equipment Data tab perform
the same function as in the Port Data tab. Only those cells which
perform different functions are discussed below.

Each column in the Data Selection area is used to configure the

data presentation for one item of equipment. Note that the user can
select an individual item of equipment more than once in the Data
Selection area. For example, if the user wanted to present the
corrected efficiency of a cyclone with red dots and the reduced
efficiency with a blue line, it would be necessary to configure this
format in two separate columns.
The Graph Definition window with the Equipment Data tab selected.
Equipment The first row of the Data Selection area on the Equipment Data tab
is labelled Equipment and it is in this row that the user selects the
item of equipment whose data are to be plotted on the graph.
Double click on the Equipment cell to view a list of the equipment
names on the current flowsheet. Move the highlight to select the
required item and left-click to make the selection.
Note that once an item of equipment has been selected, JKSimMet
places a standard set of choices for that particular equipment type
in the formatting cells in that column. The user can edit these if
required.
To remove an equipment item from the selection to be graphed and
clear all the other selections in its column, double-click on the
Equipment cell and select None from the drop-down list of
equipment names.
Function The Function cell defines which type of data function is presented
for the equipment. Double-clicking on the Function cell brings into
view the drop-down list of available functions. The list of functions
will change according to the type of equipment which has been
selected.
Move the highlight to the required function and left-click to select
that function.
The remaining formatting cells perform the same function as those
on the Port Data tab and have been discussed in the previous pages.

4.9.3 Viewing the Graph

Once the user has defined a graph format and a data set, the graph
can be viewed by clicking on the View/Refresh Graph button
at the top, right corner of the Graph Definition window. This opens
the Graph window with the selected data plotted.
The name of the

data set is shown
in the Graph
window title bar
The Graph window
The Graph window has several features which allow the user to
make changes to the appearance of the graph without returning to
the Graph Definition window and to print or copy the graph. These
are accessed via the buttons on the Graph window toolbar.
The Display X Axis Grid and the Display Y Axis Grid buttons
allow the user to add and remove gridlines from the graph.
The Display Legend button adds or removes the legend. Note that
if the legend overlaps the plot area of the graph this can be
overcome by making the Graph window wider.
The Edit button makes the Graph Definition window the active
window, allowing the user to edit the format or data definitions.
The Refresh button redraws the graph. This allows the user to
update the graph after changing data or formats.
The Copy to Clipboard button copies the graph to the clipboard
from where it can be pasted into word processing documents,
presentations etc.
The Print Graph button immediately prints the graph to the
currently selected printer. The printed graph will have the same
appearance (overall size, relative dimensions etc.) as it does in the
graph window. The size of the graph can be changed by adjusting
the Graph window as required. Note that a message window may
appear while JKSimMet spools the graph to the printer.

JKSimMet Reference Using Quick Graph
4.10 Using Quick Graph

Overview JKSimMet allows you to quickly view size distribution data in a
standard form via the Quick Graph window. The user can change a
limited range of features of the Quick Graph such as adding or
removing gridlines, plotting data as percent retained or cumulative
percent passing etc. If more choices are required in defining the
graph format the Graph Definition window should be used.
4.10.1 Opening the Quick Graph Window

To view a Quick Graph for a stream the user must first place the
cursor over the equipment unit to which the stream’s port is
attached and right-click to view the drop-down menu.
Select the Graph

option to view
the Quick Graph
window
Selecting the Graph option from the menu brings the Quick Graph
window into view. The name of the equipment unit to which the
data relate is shown in the title bar of the Quick Graph window.
Note that, by default, the graph plots the size distribution data for
all of the ports connected to the equipment unit as a cumulative
weight percent passing size format. These settings can be changed
using the buttons on the Quick Graph window toolbar.

Using Quick Graph JKSimMet Reference
4.10.2 The Quick Graph Toolbar

The Quick Graph feature is designed as a means for users to
quickly view on the screen a standard graph of size distribution
data. This helps users to compare size distributions and to check
the sizing data for discontinuities. The type of data which are
plotted and a limited range of the Quick Graph features can be
changed via the buttons on the Quick Graph window toolbar.
The functions of these buttons are described below.

The Show Single Port button displays the size distribution data for
one port only on the graph. The user can select which port’s size
distribution is displayed using the Single Port Selection list which
is described below.
The Show All Ports button displays on the graph the size
distribution data for all of the ports connected to the equipment
unit.
The Display X Axis Grid and Display Y Axis Grid buttons allow
the user to add and remove gridlines on the graph. If the gridlines
are switched on, clicking on the button again removes the gridlines
from the graph.
The Sizing Format drop-down list allows the user to select the
format for plotting the size distribution data. The options are
% Passing (cumulative weight % passing), % Weight (weight %
retained) and % Retained (cumulative weight % retained).
The Single Port Selection drop-down list allows the user to select
which of the ports attached to the equipment unit has its sizing data
displayed on the graph when the Show Single Port button is
selected. The list of port names changes to reflect the type of
equipment unit selected. Note that this list is only accessible when
the Single Port button is selected; when the Show All Ports option
is selected this drop-down list is inactive (greyed out).
The Data Type drop-down list allows the user to select the type of
data to be plotted on the Quick Graph. The choices are
Experimental, Calculated, Absolute Error and Exp and Cal (both
experimental and calculated data plotted on the graph). Note that
the type of data plotted as Calculated (mass balanced, fitted or
simulated) depends on which JKSimMet tool is selected at the
time.

JKSimMet Reference Using Quick Graph
The Print Graph button immediately prints the graph on the

currently selected printer. The graph bitmap image is enlarged to fit
the page and as a result the printed graph can appear jagged. If a
smoother printed graph is required, copy it to the clipboard and
paste it into a suitable file for printing (e.g. a word-processing
program).
The Copy to Clipboard button places a copy of the graph on the

Clipboard. This can then be pasted into other programs such as a
word processing document or a presentation file.
4.10.3 Features of Quick Graph

The Quick Graph window has some features which help to user to
analyse the data which are presented on the graph. These are
described below.
Viewing the port Quick Graph provides a shortcut for users to quickly access the
data window data window for any of the ports whose data are plotted on the
Quick Graph. To do this the user simply clicks on the line whose
data window he wishes to examine. This brings that port data
window into view.
Identifying lines While Quick Graph does not provide a legend, the user can find out
on the graph which port a line represents on the Show All Ports graph by
pointing at the line with the cursor. When this is done a pop-up
label displays the name of the port to which the data relate.
Identifying data On the Show Single Port graph the user can find out what the X
points on the and Y values are at any data point by pointing at the data marker
graph with the cursor. When this is done, a pop-up label displays the X
and Y values at that data marker.

Using Overview JKSimMet Reference
4.11 Using Overview

Overview JKSimMet allows you to collate a wide range of data using the
Overview feature. An Overview table provides a summary of the
stream data for any or all of the ports on the flowsheet. Chapter 3
provides a tutorial on the use of Overview.
Access The Overview feature is accessed by clicking on the Overview

Config button on the main JKSimMet toolbar. This brings the
Overview window into view. Note that the user can have as many
overview windows open as required, with each displaying a
different overview configuration.
A typical overview window with default settings displayed
When first opened, the overview window displays a default set of

data. The user can define one or more overviews to display the
required port information.
4.11.1 The Overview Window

The overview window consists of two main areas, the Overview
toolbar and the data display area. The overview toolbar contains a
number of buttons which perform the functions described below.
The Select List is a drop-down list of all of the overview
configurations which have been set up for the current flowsheet.
The Name box is a text box where the user can type a name for the
current overview.
The New Overview button adds a new overview to the select list.

JKSimMet Reference Using Overview
The Delete Overview button deletes the currently selected

overview. A dialogue window requires the user to confirm that the
overview is to be deleted.
As the name implies the Insert column and Delete Column buttons
add and delete a data column in the overview table.
As their names imply, the Insert Row and Delete Row buttons add
and delete port data rows in the Overview table.
The Recovery box allows the user to set the overview table in
Recovery Mode where recovery data are presented in place of the
actual mass flow data.
The Copy to Clipboard and Copy Grid to Clipboard buttons copy

the overview table to the clipboard. This allows the data to be
pasted into other software packages.
The Print Preview button opens the print preview window,

allowing the user to see the overview table as it will be printed.
The Print button prints the overview table on the currently selected
printer.
4.11.2 Configuring an Overview Table

The first step in configuring an Overview table is to create a new
overview and to name it.
Create a new To create a new Overview click on the New Overview button on
Overview the overview window. This displays a default data set which shows
four data columns for all of the ports on the flowsheet.
Name an JKSimMet allows the user to create as many overviews as required

Overview and therefore it is useful to name each one so that it may be
recalled from the Select List for display. To name an overview
click on the text in the Name box to highlight it and then type in the
new name. Press Enter to register the change. Note that the name
now appears in the Select list box and also in the title bar of the
overview window.
The next step in configuring the overview is to decide which data are to be displayed in
the table and in which order. Before doing this it may be necessary to make the
Equipment and Port columns wider in order to read the names of these items. If the
window is too small to view all of the data the user can adjust the window to the
required size.

Make a data The width of each column in the overview table can be adjusted by
column wider placing the cursor over the right border of the title cell for the
column and clicking and dragging the border until the column is
the required width.
Resize the The Overview window can be resized by clicking and dragging any
Overview window side or corner of the window.
The user can arrange the order in which the port names appear in the table by selecting
the required port name in each row. Firstly the user must select the equipment unit to
which the port is attached and then the name of the port itself.
Select an To select an equipment unit for display in the list double click on
equipment unit the appropriate cell in the column labelled Equipment. This brings
for display into view a drop-down list of all the equipment units on the
flowsheet. Move the cursor to highlight the required equipment
unit name and press Enter to register the change. If a row of blank
cells is required to help make the table easier to read the user can
select None from the list of equipment names. All other cells in this
row will remain blank.
Select a port name Once an equipment unit has been selected in the Equipment
for display column the user can select the required port. To do this, double-
click on the appropriate cell in the column labelled Port to bring
into view the drop-down list of ports associated with the equipment
unit. Move the cursor to highlight the required port name and press
Enter to register the change.
The default overview table may contain more or less data rows than are required. Rows
can be deleted or added as required using the Delete Row or Insert Row buttons.
Delete a row from To remove a row of port data from the list in the overview simply
the overview table click anywhere in the row and click on the Delete Row button. A
JKSimMet dialogue window will ask you to confirm that you wish
to delete this row. Click on Yes to remove the row from the
overview table. More than one row can be deleted by highlighting
two or more adjacent rows and using the Delete Row button as
described above.
Add a row to the To add a row to overview table click anywhere in a row in the table
overview table and then click on the Insert Row button. Note that the new row is
always added immediately above the cursor position and by default
this row contains data from the first port of the first unit in the
equipment unit list. You can select the information to be displayed
in the new row by clicking on the relevant cells and selecting from
the drop down lists.

Once the list of port names has been defined the next stage in configuring the overview
is to define which data are displayed in the data columns. All of the data which appear
on the Totals tab of the port data window (e.g. TPH solids, % solids) are available for
display in the overview table. If component data have been entered for a port these can
also be selected for display. As well as defining what data items are displayed the user
must also define what data type (e.g. experimental, fitted etc.) is displayed in each
column. The user can configure as many data columns as required to display the port
data.
Select a data item Each column displays the values of a selected data item. To define
for display the data item place the cursor in the title cell at the top of the data
column and double click. This brings into view the drop-down list
of all available data items.
Move the highlight to select the required item and press Enter to
confirm the selection. Note that an item can be selected in more
than one column. This allows the overview to display, for example,
one column with experimental data, one with data SDs and one
with fitted data. Selecting the option None from the drop-down list
results in all other cells in the column being blank (a feature which
can help to make large tables easier to read).
Note that the available size markers are set from the Flowsheet
Properties window.
Select a If the Component data item has been selected at the head of a
component name column the user must select the name of the component in the
for display second row of the title section for the column. To select the
component name double click on the second row cell in the column
to view a list of components available for display. (The list of
names will vary according to the component names which the user
has defined). Move the highlight to select the required component
and press Enter to make the selection.
Note that the second row cell remains blank if Component has not
been selected as the data item.

Select a data type Each data item has several data types associated with it and the user
for display can choose which of these is displayed in each column. Double
clicking on the third row cell in the column brings into view the
drop-down list of data types.
Move the highlight to select the required component and press

Enter to make the selection.
Add a data Clicking on the Insert Column button adds a new data column to
column to the the overview table. Each new column is added to the left of the
overview cursor position. The newly added column is configured with
experimental data for TPH solids and so must be configured to the
users requirements.
Remove a data A column can be deleted from the overview table by placing the
column from cursor anywhere in the column and then clicking on the Delete
the overview Column button. A JKSimMet dialogue window will you to confirm
that you want to delete this column. Click on Yes to delete the
column. More than one column can be deleted by selecting two or
more adjacent columns and using the Delete Column button as
described above.
4.11.3 Recovery Mode

The overview window can also display recovery data for the
appropriate data items. Clicking on the Recovery box to place a
tick in it changes the overview window to recovery mode, (as
denoted by the words Recovery Mode in the title bar). Conversely,
removing the tick from the Recovery box returns the overview to
its normal display mode.
Note that recovery values are only presented for TPH solids, TPH
water, volumetric flowrate data and for component data. Any other
data columns in the overview table remain blank in recovery mode.

A Typical Overview Window in Recovery Mode
The stream port with respect to which all of the recovery values are
calculated is indicated by its name being shown in bold text in the
table. This port is known as the recovery basis port. The default
recovery basis port is the circuit feed.
Change the The user can change the recovery basis port by placing the cursor
recovery over the name of the new recovery basis port in the overview table
reference stream and right clicking. A JKSimMet dialogue window will ask you to
confirm that the chosen port is to be the basis for the recovery
calculations. Click on Yes to confirm the change. The recovery
value sin the overview table will change to reflect the change in
recovery basis.

Printing in JKSimMet JKSimMet Reference
4.12 Printing in JKSimMet

Overview JKSimMet provides the facility to print data, graphs and the
flowsheet. The basic procedure is the same, regardless of which
item you want to print.
Printing the The flowsheet can be printed in colour or black and white to the
Flowsheet printer or copied to the clipboard. Select File from the main menu
followed by Print Flowsheet and select the desired option.
Printing To print individual equipment or port data, the window containing

Equipment and the required data must be the active window. Once the required
Port Data window is active, click on the Print button on the JKSimMet
toolbar. This will bring the print preview window into view to
allow the user to check that the appearance of the printed document
is satisfactory.
Print Preview for

Cyclones equipment
data window

JKSimMet Reference Printing in JKSimMet
Note that the printed format allows the user to see all of the data
that are contained on all selectable tabs in the data window. The
data which are displayed on separate tabs in the window are printed
in consecutive areas of the printed data.
It is worth checking that the columns in the printed tables are wide
enough for the data values to fit. If the columns are too narrow,
close the print preview window, make the column in the data
window wider and then open the print preview window again.
Print Preview The Print Preview window which opens when the Print button is
window clicked shows how the printed form of the data will appear.
By default, the print preview window shows the printed page at

25% of full size. The user can view the print preview at other
magnifications by selecting the required view from the Zoom drop-
down list.
Similarly, the user can change the orientation of the paper by

selecting the required orientation (portrait or landscape) from the
Orientation drop-down list.
The print preview window can be resized by dragging its lower

right corner. The example below shows the Cyclones print preview
window from the previous figure which has been zoomed to 100%
and resized to show all of the data.
Print Preview window at 100% zoom factor with window resized to view all data
To print the data as

shown click on this
Print button

Printing in JKSimMet JKSimMet Reference
If the printout comprises more than one page the user can move
between pages by clicking on the Next Page or Previous Page
buttons.
Once the print preview is satisfactory, click on the Print icon in the
Print Preview window to print the data. To remove the Print
Preview window from the screen close its window.
Printing Overview The user can configure one or more Overview tables to summarise
tables data selected by the user (see section 4.11 for details of the
Overview features). Printing the overview table follows the
standard procedure of making the overview window the active
window and then clicking on the Print button on the JKSimMet
toolbar. This brings the Print Preview window into view and
allows the user to check that the appearance of the printed
document is satisfactory. Make any adjustments required and then
click on the Print icon on the Print Preview window to print the
data.
Printing The Quick Graph feature allows user to create size distribution
Quick Graphs graphs for the feed and products of each equipment unit. These
graphs are printed by clicking on the print button on the toolbar of
the Fast Graph window. Note that the graph prints as a bitmap and
therefore text and graphics can appear with jagged edges. A less
jagged printout can be obtained by using the Copy to Clipboard
button, pasting the graph image into a word processing program
(e.g. MS Word) and then printing
To print the
graph as shown
click on this
Print button
Quick Graph window showing Print button

JKSimMet Reference Using Report
4.13 Using Report

Overview JKSimMet provides a Report feature to generate printed reports of
the results of mass-balancing, model fitting and simulation work.
The Report window is accessed by clicking on the Report button on
the main JKSimMet toolbar.
Each printed report is fully configurable by the user who must
select the data to be printed for any or all of the ports or equipment
on a flowsheet. There is no limit on the number of reports which
can be created by the user for each flowsheet. A useful aspect of the
report tool is the ability to create any number of report
configurations which can be used to generate printed outputs as
required. Note that unlike the overview tables which present port
data only, the Report outputs can include equipment data if
required.
Each report can be readily viewed in a print preview window and
then printed and thus provides the ideal mechanism for producing
results in a format suitable for reports or presentations. The data in
the reports can also be exported from JKSimMet in a range of
formats (e.g. tab-delimited or comma-delimited text files) using the
options available in the report Print Preview window.
The first stage in preparing a report configuration is to create a new

report.
Create a New To create a new report configuration click on the Create New
Report Report button in the Report window. This brings into view a
table which lists all of the ports and equipment items on the current
flowsheet. Note that in the default configuration none of the items
in the grid are currently selected.

Using Report JKSimMet Reference
Name a report To name the new report format double-click in the Name box to
highlight the default name of the report configuration and then type
in a new name for the report. Press Enter to confirm the name
change. The new name will now appear in the Report list and also
in the title bar of the report window.
Setting the sizing The user can choose the format which is used to present any size
data format distribution data in the report. To do this click on the Format drop-
down list and select the required sizing format from the list.
Selecting Data The user must select the equipment and port items whose data are
for the Report to be printed in the report. To do this the user can click on the box
next to the name of each item to place a tick in the box.
Alternatively, if all items listed in the window are to be included in
the report, click on the Select All Items button at the top of the
report window. To remove an item from the report simply click on
the items box again to delete the tick.
Using a Circuit A shortcut for selecting ports and equipment for inclusion in the
Select list report is to use the circuit select list option. If this is ticked the user
can choose from the drop-down list one of the Select lists which
were defined as part of the simulation, model-fitting or mass
balancing procedure. The items from the flowsheet which were
included in the select list are automatically ticked for inclusion in
the report. This feature is useful when working with large, complex
flowsheets.
The Print What The report window has a Print What drop-down list which allows
list users to print port data only, equipment data only or to print both.
This list allows users to (temporarily) not print port or equipment
data items without having to remove the ticks from all those items
in the list.
Selecting Data To select the type of data to be listed in the report (e.g. Exp, Sim
Types for the etc.) place a tick in the box next to the name of the required data
Report types in the Data types to print area of the Report window. The
user can select as many data types as required for inclusion in the
report.
Selecting Error The user can choose to include the data error in a report by placing
data for inclusion a tick in the Error box in the Error Type area of the Report window.
in a report The user must then select from the adjacent drop-down list the
particular error that is to be included in the report. The error data is
useful when working on fitting or mass-balancing data.

Selecting Port If port data have been selected for inclusion in the report the user
data can choose to print the Totals data and/or the size distribution data
for the ports by placing a tick in the appropriate boxes in the Port
data to print area of the Report window. Note that if Component
data have been entered, these can also be selected for inclusion in
the report here. If component data have not been entered, this
option is inactive (as shown here).
Previewing a Once you have configured the report to your satisfaction, click on
report printout the Print Preview button to view the report as it will be printed.
By default, the Print Preview window opens at Page 1 of the
printout with the Zoom setting at 25% of normal size. The user can
change the Zoom setting using Zoom drop-down list and if required
can resize the Print Preview window by dragging any edge or
corner.
The Next Page and Previous Page buttons on the Print Preview
window toolbar allow the user to view all of the pages in the report.
Printing the To print the report simply click on the Print button on the Print
report Preview window toolbar. Alternatively the report can be printed
directly from the Report window by clicking on the Print button on
that window’s toolbar.
Preparing a The Report window has a box marked Summary. When this box is
Summary report ticked, the Report feature uses a summary mode to present the port
and equipment data in the printed report in a different format to the
standard format. The user can choose to use whichever mode suits
their requirements.
In the case of the port data, the Summary mode prints all of the data
of a given type (e.g. Experimental) for all ports in one table. Each
data type selected is printed as a separate table, with all ports listed
in each table. This compares with the normal report mode which
prints the data for each stream on a separate page, with all data
types for each stream being listed on this one page for each stream.
This difference between the Summary and normal mode is

illustrated in the examples of Print Preview windows shown below
Equipment summary formats provide a more compact output of key
equipment data..

Print Preview Window showing Summary report data format
Print Preview Window showing normal report data format

Exporting data A useful feature of the Report Print Preview window is the ability
using Report to export data in report form from the simulator in a variety of
formats. Four buttons on the Print Preview window toolbar
provide the following data export features:
Copy data to Clipboard for pasting into other applications.
Save the data as a tab-delimited file* (suitable for importing into a

spreadsheet such as MS Excel).
Saves the data as a comma-delimited file* (suitable for importing

into a spreadsheet such as MS Excel or a word processing
application such as MS Word).
Saves the data as a text file*.
These data export options allow the user to transfer data to other
applications for preparation of presentations and reports.
Note that once any of these file types has been opened, further
saves will append data to it. That is, records of several simulations
in sequence can be accumulated for comparison.

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Model Fitting Model Fitting
CHAPTER 5
MODEL FITTING

Introduction to Model Fitting Model Fitting
5. MODEL FITTING
5.1 Introduction to Model Fitting

Purpose Chapter 5 describes how to use the JKSimMet model-fitting mode.
Model fitting allows JKSimMet to be fine-tuned to each specific
plant and operating condition, or even to particular ore types. It
does so by adjusting selected model parameters on the basis of
systematic differences between measured product data and
simulation predicted product data.
The model fitting procedure can take into account any measured
flowrates and estimates of their accuracies.
Overview For both plant designer and plant operator, model fitting is
primarily concerned with the collection of accurate experimental
data, at either pilot or full plant scale. The model fitting process
provides a powerful means of data examination or assessment as
well as the compression of thousands of data points into a few
parameters.
The parameters characterise how a particular ore behaves in a

particular plant. This characterisation can be used to find the
optimum plant settings with respect to various criteria, or even to
find an optimal plant configuration to achieve stated objectives.
As with all data analysis or prediction processes, however, the
quality of the output is strongly dependent on the quality of the
input. The computer jargon for this phenomenon is GIGO or
GARBAGE IN - GARBAGE OUT. A serious difficulty with all
realistic simulation systems like JKSimMet is that they will
produce very plausible looking nonsense from rubbishy data.
Hence, just as the spreadsheet is not a replacement for the
accountant, JKSimMet is not a replacement for a metallurgist or
process engineer. There is no substitute for professional expertise
or experience, especially in the collection and analysis of large
quantities of data. JKSimMet provides such a professional with a
tool of enormous power.
The general procedure is for model fitting is:
• collect data
• analyse data
• optimise plant using models
• adjust plant
• collect data to confirm
and start the cycle again.

Model Fitting Data Collection
5.2 Data Collection

This section is not essential for learning how to drive the model-
fitting program. However, it is highly relevant to using the model
fitting system, and should be studied in detail before gathering data
for model fitting.
The data entry menus provide a guide to the unit dimensions and
operating variables which should be recorded during each test. The
stream data or feed stream data menus provide a guide to what
should be measured wherever possible.
Flowrates Flowrate measurements are very useful indeed. Hence, calibration

of all flow measurement devices (weightometers, flow meters, etc.)
is important. Whenever possible, try for an independent flowrate
check. In small or pilot plants, time and weigh a known volume of
material.
Sample Analysis Stream size distributions are crucial characteristics for many of the
JKSimMet models. Therefore:
• use a set of sieves that you can trust,
• use the same set of sieves for sizing all of the samples in each
test (sieves can have variations and holes!).
• use a 2 sieve series (size fractions can always be combined
later for convenience)
• sieve to the top of coarse sizes, ie. less than 5% on top screen
and as close to the bottom as possible.
Percent Solids The percent solids of a slurry as measured with a Marcy scale are
subject to error, due to solids density variations in the circuit. Such
variations are common in cyclone underflow streams. Therefore,
percent solids determined from wet and dry sample weights are
preferred.
Steady State JKSimMet is a steady state simulator. Hence, models can most
usefully be fitted to data which were taken at steady state. There
are two practical approaches to this problem:
• Take a series of regular samples (every 15 minutes say) and

combine them to make composite samples which cover a period
which is long (several hours) compared with circuit fluctuations.
• Alternatively, watch the trends and, when you are convinced the
circuit is stable, take simultaneous samples of each point.
Recheck the trends. If not stable, discard the samples and try
again.

Data Collection Model Fitting
If circuit variations are a serious problem, sample and fit one
process unit at a time. JKSimMet can be used to combine the units
and predict circuit steady state behaviour.
Sampling Sampling is a topic in itself. Some useful references are those of

Gy (1982) and Lyman (1986).
For a detailed ‘How to Do It Guide’ see the Help Files and Chapter
5 of the Monograph Reference.
For a simple estimating technique for sampling requirements refer

to the paper by Lyman (1986).
Ore Type Ore type characterisation is also a substantial topic. The

Characterisation comminution models in JKSimMet come with a breakage function
based on the Rosin-Rammler distribution. This behaviour is
typical of a hard, uniform ore. Over the past decade, the JKMRC
has researched in some detail how different ores break. The model
parameters also list breakage functions for some other ore types.
For a really accurate description of breakage behaviour, a breakage
test is recommended. JKTech will carry out such tests for a
standard feed. The tests require 1000kg of –100 +12mm size ore
and can even be carried out on complete (i.e. not split!!) drill core
samples. These breakage characteristics can be used to estimate
full-scale performance of crushers and mills, and also of SAG or
autogenous mills when the JK abrasion test is added.
Hence, the results can be very useful either for existing plants or for
proposed designs.
Replicate For serious plant testing, where small differences may be worth
Sampling large sums of money, it is often worth carrying out at least one
multiple sample test. That is, instead of taking just one sample set,
take 5 to 10 replicate samples. Then process and analyse each
replicate separately. These 5 to 10 replicates will provide a mean
and standard deviation for every data point. This will provide
invaluable information about the accuracy (or lack thereof) of every
data point.

Model Fitting Data Collection
Concept: If the precision of each data point is measured (or can be estimated
Weighted Sum from experience), then each difference between experimental data
of Squares and simulation prediction can be normalized by dividing by its
precision. That is, a small difference between an accurate data
point and its simulation prediction will make the same contribution
to the weighted sum of squares as a large difference from an
inaccurate data point.
Concept: The usual measure of precision is the standard deviation. If we

Standard make repeated measurements of any data point, experimental
Deviation variations will cause variations in the measured value xi.
Then with many repeats, the mean x- of the values will provide an
estimate of the true value of x.
Subject to a number of assumptions, the expected variations from
true x can be characterized by one number - the standard deviation -
which is defined as:
n
∑ (xi - x-)2
i=1,n
Standard Deviation =
(n -1)
If the measurements are normally distributed then, out of 100

measurements, 67 could be expected to lie within plus or minus one
standard deviation of the true value (as estimated by the mean), 95
within plus or minus two standard deviations and 97 within plus or
minus three standard deviations.
Concept: Experimentally, 5 to 10 complete observations will provide a good

Estimating estimate of standard deviation. The mean of such a set of
Standard measurements should provide a good test of sampling precision - if
Deviation the test circuit was at steady state.
Concept: For accuracies of size analyses on a weight % retained basis, the

Whiten Standard Whiten errors often provide a realistic estimate. These are
Deviation calculated as relative errors:
• A standard deviation of 0.1% plus one tenth of the fraction is
assumed, up to a maximum weight of 1%.
The Select SD Values window lists a wide range of options for
setting SD models. Select an option by clicking on it and then click
on OK to close this window and return to the port data window.

Data Collection Model Fitting
The Whiten error model is useful for sizings in grinding circuits
(other than SAG feed) and acceptable for assays (at percent levels)
in mass balancing. The SD model is a generalised two term error
model ie it uses a fixed and a proportional term to estimate assay
errors. These issues are also discussed in Chapter 6.
Concept: The simulator takes all of the feed streams as input and uses the
Least Squares models and parameters to predict all of the circuit streams.
Fitting If some (or all) of these streams are measured (sampled and sized,
etc), the experimental measurements can be compared with the
simulator predictions. The sum of squares of the differences
between measured data and simulated results is taken as a measure
of goodness of the model fit. The best estimates of the parameters
are expected to be those which MINIMISE the sum of squares.
Hence, the model fitting program adjusts user selected model
parameters to find a best set of parameter estimates which make
the simulator output match the experimental measurements as
closely as possible.

Model Fitting Background
5.3 Background
The JKSimMet models are provided with a set of default
parameters and, in most cases, a range of parameter values. (See
the Supplementary Parameters Manual supplied by JKTech).
For any real mineral processing operation, the best-fit parameters
will almost certainly be different from the default values provided
with the system.
There are several classes of parameters used as model inputs:
• Machine dependent Typically dimensions and key

parameters operating adjustments.
• Ore dependent parameters For example, the work index or
specific gravity or breakage
function for a particular ore at
a particular energy.
• Calculated or measured These usually depend on a
operating parameters combination of machine and
ore dependent parameters and
ore feedrates, etc. Examples
are cyclone feed pressure and
crusher power draw.
• Circuit flowrates of solids Process instrumentation often
and water provides an estimate of, say,
solids mass flowrate to a
cyclone classifier. In some
cases, such a flow can be
treated as data. If it is
unmeasured, it may be varied
until a best fit to other data is
achieved. In this case, the
flowrate effectively becomes a
parameter.
• Model parameters which can Each model has a list of
be fitted. parameters which can be fitted.
Each parameter to be fitted is
selected from a menu for that
model. These menus are listed
with each model description in
Appendix A.
.

How the Model Fitting Program Works Model Fitting
5.4 How the Model Fitting Program Works

The model fitting program works by calculating the differences
between the predicted and the experimental data, and deriving from
these a weighted sum of squares value (WSSQ). On its first
iteration (step), the program adjusts each parameter in the
parameter list in turn by a small amount, and notes the effect of this
adjustment on the weighted sum of squares value after an internally
executed simulation. This step is used to estimate the magnitude
and direction of the adjustments to the parameters required to
minimise the WSSQ. On subsequent iterations, the program varies
all the fitted parameters simultaneously, noting the effect of the
adjustments. This process is repeated until the program is stopped
for one of the following reasons:
• a minimum WSSQ has been reached,
• the maximum number of steps set by the user has been reached,
• the adjustments made to the parameters are having no significant
effect on the weighted sum of squares value or
• operator intervention.
Whereas simulation uses given feed data and given model

parameters to predict the product data, the model fitting program
uses the sum of the squares of the differences between the predicted
and the actual product data to adjust the model parameters.

Model Fitting How the Model Fitting Program Works
Schematically:
SIMULATION
Feed Description
Circuit
MODEL Simulator Configuration
PARAMETERS
Predicted Products
and Streams
MODEL FITTING
Feed Description
Circuit
Simulator Configuration
Adjusted
Model
Parameters
Predicted Products
and Streams
Iterate to
Minimum Sum
of Squares
Measured Products
and Stream Data
Model Fit
MODEL PARAMETER
ESTIMATES
Sum of Best Fit

Squares Parameters

A Simple Example Model Fitting
5.5 A Simple Example

A very simple example has been included in the Learner
Flowsheets project of JKSimMet. This example provides a quick
guided tour of the fitting menus to get the flavour of the fitting sub-
system. You will, however, still need to work through section 5.6
(Learning Fitting) in detail with several real cases in order to
become confident with the model-fitting mode.
The example is a single Ball Mill in open circuit. There is only one
stream predicted – the product. Therefore, there is only one stream
that can be fitted.
Step 1 Load the Learner Flowsheets project and select the
flowsheet called Ball Mill Model Fit.
Step 2 Examine the mill feed and product port data. You will
find the raw data in the Ball Mill Feed Feeder
equipment unit data and in the Ball Mill Product stream
data. Run a simulation by clicking on the Simulate icon
and compare the raw and calculated values for the Ball
Mill Product. (Use a graph for easier comparison of the
size distributions).
Step 3 Now select Model-Fit mode by left-clicking on the
Model Fit icon. This will bring up the Model-Fit
tabbed dialogue window shown below.
Model Fit Dialogue Window
Step 4 Left-click on the Select tab of the Model Fit window to

view the list of equipment and streams which the user
can select to be used for model fitting. Note that the
equipment and streams which have been selected for
fitting are highlighted in blue on the flowsheet. This
feature is useful for checking that you have selected all
of the items on the flowsheet which you want to use in
the model-fitting and is particularly useful for complex
flowsheets.

Step 5 Left-click on each item in the list on the Select tab and
observe whether or not it has been selected for fitting.
If the item is selected for fitting the box labelled
Selected will contain a tick. Note also that as you click
on each item in the list it is highlighted in red on the
flowsheet. This feature is useful for identifying which
items you are selecting when the flowsheet is a complex
one.
Step 6 Left-click on the Parameters tab to examine the list of
unit parameters to be fitted. You will find the list
named Ball Mill Parameter List which shows the three
spline knots for the ball mill as the parameters to be
fitted. The initial values of the knots for the fitting are
1.0, 3.0 and 4.0.
Step 7 Select the tab Data to view a list of the port and
equipment data which can be selected for use in the
fitting. The list is named Ball Mill Data List. Note that
the Data list defines which data (and SDs) the models
use in the weighted sum of squares which is minimised
in fitting.
Step 8 The final step before running the model fitting is to set
the standard deviations (SDs) of the stream data which
will be used in the fitting (in this case, the Ball Mill
Product). Bring the Ball Mill Product port data window
into view and, from the drop-down list under Data
Type, select the SDs option. This allows you to view
the data SDs and the Error data along with the
measured and calculated data values. The SD values are
the estimates of the accuracy of the data while Err
(Error) data are differences between experimental
values and those calculated by the model-fitting.
Hint: Experimental, Calculated, SD and Error data can
also be examined on the same screen using the
overview facility which is available from Overview or
on the Data Tab of the Model Fit Window.
Step 9 Make the Model Fit window the active window and
click on the Run Fit tab. Click on the Start button to
start the model-fitting process. The model fitting
program will take these initial estimates provided by the
user and search for better ones, given the experimental
and calculated streams values. It searches until it finds
a minimum residual error (weighted sum of squares of
differences).
If the program finds what looks like a genuine
minimum, it will terminate by providing parameter
error estimates (SDs). In this example, the fit is quite
good. The Errors SDs value is less than 1. This means

that the data are slightly more accurate than the entered
error estimates suggest.
Hint: set the scroll bar slider on the Run Fit window to
allow you to see the fitted parameters being updated
after each iteration.
Step 10 The best fit values for the R/D* knot parameters are
listed in the Selected Model Parameters section, along
with the SDs of these values. (You may need to scroll
across to view these data).
Step 11 Look at the Ball Mill Product port data. Examine the
differences between experimental and fitted data by
selecting the Abs-Fit option from the Error Type drop-
down list and observing these values in the error
column. The differences are relatively small.
Step 12 As an exercise, try graphing the experimental and fitted
data.
This concludes the short guided tour of the model fitting sub-
system. The next step is to work through the tutorial and reference
section with a set of real data.

5.6 Learning Fitting

The real power of JKSimMet lies in its ability, through the model
fitting sub-system, to tune the JKSimMet simulation models to
specific real world operating conditions. To do this, the user
collects experimental (stream) data and periodically engages in
model fitting to update parameters.
Model fitting consists of the adjustment of model parameters on the
basis of collected experimental data. The data are collected from
the real plant or circuit, and primarily concerns the circuit product.
Basically, the situation is as follows. Initially, the one set of data
that the engineer has is the plant or circuit feed data. The
JKSimMet simulation provides the engineer with a set of predicted
or expected product data on the basis of this known feed. The
engineer monitors the real circuit or plant product, building up a set
of experimental data which can then be compared with the expected
or predicted data. The essence of model fitting is to analyse any
systematic difference between the predicted and experimental data,
and to use it to adjust the selected model parameters.
5.6.1 Preparation for Model Fitting

The subsequent sections of chapter 5 lead the user through the steps
necessary in order to execute the model fitting, but there are two
essential preliminaries.
Simulation The user must ensure that the circuit or test for which the fitting is
to be done has plausible simulation feed and model parameter data.
That is to say that it must have run through simulation to
convergence. Thus, it is necessary to select an appropriate test and
circuit, and to run a simulation before continuing. The simpler the
circuit used in model fitting, the better. Indeed, a circuit with a
single unit (model) is the ideal for a first fitting with a new ore
type.
If you enter new data, or in any way alter the flowsheet which you
select, you should run a new simulation, even if one has been run
before.

Learning Fitting Model Fitting
5.6.2 Start Model Fitting

Select the Model-Fit mode by clicking on the Model Fit icon at the
top of the screen. This brings the Model Fit window into view.
Model Fit dialogue with Run Fit tab active
The tasks involved in preparation for the execution of model fitting

are:
• Selection of the appropriate section of the flowsheet ie the select
list (which is a feature common to all of the JKSimMet analysis
mode dialogues – Model-Fit, Simulate and Mass Balance).
• Selection of the model data. This involves both the selection of

the data which the models must match, and entering the stream
and feed stream data.
• Setting up the parameters. This involves both the editing

(displaying and recording) of the unit parameters and the
selection of the unit parameters to be adjusted.

5.6.3 Selecting Data

Fitting involves the adjustment of parameters and the comparison
of data. As has been outlined, there are two data sources for this
comparison. They are the data output from the simulation, and the
data collected by the plant engineer and entered into the model
fitting sub-system.
Select items In contrast with earlier versions, in JKSimMet V5 the user can
for inclusion in choose any items on the flowsheet to be included in the model-
Model-Fitting fitting process. This is useful if the user wants to model a
subsection of a large flowsheet or even one piece of equipment
from a flowsheet. So the first task in preparing to model fit data is
to select the equipment and ports that will be available for use in
the fitting procedure. If an item is selected here, it will be available
for selection in the Parameter and Data lists.
Step 1 Click on the Select tab in the Model-Fit window.

Step 2 Click on the button marked New to create a new data
list. Firstly, you should give a name to the Select list by
typing the chosen name into the text box labelled Name
and pressing Enter. Any name will do, but we have
used Taconite Mill.
Step 3 Click on each of the equipment and port names in the
Equipment list in turn and select the items whose data
you wish to use in the model fitting. To select an item
simply click in the appropriate box to place a tick in it.
A glance at the flowsheet shows which parts of the
flowsheet have been selected to be included in the
model fitting as all selected items are outlined in blue
on the flowsheet.
Select the The next task is to define which port data the models must match.
Ports This means selecting the ports to be used during the fitting using
for Fitting the Data tab in the Model Fit window.
Step 1 Click on the Data tab in the Model-Fit dialogue.

Step 2 Click on the button marked New to create a new data
list. Firstly, you should give a name to the port data list
by typing the chosen name into the text box labelled
Name and pressing Enter. Any name will do, but we
have used 'Ball Mill Data Fit List'.
Step 3 Click on each of the port names in the Equipment Port
Data list in turn and select the items whose data you
wish to use in the model fitting. To select an item
simply click in the appropriate box in the column
labelled Fit? to place a tick in the box.

The maximum number of ports which can be fitted in one fit list is
ten .
Entering and Essentially, this involves entering your data and declaring your
Editing Port confidence about each item in the data set.
Data
Step 1 Bring into view the port data window of the stream
whose data you wish to edit. Note that you may find it
convenient to minimise these windows on screens other
than a very large computer display. A minimised
window will reopen at the tab and position at which you
closed it.
Step 2 Left-click on the Data section and select the SDs option
from the drop-down menu. This brings the SD and
Error columns into view in the port data window, along
with the experimental and calculated data.
STREAM DATA ENTRY (SDs type)
Port Data The Totals area of the port data window contains data pertaining to
the total stream: solids, water and volumetric flowrates, percent
solids, pulp SG and solids SG values. Note that numeric characters
displayed in blue on a white background can be entered by the user.
Numeric fields with a grey background are calculated by
JKSimMet and cannot be edited by the user.
The Size Distribution tab area contains the list of the sizings from
Top Size to Size 30 with the value (%) for each size. Whether the
% experimental value refers to % Retained, Cumulative % Retained
or Cumulative % Passing depends upon the setting of the stream
format field shown at the top left of the screen. This setting can be
changed as required by selecting the required sizing format from
the drop-down list in the Format box.

Notice that there are often more size distribution data than will fit
in the port data window. If this is the case, scroll bars at the edge
of the window will allow you to view all of the data. The Page-Up,
Page-Down, Home or End keys or the cursor arrow keys can be
used to move around.
The user must set the SD values, so we shall deal with these data
fields now.
Data The SD (Standard Deviation) column is next to the Experimental

Accuracy data. The SD field must contain a value in each data cell. There
Entry are three ways to enter values into these SD fields.
• Leave most or all of the entries at the default value of 1.0,

simply overtyping the ones you wish to change individually.
• Globally change all the SDs to one of the six other available
options by:
Step 1 Left-click on the button labelled Set SDs which is to be

found at the top right-hand corner of the port data
window.
Step 2 Select the required option from the Select SD values
pop-up window which is displayed.
• The user can change any individual field by overtyping an SD

value. The number you enter is an expression of your
confidence in the experimental value.
Concept: Note that a zero SD means the error, i.e. the difference between
Ignoring this experimental and calculated value, will be ignored in the
Data model fitting process. NB This is different from mass balance
where a zero FIXES the result at the measured value!

Concept: If you have high confidence in an experimental value, set the SD to

High Accuracy a small value.
Data
Error Display Error values can be expressed in one of several ways: Absolute
Error, Percentage Error, or Weighted Error. The user can further
choose whether the error displayed is related to the mass-balancing,
model-fitting or simulation mode of JKSimMet. The user can
determine which of these forms is displayed by the following
procedure:
Step 3 Position the cursor over the Error cell at the top of the
data window and left-click on the black inverted
triangle to make the drop-down list appear.
Error type
drop-down
list
Step 4 Select the error type required from the drop-down list
which is displayed.
Absolute Tells you the actual difference between the calculated and the
Error experimental values.
Percentage Tells you the percentage difference between the calculated and the
Weighted Tells you the number that the parameter-fitting program will use in
Error its weighted error sum of squares. You will probably find this the
most useful setting.

5.6.4 Setting Up the Parameters

The second task in preparing for model fitting is to define which
equipment parameters are to be fitted
Unit Specific Appendix A contains model descriptions and default parameter

Comments values. It also contains a section of specific comments on fitting of
each type of model and the parameters which can be selected for
fitting for each model.
Equipment The Parameter tab data in the Model-Fit window is used to define
Parameter which equipment parameters are adjusted in the model fitting.
Selection Initial estimates of the values of these parameters are entered in the
Guessed Value column. These initial estimates of the parameter
values are necessary for the first iteration of the model fitting
process. In subsequent runs of model fitting for the same model,
the user can use the values output from the previous model fitting
run.
The task is to select the equipment (ie model) parameters you want
to adjust in the fitting process.
Step 1 With the Model-Fit window as the active window,

select the Parameters tab. Firstly you should create a
new parameter list by clicking on the New button. Type
a name for your list in the Name box and press Enter.
Using the same name that you gave the data list is a
good option, but anything will do. The example shown
here is called Ball Mill Parameter List.
Parameter Step 2 Place the cursor in the first data cell of the equipment
Selection column and press Enter to bring into view the drop-
down list of equipment on the flowsheet

Step 3 Select the item of equipment which you want to model-

fit and press Enter to make the selection appear in the
cell. In this example, Ball Mill is the only item in the
list.
Step 4 Left-click on the Parameter cell and select the required
parameter from the drop-down list which appears. The
list of parameters changes with each equipment type,
only showing those parameters which can be fitted for
that particular equipment. In this case select parameter
LnR/D1.
Step 5 Note that JKSimMet automatically inserts your initial
estimate of the parameter value from the equipment
data window in the Guessed Value column. The Scale
Factor is also automatically set at 10% of the initial
estimate. If you wish, these values can be changed by
highlighting the existing value and over-typing with a
new value.
Step 6 By default, JKSimMet places a tick in the Fit? column
for each parameter as it is entered to indicate that the
parameter will be adjusted in the fitting procedure. If
you do not want a parameter to be fitted, click on the
item’s check box to remove the tick. Note that the
guessed value will be copied into the model whether it
is checked for fit or not.
This entry completes the parameter tab data entry.
Cancel Entry To delete a row of data from the parameter list, select the
equipment name in the row you wish to delete and press Enter to
bring the drop-down list into view. Select the option None from
the list to clear the data from the row.
Note: Being able to decide whether a parameter is adjusted in the

fitting is useful because it allows you to try a fit without certain of
the parameters by not selecting them for fitting and then to fit using
those parameters by simply changing the flag selecting them again.
This saves deleting and re-typing all the details. Slaved units will
use the same scale factors, guessed values and fit modes. (See
section 5.6.5 for a description of Master/Slave fitting).
Repeat the above steps for each of the parameters you wish to
include in the model fitting. The maximum number of parameters
is 10. You may, however, define as many parameter lists as you
wish.

5.6.5 Master/Slave Fitting
Master/Slave Master/slave model fitting allows the same parameters to be fitted

Fitting to two or more (up to a maximum of ten) units in a single
flowsheet. The parameters fitted will have the same values for all
the slave units. Master/Slave fitting can be used when fitting
survey data collected simultaneously from parallel units with the
same operating conditions. Alternatively, it can be used for survey
data collected sequentially from a single process unit, where it is
expected that model parameters will not be affected by any change
in operating conditions.
The circumstances that indicate whether master/slave model fitting

can be used are therefore dictated by the type of data and the type
of model to be fitted. Note that not all models are suitable for
Master/Slave Fitting.
Slave units are entered on the right-hand side of the Parameters tab.
Place the cursor in the slave column, and press ENTER to view the
pop-up list of available units. Up to 10 master units are available,
with up to 10 slave units per master.
If slave fitting is used, ensure that the appropriate slave stream SD's
are set. It is necessary to select the streams to be model fitted for
the slave units in the Select tab.
Note that the fitting statistics displayed (eg. Data SD, Residual
Error) will include the slave units.

5.6.6 Fit the Model Parameters

Before running the model fitting procedure you may wish to
change the maximum number of steps to be executed in fitting. To
do so:
Step 1 Left-click on the Control tab in the Model Fit window
and check that the required parameter list is selected in
the Parameter Fit List drop-down list. Use the cursor to
highlight the number in the Maximum Iterations box.
Overtype with the value required, and press Enter to
register the change.
The default number of steps is 100. You may well feel

that this is too few, particularly if there is more than
one item of equipment. A value of 200 to 300 is
probably better.
Having collected together the circuit simulation data
and your experimental data, and nominated which
model parameters you wish to fit, you are now ready to
execute the model-fitting program.
Step 2 Left-click on the Run Fit tab and then click on the
button marked Start to begin the model fitting.
The model-fitting program updates the unit (model)
parameters, effectively running a simulation. During
execution, the program fills in the result values, but it
will update the SDs if it reaches a satisfactory fit. For
interpretation of the model fitting results, refer to
section 5.7 (Checking the Fit).

Stopping The maximum number of steps field can be set to stop the
Execution of the iterations of the fitting program when required. Alternatively, the
Program fitting program can be stopped at any time, simply by clicking on
the button marked Stop on the Run Fit tab.
Concept: At the best-fit point, an estimate of the goodness of fit is calculated

Data Standard by dividing the weighted sum of squares (Residual Error) by the
Deviations number of points less the number of parameters, and taking the
square root. If the data and the error estimates are in agreement,
and if the model is appropriate, this number will tend towards one.
Concept: The same approach can be used for each stream point. These
Stream Data values are reported for each fitted stream in the Data tab of the
SDs Model Fit window. A small stream data SD, i.e. where SD
approaches a value of one, indicates a good match between
experimental and calculated data for that stream.
Concept: The solution of the minimisation also provides estimates of

Parameter parameter accuracy. The mathematical proof of this estimate of
Standard accuracy is complex. Intuitively, if the parameter is well defined,
Deviations the sum of squares will vary more rapidly as the parameter is
adjusted. For a more detailed explanation, see Lynch (1977),
chapter 7.
If the program finds small variations in a parameter make NO
apparent difference to the sum of squares at the minimum, it sets
the parameter SD to 1E20. Such parameter fits should be treated
with CAUTION and the data examined for problems.

Checking the Fit Model Fitting
5.7 Checking the Fit

During the execution of the fitting program, the Model-Fit window
is displayed. As the fitting program goes through each iteration the
values in the results section of the window are updated. Assuming
that the fitting reached a satisfactory conclusion, the standard
deviations (SDs) of the parameters are updated when the fitting
program stops.
There are various ways in which the user can judge whether the
results are good or bad:
• Compare the size or order of magnitude of the SDs with that of
the associated value. When the SD is small compared with the
value as a ratio, it is a good fit, when large, it is a poor fit.
• The summary values in the lower half of the Model Fit window
also indicate the success of the fit. Low values in the Residual,
Error Sum, and Errors SD fields indicate a good fit; large values,
a poor fit. Moreover, in the case of these fields, cross
comparisons between fittings can be made. If these values are
smaller in the most recent run of the fitting than they were in the
previous run, the fit is getting better. If they are getting larger,
you are going in the wrong direction.
• The engineer can also judge the relative success of the fitting by
looking at the stream data windows. Examine the Error column.
Weighted Error and Percentage Error versions of the difference
between calculated and experimental data are most useful.
These are displayed by selecting the appropriate item from the
Error drop-down list.
• The graph plotting facility of JKSimMet allows the engineer to

plot raw and fitted data on the same graph, as detailed in section
5.8 (Presentation of Model Fitting Results).
• The overview facility of JKSimMet allows key experimental and

calculated data for multiple streams to viewed in a summary
table. These overviews are configurable by the user (see section
3.10 for details).
Page 5-24 Section 5.7 Version 5.0 June 1999

Model Fitting Presentation of Model Fitting & Results
5.8 Presentation of Model Fitting Results

There are two main ways to present the results of model fitting:
• printing data
• plotting graphs
.
We shall deal with these in turn.
Printing Model Given that model fitting concerns the experimental (raw) data and
Fit Results the predicted (fitted) data for streams, our task is to print these two
types of data for the streams concerned.
To easiest method to print the data for individual ports is simply to

print the data in the relevant port data window as follows.
Step 1 Bring into view the data window for the port whose
data you want to print.
Step 2 Left-click on the Print icon on the main JKSimMet
toolbar to view the Print Preview window for this item.
Step 3 If the Print Preview shows that the layout is to your
satisfaction, click on the Print icon at the top, right-
hand corner of the Print Preview window (you may
need to resize this window to see the Print icon)
Step 4 Repeat Steps 1 to 3 for all the other ports whose data
you want to print.
These steps also apply to any other window which has data that you
want to print, such as equipment data.
The best way to produce a printed copy of the error and SD
information on the Parameters and Data tabs in the Model Fit
window is simply to print this window.
Hint: The Overview window provides a convenient means of

looking at experimental and model fitted data on the screen. This
overview can also be printed, using the Print icon.
The Report feature provides a means of printing both port and
equipment data. The user can configure the report to show
experimental and fitted data, SDs and errors for any ports. (See
section 3.11 for more information on the Report feature).

Problems & Solutions Related to Model Fitting Model Fitting
Plotting Graphs The graphs presenting model fitting results are, once again, of
of the Model stream data. They involve experimental (raw) data, and predicted
Fitting Results (fitted) data. The simplest way to begin is to configure a graph and
simply nominate the data to be plotted. You can then edit the graph
format and annotation as required.
Step 1 Left-click on the Generic Graph Config button on the

main JKSimMet toolbar to bring the Graph Definition
window into view.
Step 2 For this exercise, you will create a new graph so click
on the Port Data tab.
Note that the default setting for the graphing facility already has
some data pre-selected so you must now define which data you
want to plot on the graph.
Step 3 Specify a new Port Data list by left-clicking the New
button and typing a name for your data set into the
Name box and then pressing Enter.
Step 4 Move the highlight to the row labelled Port in the first
column and press Enter.
Step 5 Select the name of the required port from the drop-
down list which appears.
Step 6 Position the highlight on the first cell in the Format row
and press Enter.
Step 7 Select the required graph format from the Format drop-
down list. Cum % Passing is a good choice.
Step 8 Select the option Exp & Fit from the drop-down list in
the row labelled Data. Note that the list allows the user
to plot single data types (e.g. Experimental data only)
for the port or pairs of data types (Exp and Fit or Exp
and Sim). Where a pair of data types is the selected
option, JKSimMet represents the experimental data
with data markers and the calculated data with a line.
Step 9 Move to the Line row and select the required style of
line from the drop-down list.
Step 10 Move to the Point row and select the required symbol
for the data marker from the drop-down list.
Step 11 Move to the Colour row and choose the colour with
which the line and data markers will be drawn on the
graph.
Step 12 If a spline interpolation is required between the data
points on the graph click on the box in the Spline row
to place a tick in the box.

Model Fitting Presentation of Model Fitting & Results
Step 13 Set the minimum value of x to be plotted for this data

set by typing the value in the X Min cell. Place the
highlight in the cell, double-click and then type the new
value.
Step 14 Repeat step 13 for the maximum value of x in the
X Max cell.
Step 15 Repeat Steps 4 - 14 for each of the streams you want to
plot on the graph.
Step 16 Left-click on the Display Graph button at the top of the
Graph Definition window. Your new graph will now
be displayed.
You can now refine the format of the plot and print the plot, etc, as
outlined in the section 3.9 (Learning Graphing). Repeat the above
steps for each of the streams for which you wish to compare the
raw and fitted data. The quality of fit is represented by the
closeness of the points to the line, (the closer the better).
Overview This facility provides an excellent summary. Set the % passing
size properties from the Flowsheet Icon on the tool bar, e.g. P80
and % -75 µm.
Overview can summarise flows and these key sizes for

experimental and fitted data.
5.9 Problems Related to Model Fitting and

Possible Solutions
There are, of course, many problems that may be encountered
during model fitting. It is possible, however, to point out some of
the more common mistakes, so that you are aware of them.
Errors, Warnings, Some problems detected by JKSimMet produce error messages.

Faults ERRORS 140-163 are relevant to the Model Fitting module.
Please refer to the expanded descriptions of these errors in
Appendix B.
Skill Model fitting is not a cut and dried procedure. The only way to
versus Practice acquire a useful skill level is to practice on a wide range of real
data. JKSimMet offers a user-friendly environment for what are
really very complex and powerful mathematical techniques.

Problems & Solutions Related to Model Fitting Model Fitting
Initial Parameter As with all non-linear least squares programs, Model Fitting is
Estimates sensitive to initial parameter estimates. The default values and the
supplementary information provide a useful guide. However, trial
and error may be necessary to find the best estimates to use with a
new circuit or new data.
Graphical The graph capability of JKSimMet is the most powerful way to

Analysis examine your data fit. Discontinuities in size distributions
highlight poor data or a change in measurement technique.
Graphical analysis also highlights any bias in the data fit.
Different Size Be very careful of changes in size measurement technique, such as

Measurement from sieves to Cyclosizer.
Techniques
No Apparent When nothing much seems to be happening in model fitting, a

Progress simple first check is to ensure that you have a reasonable
Maximum Number of Steps setting, and that the streams and
parameters that you intend to include in the fitting are selected with
a tick in the Parameters section of the Model Fit window.
Data Note that it is necessary to have as much feed and product data as
possible for each of the unit Models to be tuned. Simulation
requires only feed data, but fitting must have some product data as
well.
Not Enough Even when you have the necessary data to perform model fitting, it
Data is essential to ensure that there are enough readings to be useful for
fitting; in general terms, the more data the better.
SDs and The SD settings in the stream data window may be set so that they
Emphasis can cause such an over-emphasis on one parameter that the
potential of the fitting is compromised. Always try to make the
SDs as good an estimate as possible.

Model Fitting Problems & Solutions Related to Model Fitting
Scale Factors The Scale Factor in the Parameters section of the Model-Fit
window can also be a source of problems. If the scale factor is too
big the fitting may stop, because any adjustment in the parameter
produces such a large change that it steps over the minimum of the
sum of squares. On the other hand, however, if the scale factor is
too small, the fitting may stop because any adjustment produces a
change of so small a scale as to be judged insignificant, even
though you may not be close to a minimum point. So, be very
careful with scale factors. As a guide, perhaps a scale factor one-
tenth of the magnitude of the parameter estimate would be a
reasonable place to start.
Parameter Appendix A contains model descriptions, default values and a

Problems section on fitting for each specific model. These comments may
help to overcome problems with parameters.
Large Weighted Examine the weighted errors carefully. These often indicate
Errors suspicious data points. A typical example is a screen top size
which contains several times the predicted weight, because the
laboratory screen stack did not extend to a large enough top size.
Set the error to zero for this fraction to fix the problem.
Knot Positions Where spline functions are used, the knot values can usually be
fitted, but not the knot positions.
These models provide a fairly smooth response because of the use

of spline functions. A simple guide to knot positioning is that
knots should be selected wherever a bend is needed. After all, the
spline function is a mathematical model of a draftsman’s spline
curve - a thin strip of steel with screw positions which are
equivalent to spline knots.
Slave/Master If problems are encountered when model fitting slave units, try
Model Fitting fitting them individually. Despite all good intentions, all data sets
in a survey may not have the same operating conditions and
therefore may require different model fitting parameter values.
Examine raw and calculated data for each unit to identify poor fits.
One set of poor data, or data with inappropriate operating
conditions, can prevent a good model fit solution being reached.

References Model Fitting
5.10 References
GY, P.M., 1982. Sampling of Particulate Materials: Theory and
Practice, 2nd Ed. Elsevier, Amsterdam.
LYMAN, G.J., 1986. Application of Gy's Sampling Theory to
Coal, International Journal of Mineral Processing, 17,
pp 1-22.
LYNCH, A.J., 1977. Mineral Crushing and Grinding Circuits,
(Elsevier, Amsterdam).
NAPIER-MUNN, T.J., MORRELL, S., MORRISON, R.D., &
KOJOVIC, T. 1996. Mineral Comminution Circuits – Their
Operation and Optimisation. JKMRC Monograph Series in
Mining and Mineral Processing 2. Series Editor T.J. Napier-
Munn, Julius Kruttschnitt Mineral Research Centre, University of
Queensland.
Page 5-30 Section 5.10 Version 5.0 June 1999

Mass Balancing Mass Balancing
CHAPTER 6
MASS BALANCING
Version 5.0 December 1999 Section 6 Page 6-1

Introduction to Mass Balancing Mass Balancing
6. MASS BALANCING
6.1 Introduction to Mass Balancing

Purpose Chapter 6 describes how to use the JKSimMet mass balancing
sub-system.
Overview Even the most carefully collected plant survey data are subject to
many sources of variation. Some of these errors are due to:
• statistical effects
• sampling procedures or design
• assaying procedures
• sizing procedures
• fluctuations in plant flowrates.
As with all data improvement processes, the usefulness of the

massaged data will be strongly dependent on the quality of the input
data. The mass balancing module can help you to assess data
efficiently and to refine your experimental technique when
problems are detected. Mass Balancing will make good quality
data better. It will not fix poor quality data or do anything more
than highlight inadequate experimental technique.
The module is used to mass balance sizing data, assay data and
flowrate data collected at steady state. The balancing process
produces best fit estimates of flowrates and a set of adjusted size
and assay data which is consistent with those flowrates.
As with model fitting, the overall process is:
• collect data,
• analyse data,
• check accuracy of data fit and
• refine experimental technique and instrumentation until desired
level of accuracy is obtained.

Mass Balancing Data Collection
6.2 Data Collection

The comments in section 5.2 are just as relevant for mass balancing
as for model fitting.
Some additional comments about assay measurements and
techniques are appropriate here.
There are well established rules for calculating the accuracy of a
sampling and assay process (Gy, 1982). These can be used to
establish an error model which can then be used to provide
estimates of standard deviation for each point. Alternatively, 5 to
10 replicate samples can be taken and processed. If these input
accuracies are established, then the program estimates of accuracy
for flowrates will be real estimates and not relative estimates.
If replicate sampling is carried out for assays on a number of
streams (ie. a range of assay values), a simple two term error model
can be generated by plotting relative standard deviation against
average assay values from each stream.
The intercept and slope of this plot will provide fixed (minimum)
and relative (%) error components which can be used in the
generalised version of the Whiten model.
You also need to s pecify a sensible maximum (absolute) error.

Background Mass Balancing
6.3 Background
Mass Balancing can be thought of as a type of model fitting. The
models in this case are quite fundamental. Hence, they do not
impose the experience knowledge (which is built into other
mathematical process models) onto the data.
These mass balancing models are:
• a mixer (for example, a pump sump),
• a general classifier (for example, a hydrocyclone),
• a unit which conserves some properties but not others

(for example, a grinding mill will preserve total assays
and flowrates but not size fractions.
The basis of the mass balancing algorithms is the differences in

composition of various streams, that is, the differences generated by
the process equipment.
Consider a process with these streams having assays a, b, c:
a b
If the flowrate in stream of assay a is 100 tph, then:

100 a = x*b + (100-x)*c
where x is the flowrate in stream of assay b and then:
x = 100 (a-c)/(b-c)
This is the basis of the traditional three-product solution, where a, b
and c may be assays for size, Cu or any other conserved property.
It does not matter what kind of assays a, b and c are, as long as there
is some difference in their values.
If the process is just a splitter and the assays are all the same:
a=b=c
and therefore x = 0/0 which is undefined.

Mass Balancing Background
Expressed another way, the flowrates can be estimated only if a

process imposes a difference on its products, that is, the information
is imparted by the process. If no information is imposed, as with a
splitter, then the information cannot be used to make estimates, as it
is not there to begin with. If this program produces a good balance
around a splitter, then the splitter is behaving as a classifier and
should probably be re-engineered.
It follows that the most useful properties to use for mass balancing
around a process unit will be those which have the largest
difference in the product streams.
This means that size assays will work well around a size classifier
such as a screen or a hydrocyclone, and copper assays will work
well around a copper flotation circuit. The reverse will generally
not be true, with some notable exceptions. For example, gold
and/or lead assays are often very useful around a hydrocyclone
classifier because its density-separating characteristic will usually
produce a large difference in these assays.
The power of this program lies in its ability to use a wide range of
assays across a large flowsheet. The program algorithm is driven
by the assays with large differences but still takes account of those
with small differences.
Concept: The mass balancing module takes all selected streams and
Mass Balancing calculates the smallest set of data adjustments which will make the
data consistent.
If some (or all) of these streams are measured (sampled and sized,
etc), the experimental measurements can be compared with the
data. The sum of squares of the differences between measured data
and adjusted data is taken as a measure of goodness of fit of the
model.
Hence, the mass balancing program adjusts user selected flowrates
to find a best set of flowrates which make the balance output match
the experimental measurements as closely as possible.
Concept: If the precision of each data point is measured (or can be estimated
Weighted Sum from experience), then each difference between experimental data
of Squares and simulation prediction can be normalized by dividing by its
precision. That is, a small difference (or adjustment) between an
accurate data point and its simulation prediction will make the
same contribution to the weighted sum of squares as a large
difference from an inaccurate data point.

Background Mass Balancing
Concept: The usual measure of precision is the standard deviation. If we

Standard make repeated measurements of any data point, experimental
Deviation variations will cause variations in the measured value xi.
Then with many repeats, the mean x- of the values will provide an
estimate of the true value of x.
Subject to a number of assumptions, the expected variations from
true x can be characterized by one number - the standard deviation
defined as:
n
∑(xi - x-)2
(i=1,n)
Standard Deviation = (n-1)
If the measurements are normally distributed then, out of 100
measurements, 67 could be expected to lie within plus or minus one
standard deviation of the true value (as estimated by the mean), 95
within plus or minus two standard deviations and 97 within plus or
minus three standard deviations.
Concept: Experimentally, 5 to 10 complete observations, that is, sampling

Estimating plus analysis, will provide a good estimate of standard deviation.
Standard The mean of such a set of measurements should provide a good test
Deviation of sampling precision - if the test circuit was at steady state.
Concept: For accuracies of retained size analyses, the Whiten errors often
Whiten Standard provide a realistic estimate. These are calculated as relative
Deviation errors:
• For fractions greater than 10%, a standard deviation of 1.0% is
assumed.
• For fractions less than 1%, a standard deviation of 0.1% is
assumed.
• For fractions between 1% and 10%, a standard deviation of
0.1% plus one tenth of the fraction is assumed.

Mass Balancing How the Mass Balancing Program Works
6.4 How the Mass Balancing Program Works

As noted earlier, the mass balancing problem is a special case of
the non-linear least squares fitting problem.
The mass balancing program used by JKSimMet is a program
called MBal written by Dr Bill Whiten and based on an algorithm
developed by Dr Rob Morrison. The balancing algorithm uses
special assumptions about data accuracy to linearise the problem.
This allows for an initial flowrate solution which is analogous to
the multiple linear regression solution, that is, a solution which is
computationally rapid and does not require initial estimates of
flowrates other than one flowrate to use as a basis for all others.
The mass balancing program refers to this algorithm as the
Morrison solution. If the data are accurate, these flowrates will be
indistinguishable from those produced by the correctly weighted
solution.
The Morrison solution provides the initial flowrate estimates for
what becomes essentially a constrained non-linear least squares
fitting.
A minimum set of flowrates is adjusted to minimise a true
weighted sum of squares of data adjustments. However, the key
difference between mass balancing and model fitting is that all data
streams are adjusted, that is, the imbalances in the mass balance are
distributed over both feed and product streams.
For the model fitting minimisation, all of the errors are allocated
over the product streams. That is, the feed streams are assumed to
be accurate.
This difference is important where aspects of the feed stream are
more difficult to measure than those of the products. This is
especially true with streams of coarse particles encountered in
crushing and screening plants. For these plants, sampling error
becomes critical and the mass balanced feed stream will usually be
more useful than the experimental data as a basis for assessment of
operation and for simulation.

How the Mass Balancing Program Works Mass Balancing
Schematically:
Mass Balancing
Product 1
Feed
Product 2
Mass Balance Adjusted Data
Feed (+ δ) Product 1 (+ δ)
Product 2 (+ δ)
(minimize adjustments)
(minimize adjustment)
Model Fitting
Product 1
Feed SIMULATION
Product 2
Parameter Adjustments
Product 1 (Observed - Calculated)

Feed
Product 2 (Observed - Calculated)
Minimize the difference

between observed and
calculated

Mass Balancing A Simple Example
6.5 A Simple Example

The simplest, non-trivial case for mass balancing is a separator of
some type which receives one feed stream and separates the feed
stream into two products. Interestingly, this is also the most
common application of mass balancing.
This example provides a quick guided tour of the mass balancing
module to get the feel of the system. To use it effectively, you will
need to work through Learning Mass Balancing (Section 6.6).
The example which is included in the Learner Flowsheets project

is called Example Cyclone Mass Balance.
This example is a single hydrocyclone in open circuit.
Step 1 Load the Learner Flowsheets project. Select the
flowsheet named Example Cyclone Mass Balance
Step 2 Left-click on the Mass Balance icon on the toolbar to
activate the mass balancing mode and to bring the Mass
Balance window into view.
Step 3 Click on the Select tab to view the list of units and
streams. Note that the current list is called Select-1 and
that the user can set up more than one list of selected
items.
Click on each stream or unit name in turn to see which
experimental data have been selected for use in the
mass balance. The presence of a tick in the boxes
marked Selected, Water, Feed etc. indicates that the
item will be included in the mass balance. You will
find the unit named Cyclone has three ports selected.

A Simple Example Mass Balancing
You will find that all the units and water additions and
streams are selected initially. You may turn these on
and off with by left-clicking on the box to make the
tick appear or disappear as required.
Step 4 Click on the Run Balance tab and then select the GSIM
option on the check box on the top right hand corner of
the Run Balance tab window. Also ensure that Select-1
is the option chosen in the drop-down list for the Select
list.
Data Entry Step 5 Bring the Cyclone Overflow data window into view.
Step 6 From the Data drop-down list select the SDs option and
from the Error drop-down list select the Abs-Bal
option. You will see the stream data in a format which
is almost exactly like that in Model Fitting.
The experimental stream data and the related SDs are

displayed as well as the balanced data and its related
errors.

Stream Data The Totals tab section of the window contains the experimental
solids and water mass flow values and related data for the stream.
The Size Distribution tab contains the list of the sizings from Top
Size to Size 30 with the value (%) for each size fraction. Whether
the % experimental value refers to % Retained, % Passing, or
Cumulative % Passing depends upon the choice of stream format
selected in the Format drop-down list at the top left of the screen.
The Components tab section of the window contains any assay data
for the stream.
Scrolling Notice that the Size Distribution tab section contains too much data
to display all of it in the window at one time. You can scroll
through the data by using the Page-Up, Page-Down, Home or End
keys, or the cursor up and down control keys. You may also click
on the Print icon on the JKSimMet tool bar for a printout of the
window you are working on.
Data The user must set the data standard deviation (SD) values in the
Accuracy column labelled SD. This column must contain a value in each cell
Entry where corresponding experimental data are entered. Note that this
standard deviation is your estimate of data accuracy obtained from
repeat samples or from experience.
There are three ways to enter values into these SD fields.

• Leave most or all of the entries at the default value of 1.0 and
simply over-typing the ones you wish to change individually.
• Globally change all the SDs to one of the three other available
options by:
Step 1 Click on the Set SDs button at the top,
right-hand corner of the stream data
window to bring the Select SD Values
window into view.

A Simple Example Mass Balancing
Step 2 Select the required option from the Select

SD Values window which is displayed
and click on the OK button to change the
SDs for the stream to the option which
you have chosen.
• The third option is that you can change the individual fields by
over-typing an SD value. The number which you enter is an
expression of your confidence in the experimental value.
Concept: Note that in mass balancing mode a large SD means the error will
Ignoring be largely ignored. This is different from Model Fitting where a
Data in Mass zero SD switches an error off completely. In mass balancing mode
Balancing a zero value for the SD will make the mass balancer hold the
experimental value constant, ie. it will not be adjusted.
Concepts: If you have high confidence in an experimental value to be used in

High Accuracy mass balancing, set the SD to a small value.
Data
Concepts: If both the experimental value and SD are set to zero, the mass
Calculating balancer will treat this datum as unknown, and estimate a value, if
Missing Data there are sufficient other data provided. This is useful when flow
data cannot be obtained in the stream sample survey.
Now that we know about setting SDs, we can continue our tour.
Step 7 Look at the data window for each port. For this
example you should examine the Feeder called Cyclone
Feed and the Cyclone Underflow and Cyclone
Overflow port data windows.
Step 8 Bring the Mass Balance window into view and select
the Run Balance tab. Left-click on the button marked
Start to run the mass balance algorithm. The program
will execute and when it is completed the results will
be displayed.
Step 9 Bring into view the port data windows and examine the
raw and adjusted data in each stream.
Step 10 Compare the raw and adjusted data graphically by
selecting Graph from the Cyclone properties list (Right-
click on Cyclone Icon). Select experimental then
calculated for a quick comparison.

For a numerical comparison of the experimental and calculated

data select the absolute difference option on the Error drop-down
list.
This completes our brief tour through Mass Balancing.

Learning Mass Balancing Mass Balancing
6.6 Learning Mass Balancing

The mass balancing module of JKSimMet is useful in two areas.
Firstly, it provides a check on data accuracy which is not model
dependent. The mass balancing models are correct (that is, they
contain no built in experience). Hence, if the data balance well but
the model fitting does not fit well, it indicates that the model is not
appropriate.
Where coarsely sized samples are used, as in crushing and
screening circuits, the mass balanced data may be more useful for
model fitting than the raw data.
Secondly, mass balancing is useful for determining flowrates and
recoveries around complex circuits. The example which we will
use in this section, Learning Mass Balancing, is concerned with
flowrates and recoveries in a copper flotation circuit.
6.6.1 Preparation for Mass Balancing

For our tutorial, mass balancing is performed on a circuit flowsheet
that has already been established. Ensure that you have either
selected an existing project, or you have input a new flowsheet (see
section 3.7 on Creating a New Project if you are unfamiliar with the
steps necessary to establish a project).
A tutorial example called Copper Flotation has been provided for

this section.
Step 1 Load the Learner Flowsheets project and select the
flowsheet named Copper Flotation from the drop-down
list. If necessary, resize the flowsheet window to view
the entire flowsheet. Ensure that the flowsheet is
locked.
Step 2 Click on the Mass Balance icon on the toolbar to bring
the Mass Balance window into view.

Mass Balancing Learning Mass Balancing
Notice that the Mass Balance window has a four selectable tabs for
the user to enter the information required for mass balancing. The
items in the Select and Component sections need to be defined
before running the mass balancing. If you have not defined these
items, JKSimMet will provide error messages to indicate what
information is missing.
6.6.2 Model Types for Mass Balancing

In Version 5 of JKSimMet the flowsheet drawing for mass
balancing is the same one used for simulation and model-fitting,
with the full range of equipment icons available to draw a circuit
diagram. However, no matter what equipment icon is visible, there
are only two model types in mass balancing. These are:
• classifier or mixer unit
This unit either selects particles to go to different product ports
of the unit (classifier) or adds particles from different feeds
(mixer). That is, particles are sorted or mixed in this type of unit,
not broken down or altered.
• transform unit
In this unit assays are preserved but size structures are
destroyed. In mass balancing all comminution devices are
transform units.
The mass balance algorithm decides which type of mass balance
unit is required according to the flowsheet icon selected by the
user.
6.6.3 Selecting Data

As is the case in the Simulation and Model-Fitting modules you
may select a single unit or a cluster of units on your flowsheet to
mass balance. This allows you to check small parts of a circuit for
data consistency.
Step 1 Bring the Mass Balance window into view.
Step 2 Left-click on the Select tab to bring the Select section
into view.

For the Copper Flotation example the selection list is

called Mass Balance Select List 1. The default
selection for a new select list is for none of the units
and streams to be selected. Therefore the first stage in
defining a select list is to examine the list of equipment
and streams and to select the required items by clicking
on the box next to the item name to enter a tick. A
Select All and a Select None button have been provided
to help users to configure select lists quickly.
Note that as you click on each item on the list its
flowsheet icon is highlighted in red. Also note that
items which have been selected for inclusion in the
mass balancing are highlighted in blue on the
flowsheet. These visual cues help users to identify the
equipment and streams on complex flowsheets.
Step 3 Work through the Select list and ensure that:

• all equipment units are selected
• all streams are selected
• all water additions are not selected
Note that for GSIM, percent solids and internal water flows are
always enabled.
Because each Select list has a name, you may set up several
different lists to examine different sections of a circuit. You can
select every stream and flow to balance or any single unit or
selection of streams.
Note: in V5.0 stream data are stored in equipment ports. To
balance a subset of the data, you need to choose both equipment
and ports.
The “water” check box, applies to Water Feeders. These should
only be used with GSIM or when “% solids as a component” is
checked on the component tab.

6.6.4 Component
The mass balancing module can analyse two types of data, namely
components or size distributions. The model-fitting and simulation
modes in JKSimMet only use size distributions. The size format is
called GSIM for Grinding Simulation. JKSimMet uses GSIM as
the default component type. If GSIM is selected via the GSIM
Mode check box on the Run Balance tab or the Components tab, no
further data entry is required.
To use GSIM mode

click in this box to
select it. No further
component data entry
is required.
However, it is possible to define your own labels for other

measurements of stream characteristics, such as assays, which can
be used to mass-balance the flows around a circuit. The user must
specify the component list names before running mass balancing.
Note that while the mass balance module can handle stream
components other than size e.g. assays, these cannot be combined
with balancing by size distribution. Therefore a circuit can be
balanced based on size distributions only or assays only.
To perform a mass balance using data other than size the user must
select a Component list and give it a name. The next step is to
define each of the components.
Step 1 Left-click on the Component tab to view the
component list. For the Copper Flotation example, the
list is called CuFe and the components are copper and
iron assays, %Cu and %Fe.

Step 2 Ensure that both the %Cu and %Fe assays are selected
for use (i.e. each has a tick in the box in the Use
column which is beside the Component Name column).
Step 3 Relative SDs may be specified as automatically
calculated from here. However, their use is not
recommended as a balance using relative SDs takes
most note of the smallest assay values which are often
the least well defined.
Step 4 The Control area of the Component section has a box
marked %Solids as a component. If this box does not
have a tick in it, all %Solids, water flows etc. are
ignored i.e. adjustment differences are absorbed in the
unspecified components and will not be shown on the
screen or printouts. For the Copper Flotation example
we will leave the box empty.
Typically you would use % solids as a component when
balancing a set of specific gravity fractions. If you use
% solids as a component you must specify appropriate
water additions. For what happens when % solids are
included as a component see section 6.6.5 on Water.
Entering Once a Component list has been defined in the Component tab of
Component the Mass Balance window, JKSimMet sets up the correct number
Data of data cells for the component data to be entered in each of the
port data windows. The component data can be accessed by
clicking on the Component tab of the port data window.
The flowsheet is now set up to mass balance the data using
component data, in this case assay data. All that remains to be done
is to enter the assay data into the port data windows.
Step 1 To enter (or examine) stream assay data, open a port
data window and click on the Component tab. This
window will now contain as many rows of components
as the user has defined in the Mass Balance window
Component tab. The user enters new assay data (or
edits existing data) by typing over the values in blue
text in the column marked Exp. In the Copper Flotation
example the %Cu and %Fe assay data have already
been entered as shown in the example below.
Step 2 Select the SD’s error display type from the Data drop-
down list.

Step 3 Select the data standard deviation value by clicking on

the Set SDs button and selecting the required SD from
the choices presented in the Select SD Values pop-up
window. Alternatively the user can type in their own
values for the SDs. In the Copper Flotation example
the assay SDs are set to 10%. However, for less well
defined data, the Whiten Error provides a more realistic
error model.
Step 4 Repeat steps 2 and 3 above for each port in turn.
Step 5 Finally, open the Feed unit equipment window to
examine the feed stream data. Ensure that the measured
feed flowrate has been entered (and the % solids by
weight if available).
Error Display The right-most column under the Components tab in the stream
data window is the Error column, and the values in it can be
expressed in one of three ways; Absolute Error, Percentage Error or
Weighted Error. The user can select which of these forms is
displayed by the following procedure:
Step 1 Click on the Error box to view the drop-down list.

Step 2 Select the required mass balance error type from the list
(either Abs-Bal for absolute error, Pct-Bal for
percentage error or Wtd-Bal for weighted error).
Absolute Error Tells you the actual difference between the calculated and the
experimental values.
Percentage Tells you the percentage difference between the calculated and the

Weighted Tells you the number that the program will use in its sum of
Error squares. You will probably find it the most useful setting. The
value of this weighted error is
(exp - adj)2
 S.D. 
 
6.6.5 Water
If you have selected %Solids as a component on the current Mass
Balance window Component tab you can also mass balance any
water additions to the circuit.
In Version 5, mass balance water additions are made by selecting
the appropriate water feeder and including it on the Select list. For
this example, you will need to add two water feeders to the
flowsheet. Measured data and estimated SDs are entered in the
water addition data window. This removes the need for the water
addition list used in Version 4.
See Appendix A1.2 for a detailed description of the Water Feeder.
Some typical water addition and % solids data are tabled below.
Select % Solids as a component on the Component tab (see section
6.6.2 on Components) and also select water additions on the Select
tab (see section 6.6.4 on Selecting Data) to use this facility
Stream % Solids % Solids

Exp SD
FEED 30.0 1.00

COMB SCAV CONC 28.0 3.00
RGH 1 CONC 45.0 2.00
RGH 1 TAIL 29.0 2.00
RGH 2 CONC 40.0 2.00
RGH 2 TAIL 28.0 2.00
SCAV CONC 35.0 2.00
FINAL TAIL 27.0 2.00
CLNR SCAV CONC 40.0 4.00
CLNR FEED 28.0 3.00
CLNR SCAV TAIL 28.0 3.00
CLNR 2 TAIL 40.0 4.00
CLNR 1 CONC 45.0 3.00
CLNR 1 TAIL 30.0 5.00
FINAL CONC 50.0 5.00

Water Feeders:
Clnr Feed Sump 20 SD 1.0
Scav Conc Sump 15 SD 1.0
Remember:
Select the Water Feeders and tick % solids as a component in the
Mass Balance dialogue window.
6.6.6 Solution Controls

With the Mass Balance window as the active window, click on the
Control tab to bring the control section into view.
Note that it is not necessary to understand this section to use the

mass balance module. The following comments are for users with
a mathematical background.
The mass balancing algorithm runs in several stages.

The first is the simple solution which is analogous to multiple
linear regression. Unless the data has serious problems it will
converge in one step; that is, the second solution will be the same
as the first.
If small negative values occur, increase the number of steps to
eliminate these values. However, recheck your data carefully.
Negative values indicate measurement bias.
For higher numerical accuracy you may increase the iteration
limits. However, there will be no gain in the balance accuracy
because data accuracy will be the usual limit.

Hint: Read section 6.9 on Problems relating to Mass balancing
before adjusting these settings.
The values shown above are the default values.

If the adjusted data show unacceptable inconsistencies (for
example, Au assays in ppm or 1.0 E-06 will not work too well with
a convergence criterion of 1.0 E-05) then you must either reduce
the limit or, more sensibly, re-scale the assay. For example,
express your gold assays as Au ppm and do not constrain the assay
total to 100%.
6.6.7 Carrying out the Mass Balance

This is the simplest step. Once the components have been
specified, the desired equipment and streams selected and the data
have been input, the mass balancing can begin.
Step 1 Click on the Run Balance tab of the Mass Balance
window.
Step 2 Ensure that the correct Select and Component lists are
selected in the cells above the main data area. For the
Copper Flotation example we will use the existing
Select list Mass Balance Select List 1 and the
Component list CuFe.
Step 3 Left-click on the Start button to start the mass
balancing program.

The mass balancing program will run and when it is complete the
results will be summarised in the Mass Balance window as shown
below. The user can also examine the detailed data in the port data
windows or using the Overview or graphing features.

Checking the Balance Mass Balancing
6.7 Checking the Balance

During the execution of the balance program, the Mass Balance
window is displayed. Once execution has stopped, the values in
the results section of the window are updated. Assuming that the
balance has reached a satisfactory conclusion, the calculated
standard deviations of the solid flowrates are also updated.
The standard deviations calculated by the mass balancing program
for each solids flowrate are analogous to the Model Fitting
estimates of parameter accuracy, that is, solids stream flowrates are
the parameters of Mass Balancing.
There are various ways in which the user can assess the results:
• The overview window is probably the most useful way to check
data and results. It also allows recovery of any component to be
displayed for all streams. See Section 6.8.1 for details of the
overview facility.
• Compare the size or order of magnitude of the SDs with that of
the associated value. When the SD is small compared with the
value as a ratio, it is a good fit; and when large, a poor fit.
• The summary values in the Sum of Squares section at the foot of
the Run Balance tab also indicate the overall success of the fit.
Low values indicate a good balance while large values of these
items indicate a poor balance. Moreover, in the case of these
fields, cross comparisons between mass balances can be made.
If these values are smaller in the most recent run of the balance
than they were in the previous run, the balance is getting better.
If they are getting larger, your mass balancing is going in the
wrong direction.
• The engineer can also judge the relative success of the mass
balancing by looking at the port data windows. Examine the
values in the Error column. The Weighted Error and Percentage
Error versions of the difference between balanced and
experimental data for sizings are most useful.
• The graph plotting facility of JKSimMet allows the user to plot
raw and balanced size distribution data (GSIM) on the same
screen, as detailed in section 6.8 (Presentation of Mass
Balancing Results).
• Mass Balancing can be carried out one unit (or a small set of
units) at a time. This allows you to put the test data under a
microscope. If circuit conditions were changing as you did your
test work, unstable sections will give unusable results and
varying conditions will usually produce nonsense.

Mass Balancing Checking the Balance
Concept: At the best-fit point, an estimate of the goodness of fit is calculated

Data Standard by dividing the weighted sum of squares (Residual Error) by the
Deviations number of points less the number of parameters, and taking the
square root. If the data and the error estimates are in agreement,
and if the model is appropriate, this number will tend towards one.
With Whiten SDs, good data achieve values in the range 1 - 4.
Concept: The same approach can be used for each stream point. These
Stream Data values are reported for each fitted stream in the Mass Balance
SDs window and the stream data windows.
The solution of the mass balancing minimisation also provides

estimates of parameter accuracy. The parameters in this case are
the stream flowrates. The mathematical proof of this estimate of
accuracy is complex. Intuitively, if the parameter is well defined,
the sum of squares will vary more rapidly as the parameter is
adjusted. For a more detailed explanation, see LYNCH (1977),
chapter 7.
If the program finds that small variations in a parameter make NO

apparent difference to the sum of squares at the minimum, it sets
the parameter SD to 1E18 Such mass balance results should be
TREATED WITH CAUTION.
Note also that such a result may mean you are trying to balance
around a splitter or a classifier which is not classifying.

Presentation of Mass Balancing Results Mass Balancing
6.8 Presentation of Mass Balancing Results

There are two main ways to present the results of mass balancing:
• the overview window and
• printing
We shall deal with these in turn. For mass balanced data, graph
plotting is limited to GSIM format.
6.8.1 Overview
The overview window gives you a powerful means of summarising
your data and checking it for adjustment problems. Each overview
data set defined by the user displays a list of data from all selected
streams. The user can select the types of data which are displayed
in the overview window.
The best way to use the overview feature is to compare
experimental and calculated values for each assay (or size fraction)
across the complete circuit. This will give a very useful picture of
the accuracy of the data and the mass balance. Note that the
overview window can be configured to show either data or
calculated Recovery information.
Step 1 Left-click on the Overview Config button on the main

JKSimMet toolbar. This brings the Overview window
into view.
Step 2 Select the existing overview.

Mass Balancing Presentation of Mass Balancing Results
Step 3 In order to make it easier to view the data in the
overview window, resize the window by clicking and
dragging the bottom, right-hand corner of the window.
Also widen the Equipment and Port columns by
clicking and dragging the right-hand border of the title
cell in each column.
Step 4 You can now add a column to view the Fe assay SD
data by clicking on the Insert Column icon at the top of
the overview window.
Step 5 Place the cursor in the top title cell of the new column
and press Enter to bring a drop-down list of options
into view. Select Components from the list.
Step 6 Place the cursor in the middle title cell of the new
column and press Enter to bring a drop-down list of
component options into view. Select %Fe from the list.
Step 7 Place the cursor in the lowermost title cell of the new
column and press Enter to bring a drop-down list of
options into view. Select Calc Bal SD from the list of
options. The overview window should now look like
the picture below.
Recovery To examine recovery data for the components in the streams select
Selection Recovery by placing a tick in the Recovery box.
Note: The balanced recovery selection will calculate recoveries
based on mass balanced assays and flowrates.
By default, the recovery is calculated with respect to the circuit feed
stream. This reference stream is labelled in bold text in the
Overview table. To change the stream which is the reference for

recovery calculations, move the cursor to the row in the overview
window which has the named stream in and right-click in the
equipment column. This brings up a dialogue window as shown
below which allows you to define the selected stream as the
reference for the recovery calculations.
6.8.2 Printing the Mass Balance Results

Printing Printing can be selected from any window by clicking on the Print
Mass Balance icon on the JKSimMet toolbar. When this is done, the current
Results window will be printed.
Given that mass balancing concerns the experimental (raw) data
and the adjusted (mass balanced) data for streams, our task is to
print these two types of data for the streams concerned. One way to
do this is to print individual port data windows. In this case ensure
that the port data window Data type is set to SD’s.
An alternative method for printing the experimental and adjusted
data is to configure a Report. This allows the user to select any of
the port data types for printing and includes a Summary format
which is useful for comparing data.
To print recovery data, use the overview table with the Recovery
option selected. Remember to select a stream to use as the recovery
basis. (If this stream is the feed stream, this will produce an
element distribution which is often the objective of mass
balancing).

6.8.3 Plotting Graphs

Plotting Graphs The graphs presenting mass balance results are, once again, of
of the Mass stream data. They involve experimental (raw) data and adjusted
Balancing Results data. The simplest way to begin is to select the default format
options available in the graphing sub-system and simply nominate
the data to be plotted. You can then edit the format and axes as
required.
At present, graphing is available only for GSIM format. Therefore,

to examine graphing for mass balancing, leave the Copper Flotation
flowsheet and select the flowsheet named Example Cyclone Mass
Balance. For this exercise, you will create a new graph.
Step 1 Left-click on the Generic Graph Config button on the

main toolbar to open the Graph Definition window
Step 2 Left-click on the Format tab to make this the active tab.
Step 3 Left-click on the New button at the top, right corner of

the Graph Definition window to create a new graph
format.
Step 4 Place the cursor in the Name text box and double-click
to highlight the default graph format name. Now type
in a new format name and press Enter. Any new name
will do.
Step 5 Change the labels and the information in the Axes and
Data Interpretation area of the Format tab, using the
picture below as a guide.

The next step in configuring the graph is to tell JKSimMet where to

find the data to be plotted.
Step 6 Left-click on the Port Data tab to make this the active
tab and click on the New Data icon to create a new
graph data set.
Step 7 Name your data set, following the procedure described

in Step 4.
Step 8 Move the cursor across to column 1 of the row labelled
Port in the Data Selection - Ports area of the window
and press Enter to view the drop-down list of ports
whose data can be graphed. Select the Cyclone
Underflow by highlighting its name and pressing Enter.
Step 9 Move the cursor to the Format cell and press Enter to
view the drop-down list of format options. For this plot
select the Cum. % Passing option.
Step 10 Move the cursor to the Data cell and press Enter to
view the drop-down list of data which can be plotted.
Note that individual data types (e.g. Simulated) or pairs
of data types (Experimental and Simulated) can be
selected. In the latter case the Experimental data are

represented by the data marker and the calculated data
are represented by the line. For this graph select the
Exp & Bal option.
Step 11 If you would like to change the style of line or data
marker or the colour used to display the data on the
graph select the required items in the Line Point and
Colour cells respectively.
Step 12 Ensure that the box in the Spline cell is not ticked.
Step 13 Move the cursor to the X Min cell and enter
appropriate values in the minimum graph range for the
lines you want to plot. This is a type-over field. In this
case enter the value 0.01 for the minimum value of X
to be plotted.
Step 14 Repeat Step 13 for the X Max cell, in this case entering
the value 10 for the maximum value of X to be plotted.
Step 15 Repeat Steps 8 - 14 for all streams required, placing
each in a new column.
Step 18 Left-click on the Display Graph icon at the top right-
hand corner of the Graph Definition window to view
your graph. The plot for the Cyclone Mass Balance
Example looks like the picture below.
You can now refine the format of the graph and print it etc., as
outlined in the section 3.8 (Learning Graphing). Repeat the above
steps for each of the streams for which you wish to compare the
raw and calculated data. The goodness of fit is represented by the
closeness of the points to the line; the closer the lines and points,
the better the fit.

Problems and Possible Solutions Mass Balancing
6.9 Problems Related to Mass Balancing

and Possible Solutions
There are, of course, many problems that may be encountered
during mass balancing. It is possible, however, to point out some of
the more common mistakes, in order to alert you to some of the
major pitfalls.
Errors, Warnings, Some problems detected by JKSimMet produce error messages.

Faults See Appendix B for such problems.
ERRORS 120-139 are relevant to the Mass Balancing module.
Please refer to the expanded descriptions in Appendix B.
Skill Mass Balancing is not a cut and dried procedure. The only way to
versus Practice acquire a useful skill level is to practise on a wide range of real
data. JKSimMet offers a user-friendly environment for what are
really very complex and powerful mathematical techniques.
Graphical The graph capability of JKSimMet is the most powerful way to

Analysis examine your data fit (in GSIM stream format only).
Discontinuities in size data highlight poor data or a change in size
measurement technique. Graphical analysis also highlights any
bias in the data fit.
Different Sizing Be very wary of changes in size measurement technique e.g. from
Techniques screens to Cyclosizer.
Different Assay Where assay techniques change between stream samples, as they
Techniques sometimes do for different assay ranges, there may be inherent
biases within the assay techniques. These will lead to biases within
the mass balance.
Data Note that it is necessary to have enough feed and product data to
achieve a useful mass balance.
Some Common There are a couple of simple traps which can appear in many
Mass Balancing guises. If you become aware of these now you may recognize them
Pitfalls more easily when you encounter them.

Mass Balancing Problems and Possible Solutions
6.9.1 The Middlings Problem

If we return to our one unit flow diagram and add on a middling
stream of assay m:
b
a
m
It is easy to see that there are not enough assays to go around.

However, if we have two assays in each stream, we would write
them out as simple equations and solve for two unknowns.
However, as m really is a middlings stream, it will be close to a in
composition and very often recycled back to it.
In this case, no matter how accurately we can sample and assay the
streams, we can only find out:
• the ratio between flows b & c (if m goes elsewhere)
or
• the flows in b and c if a is recycled.
However, the actual flowrate in m can be either zero or infinity.

There is a straightforward solution. Measure (or estimate) the
flowrate in stream m and input this flowrate as data.
The mass balancing module allows you to do this.

Problems and Possible Solutions Mass Balancing
6.9.2 The Infinite Division Problem

The Infinite If one wishes to extract maximum information from a survey, it is
Division Problem not unusual to assay on a two (or even three) dimensional matrix,
for example, assay by size or assay by size by specific gravity.
This subdivides the stream into even smaller sub-groups. Each
sub-group has an extra step of processing and an increased relative
error. Hence, we tend towards trying to solve for (0 - 0) / (0 - 0).
This is not a useful numerical exercise.
Once again, the solution is straightforward. Use the total assays
with large differences to calculate the Mass Balancing flowrate
solutions. Once you have these flowrates, fix them by entering
them as experimental flowrates with low standard error estimates
and add all of the small assays into the problems.
Now that the flowrates are defined, the Mass Balancing module can
allocate the minimum adjustments required to make all of the
fractional assays consistent.
(Note this balancing module does not balance across the matrix for
more than one component at a time - this component is usually
size.)

Mass Balancing Metallurgical Accounting
6.10 Metallurgical Accounting

The day to day data collected from a mineral processing plant are
rarely consistent and will almost always contain redundant
information. In general, any two methods of calculation will yield
different results. The challenge for metallurgical accounting is to
produce adjusted data which are both self-consistent and as
accurate a representation of plant performance as possible.
Consider a typical base metal concentrator with several products
from several circuits,
Feed
x Copper Au x Lead x Zinc x Tailings
Circuit Circuit Circuit
x x x
Cu Au Pb Zn
Conc Conc Conc
At each point marked ⊗, we have Au, Cu, Fe, Pb and Zn Assays.

For the feed, we have weightometer readings and for the
concentrates we have load out weights with stockpile surveys.
If we select an accounting period which is large compared with the
circuit residence time, we can carry out a mass balance over this
complete data set. If large adjustments are required, these may be
measurement problems in sampling or assay techniques. Select
smaller circuits to mass balance to isolate these problems.
Once a consistent set of adjusted data is produced for each
accounting period, the sums of these sets will also be consistent.
If assays and flowrates are available on a short time scale, eg.
several times per shift, these data can be balanced for each time
period, printed to file or exported to most Windows spreadsheet
and word processing packages by copying and pasting.
JKMetAccount For users with a serious interest in metallurgical accounting, the
JKMetAccount program was created to enable the Metallurgist or
Plant Manager to track the performance of a mineral processing
plant over time. It's major strength comes from harnessing the
power of the JKMBal mass balancing engine within a rigorous data
management environment. Changes to your plant flowsheet, which
can cause major problems for a spreadsheet based accounting
system, are handled with ease by JKMetAccount. Combine these
features with a graphical flowsheet drawer and the ability to use the
full formatting power of Excel in your reports and you have a tool
that we believe you will soon come to regard as indispensable.
Further details are available from JKTech or at
www.metaccount.com

References Mass Balancing
6.11 References
LYNCH, A.J., 1977. Mineral Crushing and Grinding Circuits,
(Elsevier, Amsterdam), Chapter 7.
LYMAN, G.J., 1986. Application of Gy's sampling theory to coal,
International Journal of Mineral Processing, Vol 17:1-22.
GY, P.M., 1982. Sampling of particulate materials: theory and
practice, 2nd Ed, (Elsevier, Amsterdam).
MORRISON, R.D., 1976. A two stage least squares technique for
the general material balance problem, JKMRC Internal
Report No 61 (unpublished).

Appendix A Model Descriptions
APPENDIX A
Model Descriptions
Version 5.1 November 2001 Appendix A Page A-1

Introduction Appendix A
A1 Introduction
This appendix of model descriptions contains:
• a description of each model available in JKSimMet

• key equations which are the mathematical basis of the models
• known limitations and restrictions
• some guidance and restrictions for parameter fitting
• typical model parameter values, where appropriate
There are a number of generic models included in JKSimMet,

which can be used to describe the behaviour of a wide range of
processes. For example, the simple efficiency curve model can be
used to describe any sort of classification device, such as a cyclone,
or a spiral classifier. Selection or fitting of parameters for these
models will depend entirely on the type of process being modelled.
Most of the process units available to the user when drawing the
flowsheet can be described by a number of models. Typically, a
process unit will have a specific model, developed for that
particular device, and a number of generic models. Selection of the
appropriate model is at the user's discretion and will often depend
on available test data.
A1.1 Parameter Defaults and Range Limits

Model parameters in V5 have default values and a permitted range.
The default value and range can be viewed by double clicking on
the parameter value.
These values are not currently editable by the User.
A1.2 Model Differences in JKSimMet V5.0

and 5.1
To provide a more ‘obvious’ structure for Version 5, a class of
feeder models has been added.
These provide:
• A source for ore
• A source for water
Later modules will provide access to configuration data. For the

long term option of a full dynamic simulator, the feeder models
will provide a way of inputting variation with time.
Page A-2 Appendix A1 Version 5.1 November 2001

Appendix A Introduction
A1.2.1 Ore Feeder
Ore Feeder The ore feeder (called Feed) is a specialised piece of equipment
which has a single ‘product’. The Feed unit allows you to set up
the flowsheet ore SG and the default size distribution.
The size markers, i.e. Percent passing a particular size and size at
a particular percent passing can be set by double clicking on those
fields on the Totals tab. Note that while the flowsheet properties
dialogue allows you to set global properties for Data Information
blocks and tools such as simulation and model fit, these
properties for the feeder and ports may be set at different values
for each.
A1.2.2 Water Feeder
Water Feeder The water feeder replaces the ‘Unit Feed Density’ section of each
model in JKSimMet Version 4. The three models provided with
the Water Feeder are functionally identical to the three options for
‘Unit Feed Density’.
Option 1 - Feed No water is added.

Streams
The model reports on flow rates of solids and water added to the
piece of equipment to which it is connected. This information is
redundant as it is also contained in the feed port of that piece of
equipment. This model is provided for compatibility with
Version 4.
Version 5.0 December 1999 Appendix A1 Page A-3

Option 2 – This option allows the user to set a maximum percent solids for
Required % the total feed to the connected equipment.
Solids
If the feed percent solids is higher than ‘Required % Solids’ the
water feeder adds additional water to achieve the required percent
solids.
If the percent solids value is already lower than required, the

water feeder adds no water. It does NOT remove water to
achieve the required value.

Appendix A Introduction
Option 3 – Water Water Addition is the recommended mode for common use. The
Addition user specifies the required water addition in cubic metres per
hour.
This option has two more uses. The experimental water addition
may be used as a parameter in Model Fitting. That is, a model fit
may use water addition as a parameter when water flows were
unmeasured or the measurement is dubious.
The ‘exp Water Addition’ is subject to optional update after a

model fit as are all other parameters.
Note that percent solids or water flow from the circuit should be
constrained by a small SD value to provide a constraint on total
water addition.
The third use of this option is for mass balancing of water

additions.
The User provides the ‘exp New Water Addition’ and an ‘sd’
estimate on this model. The other requirement is that the Water
Feeder and Water are selected on the Select Tab of the Mass
Balance tool.
The balanced water addition is returned to the calc* field of the

Water Feeder. If you wish to use this value for fitting or
simulation, copy it into the Exp value.

A1.2.3 Variable Rates SAG Mill Model
Variable Rates The Variable Rates SAG model also has some differences –
SAG Model detailed in Appendix 11.
A1.2.4 Splitters
Splitters The range of splitter models has been increased. These are
discussed in Appendix 14.

Appendix A Hydrocyclone (Model 200, 201)
A2 Hydrocyclone (Model 200, 201)
A2.1 Model Description

The model is based on the concept of a reduced efficiency curve,
which in turn is developed from the actual efficiency curve and the
corrected efficiency curve for the classifier treating a particular ore.
The important concept is that the reduced efficiency curve is a
characteristic function of an ore and is independent of the
dimension or operating conditions of the cyclone. A typical set of
efficiency curves for a cyclone is shown in Figure A2.1.
The model consists of a series of equations which are described

below. At least one cyclone test on a particular ore is required to
provide data for the calculation of constants in the equations.
A2.2 Model Equations

The model consists of a series of equations which are described
below.
Pressure- The pressure-throughput relationship can be expressed as:

Throughput
Relationship
Q = KQ2 Dc2 (P/ρp)0.5 (Do/Dc)0.68 (A2.1)
where
KQ2=KQ1 (Di/Dc)0.45 (θ)-0.1 (Lc/Dc)0.2 (A2.2)
The proportionality constant, KQ1, is a function of the feed material

and the diameter of the cyclone. For cyclones of Krebs design,
treating identical feed solids, the dependence on cyclone diameter
may be empirically represented by the equation
KQ1=KQ0 Dc-0.1 (A2.3)
where KQ0 depends on feed solids characteristics (eg. specific

gravity) only.
Version 5.1 November 2001 Appendix A2 Page A-7

Hydrocyclone (Model 200, 201) Appendix A
Classification For normal industrial operation, the classification size can be

Size Relationship related to the variables according to the equation
d50c/Dc=KD2(Do/Dc)0.52 (Du/Dc)-0.47 λ0.93(P/{ρp g Dc})-0.22
. . . (A2.4)
where KD2 is related to the minor design variables Di, Lc and θ by

KD2=KD1 (Di/Dc)-0.5(Lc/Dc)0.2 (θ)0.15 (A2.5)
and KD1 may be written as

KD1=KD0 (Dc)-0.65 (A2.6)
KD0 depends on feed solids characteristics only (such as size

distribution and specific gravity).
(Note that the classification sizes for specific minerals within the
feed stream can be estimated using the following formula:
FeedSG -1
d 50c ( m ) = * d 50c
MineralSG -1
where FeedSG is the mean feed solids density, d50c is the overall
corrected d50, MineralSG is the density of the specific mineral of
interest, and d50c(m) is the corrected d50 of the mineral of
interest.)
Recovery to Water recovery (Rf) and volume pulp recovery (Rv) to underflow
Underflow are related to the major variables by:
Relationships
Rf=Kw2(Do/Dc)-1.19 (Du/Dc)2.40 (P/{ρp g Dc})-0.53 (λ)0.27

. . .(A2.7)
and
Rv=Kv2 (Do/Dc)-0.94 (Du/Dc)1.83 (P/{ρp g Dc})-0.31 (A2.8)
Further, the effects of inlet diameter, cone angle and cylinder length
have been evaluated as
Kw2=Kw1 (Di /Dc)-0.50 (θ)-0.24 (Lc/Dc)0.22 (A2.9)

and
Kv2=Kv1 (Di/Dc)-0.25 (θ)-0.24 (Lc/Dc)0.22 (A2.10)

Here Kw1 and Kv1 are constants also depending on feed solids
characteristics. The current data indicate that Kw1 and Kv1 are
independent of cyclone diameter for geometrically similar cyclones
treating identical feed solids. Small quantities of viscosity
modifiers such as clay, can have a marked effect on these variables.
Efficiency Curve The efficiency curve used in this model is given below:
Relationship
Eo(d/d50c)=C⋅(1+β⋅β*⋅d/d50c) (exp(α) - 1)/(exp(α⋅β*⋅d/d50c)

+ exp(α) - 2) (2.11)
When β is 0, β* is 1 the above equation reduces to

Eo(d/d50c)=C⋅(exp(α) - 1)/(exp(α⋅d/d50c) + exp(α) - 2) (A2.12)
The shape parameter β determines the initial rise, while α
determines the slope at larger values of d (d≈d50c). Both α and β
are normally constant for given feed solids, while C and d50c vary
with cyclone dimensions and operating conditions. The
parameter β* is determined, for given values of α and β, by the
condition that
Eo(1) = C/2 (A2.13)
β* is calculated iteratively in the model.
Figures A2.1 and A2.2 show the effects of α and β on the shape of
the efficiency curve.
Modified An alternative to the standard efficiency curve is available with the
Efficiency Curve Nageswararao Fines hydrocyclone model.
With this model the user can specify the value of the reduced
efficiency curve (ie. fraction reporting to overflow) at 33% and
66% of the d50c size.
The curve is fixed (by definition) at the 100% point for zero size
and at the d50c. A cubic spline curve is used to describe the
efficiency curve for sizes below the d50c point. For sizes larger
than the d50, a log-normal distribution curve is used. The log-
normal curve is determined so that there is no discontinuity in slope
at the d50c point.
Figure A2.3 below shows how the modified efficiency curve
works. The user needs to specify (or model fit) the values of the
curve at 33% and 66% of the curve only.

The other parameters used by the model are used in the same way
as the standard Nageswararao model.
The Nageswararao-Fines model is useful for describing asymmetric
efficiency curves where a long 'tail' exists for either coarse or fine
material.
Interactions The interactions of variables within a cyclone are complex. Refer

to section A2.7 (Summary Table) for a summary of interaction
dependencies.
Scaling Facilities for scaling the operation of the hydrocyclone are built
into the model.
100
Increasing Alpha
% of Feed to Overflow (corrected)
80
60
40
20
0
0.00 0.50 1.00 1.50 2.00 2.50
d/d50 (corrected)
Figure A2.1: Effect of α on Reduced Efficiency Curve

180
160
Increasing Beta

140
120
100
80
60
40
20
0
0.00 0.50 1.00 1.50 2.00 2.50
d/d50 (corrected)
Figure A2.2: Effect of β on Reduced Efficiency Curve
180
160
140 Efficy. curve at 0.33xd50c
120
100 Efficy. curve at 0.66xd50c
80
60
Efficy. curve at d50c
40
20
0
0.00 0.50 1.00 1.50 2.00 2.50
d/d50(corrected)
Figure A2.3: Efficiency curve used in the Nageswararao-Fines

Model

A2.3 Hydrocyclone Model Printout

(Nageswararao) (Model 200)
Hydrocyclone Model Printout

(Nageswararao - Fines) (Model 201)

A2.4 Symbols
Symbol Meaning
α reduced efficiency curve sharpness parameter

β reduced efficiency curve hook parameter
β* reduced efficiency curve calculated parameter
C 100 - Rf or recovery of water to overflow, %
Dc cyclone diameter, m
Di diameter of circle with the same area as cyclone inlet, m
Do diameter of circle with the same area as vortex finder, m
Du diameter of circle with the same area as spigot, m
Eo(d) percentage of feed material of size d reporting to overflow
g gravitational acceleration
KD constant in the classification size relationship
KQ constant in the volume pulp recovery relationship
Kv constant in the volume pulp recovery relationship
Kw constant in the water recovery relationship
Lc length of cylindrical section, m
P feed pressure at inlet, kPa
Q cyclone throughput, m3/hr
Rf recovery of water to underflow, %
Rv volumetric recovery of feed pulp to underflow, %
d mean size of particle, mm
d50c size of a particle in feed which has equal probability of
going to underflow or overflow, due to centrifugal action,
mm
Cv volumetric fraction of solids in feed slurry
λ 101.82Cv/ (8.05 ∗ (1.0 − Cv)2)
ρp density of feed pulp, tonnes/m3
θ cone full angle, degrees

A2.5 Known Restrictions

• As the feed becomes coarser, d50c tends to decrease even
when all the other variables are kept constant. The effect of
size distribution of the feed material becomes insignificant
when the feed consists of mainly –53 µm particles, and also
when the proportion of –53 µm particles is less than 25% of
the feed solids.
• The analytic form used does not provide a perfect
representation for the reduced efficiency curve. As a result
the model often tends to predict fewer coarse particles in the
overflow than occur in real operation, however, the magnitude
of the error is considered to be small.
• Viscosity variations due to changes in pulp density are largely
accounted for by the model. Viscosity variations caused by
variable quantities of slimes affect the parameters in quite a
systematic way.
• As viscosity (or slimes fraction) increases, the cut size
becomes coarser, the water split to overflow is reduced, and
the cyclone pressure drop becomes larger. However, the
reduced efficiency curve remains relatively constant until the
onset of roping.
• The model may be used to estimate operation during roping:
– the cut size will become 5 to 10 times larger (ie. multiply
KD0 by 5 to 10 times
– the efficiency curve will become an “inefficiency” curve
with an α value typically of 0.1 - 0.2.
– water split and pressure drop are relatively unaffected
although a small drop in pressure is often claimed. This
may result from a reduced volume of solids to overflow.
• The onset of cyclone roping is difficult to predict. In general
50% solids by volume is a practical underflow limit.
However, very coarse underflow may achieve higher density
and finer ones somewhat lower density as detailed below.
JKSimMet will warn you that roping is likely if either of the
density limits (detailed below) are exceeded.

Cyclone Roping If the cyclone feed density is less than 35% solids by volume, the
Constraint SPOC constraint (Laguitton 1985) is claimed to predict onset of
roping.
Vol % solids in U/F = Limiting Vol % solids (~56)

+ 0.2 (Vol % Solids in Feed -20)
The limiting % solids is defined as the onset of roping at a

volumetric feed density of 20%.
In tabular form:
at sg 2.7 at sg 4.0
Feed Underflow Feed Underflow Feed Underflow
Density Density Density Density Density Density
% by Volume % by Weight % by Weight
5 53 12.4 75.3 17.4 81.8
10 54 23.1 76.0 30.8 82.4
15 55 32.3 76.7 41.4 83.0
20 56 40.3 77.5 50.0 83.6
25 57 47.4 78.2 57.1 84.1
30 58 53.6 78.8 63.1 84.7
35 59 59.2 79.5 68.3 85.2
Empirical Industrial experience demonstrates that a coarse underflow will

Constraint remain in spray discharge at a higher density than a fine underflow.
This is intuitively reasonable in terms of slurry viscosity but
difficult to predict.
Plitt et al (1987) have developed an empirical relationship based on
Lynch (1965) data and others.
 - 50% passing U/F size µm 

Vol % Solids in U/F = 62.3 1 - exp ( )
 60 
This approach puts a 50% solids by volume limit on an underflow

with 50% passing 100 µm and 60% at a P50 of around 200 µm.
This function decreases sharply with size dropping to 45% solids
by volume at a P50 of 80 µm and 40% at a P50 of 60 µm.

In tabular form:
Roping onset Underflow % Solids % Solids

% Solids by Vol. 50% passing (µm) at sg 2.7 at sg 4.0
35.2 50 59.4 68.5
39.0 60 63.3 71.9
45.9 80 69.6 77.2
50.5 100 73.4 80.3
53.9 120 75.9 82.4
58.6 170 79.3 85.0
60.0 200 80.2 85.7
61.3 250 81.0 86.4
The two effects are probably competitive to some degree. Further,

each operation has a 'comfort limit' on cyclone underflow density
which may be a good deal lower than the above limits.
A2.6 Summary Table
SUMMARY OF THE EFFECTS OF VARIABLES ON

CYCLONE OPERATION
Variable Resultant effect on parameter
Increased Q d50c Rf Rv
Dc increase (.57) increase (.82) decrease (-.4) decrease (-.55)
Di increase (.45) decrease (0.5) decrease (-.5) decrease (.25)
Do increase (.68) increase (.52) decrease (-1/19) decrease (-.94)
Du -- decrease (-.47) increase (2.4) increase (1.83)
Lc increase (.2) increase (.2) increase (.22) increase (.22)
p increase (.5) decrease (-.22) decrease (-.53) decrease (-.31)
λ -- increase (.93) increase (.27) --
ρp decrease (-.5) increase (.22) increase (.53) increase (.31)
θ decrease (-.1) increase (.15) decrease (-.24) decrease (-.24)
Note: The numbers listed in brackets are exponents for dependence

of the parameter on the variable.
Examples of the effects of α and β on reduced efficiency curves are

given in the attached Figures A2.1 and A2.2. The β* parameters
used in the model are calculated.

A2.7.1 Fitting the Cyclone Model (200)

PARAMETER MENU
Pressure Data If you wish to predict cyclone pressure accurately at other

conditions you will need at least one accurate pressure
measurement and a set of at least two out of three of the feed,
underflow and overflow samples.
If pressure data are not available, an approximate pressure can be

estimated from the manufacturers published data.
The calculated pressure is used in the equations for classification

size and recovery to underflow. Hence, the cyclone pressure is an
important measurement.
The measured or assumed pressure data must be entered on the

Performance Data tab of the cyclone equipment data window. If an
accuracy estimate is available, use it to calculate the standard
deviation. If not, use 10% of the pressure value.
The capacity constant KQO can be calculated from the cyclone

flowrate and the cyclone dimensions. (Refer to equations A2.1-
A2.3).
Typical values of KQO are in the range 300-600. The scale factor
for fitting should be 100.
To make the pressure observation available to the fitting

calculation, it must be selected with a tick on the Equipment Data
tab of the Model Fit dialogue window.
Classification Equations A2.4 to A2.6 define the cut size. KDO is typically a
Size (KDO) small number - say 0.001 to .00001. Therefore, a scale factor of
0.0001 is usually suitable.
Water Split % to The actual water split to overflow (Cal WS) is fitted rather than the
O/F (Cal WS) two parameters, KV1 and KW1, which are defined by a single
water split.
When model fitting a single set of cyclone data, ALWAYS fit

Cal WS. A good starting point is 50% with a scale factor of 5.
After fitting, the calculated values of KV1 and KW1 are displayed
on the cyclone equipment data window (Model Parameters tab).

Efficiency Curve The reduced efficiency curve is an "S" shaped function as shown in
α and β)
(α Figure A2.1.
Typical values of a α range from 0.5 to 4. Beyond 5, the efficiency

curves become very sharp and larger numbers are not significant. A
good initial estimate is 2.0.
The β factor modifies the "S" curve to add an additional "hook" - or

a negative portion to the actual efficiency curve. A typical value is
zero. However, a poor fit at fine sizes can be tested by trying
values of β of 0.01 to 0.5. Fitting of β is available but not
recommended. A scale factor of 0.1 is suitable once a good initial
estimate has been found by trial.
If the efficiency curve is a poor fit at coarse sizes, try the alternative
fines modified or spline efficiency curve models.
Master/Slave Multiple sets of cyclone data can be model-fitted using the

Fitting Master/Slave facility, with one important provision. The water
split (Cal WS) cannot be fitted using Master/Slave fitting.
Fit KD0, KQ0, α and Cal WS for each data set independently, and
determine the average values of KV1 and KW1 for each cyclone
data set from the fit. Use the average values of KV1 and KW1 in
each cyclone data set. Use Master/Slave to fit KD0, KQ0, α and (if
required) β, over all data sets.
A2.7.1 Fitting the Nageswararao Fines Model

(201)
PARAMETER MENU
The comments in A2.7.1 above apply equally to Model 201 except

for the Efficiency Curve parameters α and β which are replaced by
Eff @ 0.33 (of d50c) and Eff @ 0.66 (of d50c).
Typical values are 0.85 and 0.65 respectively.

A2.8 References
DE KOOK, S.K., 1956, Symposium on recent developments in the
use of hydrocyclones - a review J. Chem. Metal. Min. Soc.
S.Afr., Vol. 56:281-294.
KAVETSKY, A., 1979. Hydrocyclone modelling and scaling.
JKMRC report to AMIRA, November.
KELSALL, D.F., 1953. A further study of the hydraulic cyclone.
Chem. Eng., Sci., Vol. 2:254-273.
LAGUITTON, D. (Ed), 1985. The SPOC Manual Simulated
Processing of Ore and Coal, CANMET EMR Canada, Ch.
5.1 (Part B).
LYNCH, A.J. 1965. The characteristics of hydrocyclones and their
application as control units in comminution circuits, AMIRA
Progress Report No. 6, University of Queensland
(unpublished).
LYNCH, A.J. and RAO, T.C., 1965. Digital computer simulation
of comminution systems. Proc. 8th Comm. Min. Metall.
Congr., Aust., N.Z., Vol. 6:597-606.
NAGESWARARAO, K., 1978. Further developments in the
modelling and scale-up of industrial hydrocyclones. Ph.D.
Thesis (unpublished). University of Queensland.
PLITT, L.R., FLINTOFF, B.C. and STUFFCO T.J., 1987. Roping
in hydrocyclones. 3rd International Conference on
Hydrocyclones, Oxford England, Elseveir, pp21-23.
YOSHIOKA, N. and HOTTA, Y., 1955. Liquid cyclone as a
hydraulic classifier. Chem. Eng. Jpn., Vol. 19:632-640.

(Blank Page)

Appendix A Single Deck Screen (Model 230)
A3 Single Deck Screen (Model 230)

Mechanistically a screening process can be regarded as a series of
trials, as a result of which particles of a particular size have a
probability of entering the fine product. This concept of defining
the screening efficiency in terms of a number of trials (or bounces)
is the basis for a screen model.
A typical efficiency curve for a vibrating screen is shown in
Figure A3.1. There are three regions on the curve:
Particle Size
Figure A3.1 :A Typical Efficiency Curve for a Vibrating Screen
• the region describing the above-aperture size material (region

A),
• the region describing the below but near aperture size material in
which the probability of passing through the aperture is directly
dependent on particle size (region B),
• the region describing the ultra-fines that adhere to the coarse
particles (region C).
Region B of the efficiency curve is the important region for

modelling purposes, and it can be described by the equation
(Whiten and White 1977).
E(x) = exp[-TRN.fo.(1-x/d)k] (A3.1)
where E(x) is the fraction of particles in the feed of size x which

enter the coarse product, d is the screen aperture; fo the fraction
open area, TRN is the efficiency parameter and k is a minor
parameter used for precise fitting purposes. Typically, the value of
k is about 2. The performance of the screen in region C can only be
determined experimentally since it will be dependent on local

Single Deck Screen (Model 230) Appendix A
conditions such as the moisture content of the ore which causes
small particles to adhere to large particles. For design purposes it is
necessary to make a reasonable assumption about the shape of the
curve in region C and this assumption is made by the design
engineer based on knowledge of local conditions.
The typical dependence of the efficiency parameter, TRN, which is
analogous to the number of trials, on the feed rate is shown in
Figure A3.2 for different materials used for the screen deck.
100
Steel
10
Rubber
1.0
0 F W1 FW2 High
Feed Rate/Unit Width
Figure A3.2: The dependence of the screen efficiency parameters on the

feed rate for rubber and steel decks.
The explanation of Figure A3.2 is that when the feed rate to screens
with rubber decks is low the particles move independently,
accumulate energy, take large bounces and have little opportunity
to pass through the screen aperture.
An increase in feed rate causes an increase in inter-particle
collisions, reduction in particle energy and bounce lengths, and an
increase in number of trials. Hence, the screen efficiency increases.
A further increase in feed rate causes more particle interference, a
decrease in the number of trials due to particles not reaching the
screen surface, and a decrease in screening efficiency.
With steel screens, however, the coefficient of restitution is low
and particles do not accumulate energy. Particle bounces are small
and high efficiencies occur at low feed rates. As the feed rate
increases the inter-particle interference increases and this reduces
the number of trials and the screening efficiency.
Page A-22 Appendix A3 Version 5.0 December 1999

Model A better understanding is required of the relationship between

Limitations particle shape, aperture shape and screen efficiency, and also of
screening performance in the difficult area between dry and wet
screening. The first is a problem of optimization of existing
screens, the second is a problem of plant operation.

Region B (Figure A.3.1) is described by equation 1.
E(x) = exp (- TRN * P/T) (A3.2)
where
P = fo*((1-fs) (1 - x/d)2 + fS*(1 - x/d))T (A3.3)
and
fS = 1 - (W/L) (A3.4)
In region A
E(x) = 1.0 (A3.5)
In region C an adjustment is made using the submesh factor (SF).
This adjustment transfers some of the submesh material in the
undersize stream to the submesh fraction of the oversize stream,
that is to account for the small particles that adhere to the larger
ones.
The important operating parameter is feed rate per unit screen
width (FW) and this function is approximated by several straight
lines as shown in Figure A3.2.
The number of trials TRN is related to operating parameters by a
set of regression equations of the following form.
Ln(TRN) = A + B * FW + U * P1 + V * P2 FW<FW1 (A3.6)
Ln(TRN) = C + D * FW + U * P1 + V * P2 FW1<FW< FW2
(A3.7)
where
C = A + (B-D) * FW1 by continuity (A3.8)
and
Ln(TRN) = C + D * FW2 + U * P1 + V * P2 FW>FW2 (A3.9)
SF is also related to operating parameters by a regression equation
SF = E + F * PSF + G * TSF (A3.10)

Fines Factor The fines factor is used to describe the "piggyback" effect of fines
on coarse material.
The material coarser than the "fines critical size" is considered in

terms of its notional surface area.
n
Vol i
Area of particles α ∑
(x i + x i+1 ) / 2
i
and SF* Area is the t/h of fines which are carried into the oversize
product.
Moisture For damp ores, the behaviour of moisture can be very important.
Behaviour There are sometimes several kinds of moisture. The only one of
interest to this model is in the fines, that is, fractions finer than the
"Moisture Split Critical Size XM".
All of the feed moisture is assumed to be carried in material finer

than this size. It is then allocated across the coarse and fine
products in proportion with how the material finer than XM is
allocated.
Scaling The model allows scaling of screen length by linear scaling of the
number of trials parameter, TRN.
Scaling of screen width is accomplished within the normal model

structure as FW is feed rate per unit width.
Aperture, fraction open area and slot shape are also included as
normal model parameters.

A3.3 Single Deck Model Printout showing

Default Parameter Values

A3.4 Symbols
Symbol Meaning
xi size of particles in the ith size fraction
E(x) fraction of particles in the feed of size
x which enter the coarse product
X1,X2 lower and upper screen sizes at fraction being

considered
X3 a critical size - if required - close to
screen aperture. However V is usually zero
X4 sub-mesh screen size, i.e., the smallest sieve in

the series
TRN efficiency parameter (number of bounces or
trials)
fo fraction open area
T total area of screen
W width of apertures
L length of apertures
fs fraction slot = 1-(W/L)
d maximum size of particle than can pass
through the screen, ie. aperture size
FW solids feed rate/unit width of screen
P1 % of feed of size x such that X1<x<X2
P2 % of feed < size X3
SF submesh factor
PSF % of feed < size X4
TSF tonnes/hour feed of size , X4
XF fines factor critical size
XM moisture split critical size
A Regression constant
B "
C "
D "
E Regression constant
F "
G "
U "
V "


Accurate application of the screen model requires data from the
screen to be simulated for parameter fitting. For simulation of
screens for which data are not available, data for a similar screen
type with similar feed may be used. Using data from operations
with markedly different screens or feeds will not provide useful
results.
The same square root of two series of screen sizes should be used
for both fitting and simulation.
The regression equations of the screen model make it quite
complex and more difficult to handle than most JKSimMet models.
For most processing plants only the tonnage dependence is
required. That is the values of U and V can be left at zero. For
wire mesh screens often equation A3.5 is adequate on its own.
Where there are large variations in the fitted submesh factor (SF)
try the dependencies of equation A3.9 as detailed in Sub Mesh
Factor Modelling. However, a constant SF is often adequate.
In a situation where you really want to tune a screen and are
prepared to collect a lot of accurate data, contact JKTech for
assistance with the parameter and regression fitting.

A3.6 Parameter Fitting the Screen Model
PARAMETER MENU
Ap Length
Ap Width
OA %
A int (TRN)
B*FW (TRN)
D*FW (TRN)
U*P1 (TRN)
U*P2 (TRN)
E int (FF)
F*PSF (FF)
G*PSF (FF)
XF
XM
The basic concept of a number of trials is quite simple. However,

the extensive correction factors and sectionalised curves make this
quite a difficult model to fit.
The Model Fitting program can process only one set of flowsheet
data at a time. However, one flowsheet may contain many
measured sets of screen data. Clearly, the flowrate and near size
dependencies require several sets of data to define the curves
shown in Figure 2.
To describe any particular set of screen data, only a number of trials
TRN (parameter 22) and a submesh factor SF (parameter 23) need
to be found. Good initial estimates for these parameters are 5 and
0.1 respectively. However, both TRN and SF are calculated
variables in this model. Therefore, we need to fit them as
regression parameter A (Ln TRN) and regression parameter E with
FW1 set to a larger value than any anticipated screen feed rates per
unit of width and with B, V, U, D, F and G all set to zero.
Master/Slave Master/Slave model fitting allows the secondary dependencies on

Fitting the parameter menu to be established when multiple sets of data are
available. Setting up Master /Slave fitting is detailed in section
5.6.5.
Parameter dependencies are discussed in A3.7.
However, fitting of multiple data sets is complex and assistance
from JKTech consultants is strongly recommended if you intend to
tackle this aspect of the fitting process.
Aperture Length Where screen data do not provide precise aperture and wire
and Width dimensions, the screen aperture can be fitted to the data.
Note that for slotted screens, effective aperture length depends on
the shape of the particle because the size data are measured using
square mesh screens.

Selection of feed Screen performance can be affected by the feed size distribution.
size parameters This is usually a secondary dependence compared with feed rate.
X1 to X4 However the model does allow it to be incorporated. X1 and X2
are the upper and lower sizes of a critical size fraction (or
fractions). If a particular range of sizes in your feed data is highly
variable use X1 and X2 to bracket it.
Set X3 to the screen aperture; or the average screen aperture, if you

are going to fit several screen mesh sizes.
Set X4 to say - 2 or 3 times the submesh top size. The finer part of
a size distribution has most of the surface area and will tend to
dominate surface carryover.
Traditional screen design techniques relate a different “fines factor”
to half of the screen aperture. You can use X3 set to half the screen
aperture to approximate this dependence if there are large
variations in fines in the feed.
Similarly, a traditional approach would use a “near size”
dependence of aperture size to half aperture size and X1-X2 can be
set to estimate this dependence.
A3.7 Regression Model Parameters

Trials versus This is the important dependence.
Feedrate
Fit each of the data sets available. This will give you a set of TRN
values at each fitted feed rate. You may also have a set of fractions
between P1 and P2 at each TRN value.
The next step is to plot up (TRN) versus feedrate. Any graphing
package eg MS Excel, can be used. Select FW1 and FW2 to let
you describe the curve accurately in three sections. An alternative
method is to print out your graph (with a full grid) and rule on
several line sections to suit. Their slopes and intercepts will
provide B and A and D and C respectively.
A multiple linear regression program can also be used - if you are
adept with such programs. Most spreadsheet programs (eg. Lotus,
MS Excel) have built-in multiple linear regression functions).
Critical Size If your Trials (TRN) versus feedrate data are erratic and your data
Dependencies are a good fit (less than 2 stream SD with Whiten weights), then it
is worth trying P1 and P2 dependencies.
Use a multiple linear regression program to fit ln (TRN) against

feedrate, P1 and P2 and divide into separate data sets using your
estimates of FW1 and FW2.

You can impose the continuity constraint by correcting equations 6
and 8 Ln(TRN) values by equation 7.
If you have a constrained non-linear fitting program which can
handle multiple equations, you can fit FW1 and FW2 as well.
However, you will need lots of good data.
Submesh Factor This is the other important dependence. For many operations, SF is
Modelling small and more or less constant. However, for operations with
damp ore, it can be crucial to a good model.
Once again, plot your best fit SF values against the calculated PSF
and TSF values from the parameter screens and draw a linear
regression line against any one variable. Print out the graph with a
fine grid for this slope (for G) and the intercept E. points.
Running the Input your estimated values back into the screen menu and import
Screen Model to each of your data sets. Try a simulation and check agreement
on product streams. Expect to make errors in this procedure the
first few times.
Master/Slave For up to 10 data sets, Master/Slave fitting provides an excellent

Fitting way of estimating these dependencies for good data. You can add
secondary dependencies one at a time to test for a significant
reduction in the sum of squares.
Hint : Only the undersize and a flowrate is needed for a full screen
fit.
A3.8 References
WHITEN, W.J. and WHITE, M.E., 1977. Modelling and
simulation of high tonnage crushing plants, XII
International Mineral Processing Congress, Brazil, Volume
II, 148-158.
WHITEN, W.J., 1984. Models and control techniques for crushing
plants, Control 84, Mineral/Metallurgical Processing,
(Editor, J A Herbst), Publishers - AIME, New York, 217-
225.

Appendix A Efficiency Curves (210, 610, 211, 611, 203)
A4 Efficiency Curves (Models 210, 610,

211, 611, 203)
(General Classifier Models)
A4.1 General Model Description

These models (210, 211, 203) use simple efficiency curves to
describe the operation of any classification device. They are also
provided as some of the optional models for the flotation cell and
flotation column (610, 611). For these two flotation devices, the
concentrate is the coarse stream.
A4.2 Simple Efficiency Curve (210, 610)
A4.2.1 Model Description

The model is simply an efficiency curve with a fixed d50c and a
fixed water split to fine product. Refer to Figures A2.1 and A2.2 of
the Hydrocyclone model for efficiency curve shapes. A typical
DSM screen has an α value of 4 and a β value of 0.
The model can be used to approximate many classifiers. Therefore

the default parameter values should be used with caution.
A4.2.2 Model Equations

Relationship
Eo(d/d50c) = C⋅(1+(β⋅β*⋅d/d50c)) (exp(α) - 1) / (exp(α⋅β*⋅d/d50c)
+ exp(α) - 2)
When β is 0, β* is 1 and the above equation reduces to:
Eo(d/d50c) = C⋅(exp(α) - 1) / (exp(α⋅d/d50c) + exp(α) - 2)
determines the slope at larger values of d (d ≈ d50c). Both α and β
are normally constant for given feed solids. The parameter β* is
determined, for given values of α and β, by the condition that:
Eo(1) = C/2
β* is calculated iteratively in the model. C is the fractional water
split to the fine product.
Scaling This form of the model does not permit scaling.

Efficiency Curves (210, 610, 211, 611, 203) Appendix A
A4.2.3 Efficiency Curve Model (210) Printout

(with default values)
A4.3 Simple Efficiency Curve - Water and

Fine (Model 211, 611)

The model is also a simply an efficiency curve with a fixed d50c as
described above for Model 210 with the added feature of allowing
the fines and water splits to be different.

Efficiency Curve The efficiency curve used in this model is the same as that
Relationship described in A4.2.2 above except that C (fractional water split to
fine product) is replaced in the equations with a separate parameter
F (fractional split of fines to fine product):
Eo(d/d50c) = F⋅(1+(β⋅β*⋅d/d50c)) (exp(α) - 1) / (exp(α⋅β*⋅d/d50c)

+ exp(α) - 2)
Eo(d/d50c) = F⋅(exp(α) - 1) / (exp(α⋅d/d50c) + exp(α) - 2)
determines the slope at larger values of d (d ≈ d50c). Both α and β
are normally constant for given feed solids. The parameter β* is
determined, for given values of α and β, by the condition that:
Eo(1) = F/2
β* is calculated iteratively in the model. F is the fractional fines
split to the fine product.
The water split is calculated directly from C, the fractional water
split to fines product.


A4.4 Splined Efficiency Curve (Model 203)

The model is also a simply an efficiency curve but the analytic form
of the curve used in Models 210 and 211 is replaced by a four knot
spline curve.

Efficiency Curve The efficiency curve in this model is provided by specifying four
Relationship pairs of coordinates through which a smooth curve (piecewise
cubic spline function) is constructed. Fine end of the curve is
specified by the water split as in Model 210.


A4.5 Symbols
Equivalent
JKSimMet
Symbol Meaning
parameter
Reduced efficiency curve sharpness
α Alpha
parameter.
Reduced efficiency curve dip
β Beta
parameter.
Parameter for describing the
β* Beta*
reduced efficiency curve.
C Water split to fines product. WS%Fines
F Fines split to fines product FI%Fines

Size of particle in the feed which
d50c has equal probability of going to D50c
fine or coarse product.
Range of Validity The highly simplified form of these models means that
extrapolation away from the conditions at which the parameters
were determined will significantly decrease the accuracy. If a wide
range of data is available, it may be possible to use Model 251 (see
Appendix A5) which has a variable cut point.

A4.7 Fitting the Efficiency Curve Models
A4.7.1 Fitting the Simple Efficiency Curve

Model (210, 610)
PARAMETER MENU
This is a simple model to fit as it has no scaling capabilities. Fit

the water split, alpha and d50c. See the comments regarding fitting
Beta in the cyclone model description (Appendix A2).
For DSM Screens, initial estimates of 4 for alpha and 50% for the
water split should be adequate for most data sets. An initial d50c
estimate of half of the actual screen aperture is appropriate.
A4.7.2 Fitting the Simple Efficiency Curve

Model – Water and Fine (211, 611)
PARAMETER MENU
This also is a simple model to fit as it has no scaling capabilities.

Fit the water split, the fines split, alpha and d50c. See the
comments regarding fitting Beta in the cyclone model description
(Appendix A2).
A4.7.3 Fitting the Splined Efficiency Curve

Model (203)
PARAMETER MENU
This also is a simple model to fit as it has no scaling capabilities.

Fit the water split and the four efficiency values at the knots on the

spline curve. It is important to remember to set the size values for
the knots before attempting model fitting.
Even though it seems incorrect, it is possible for the fitted
efficiency values to be greater than 1 or less than 0. Sometimes,
model fitting arrives at values at the ends of the curve which are
outside the 0 – 1 range in order to achieve the best shape for the
curve inside the 0 – 1 range. This is due to the properties of the
spline curve for which the values at the ends of the curve have an
effect on the shape of the curve in the centre region.
The simulation model code truncates the efficiency values to be
less than 1 and greaster than 0.
The combination of these two features, control of the shape of the
centre of the curve and truncation at 0 and 1 ensures that the model
predictions are sensible.
A4.8 References
LYNCH, A.J., 1977, Mineral Crushing and Grinding Circuits.
(Elsevier, Amsterdam) pp. 124-126.

Appendix A Efficiency Curve Variable D50c (Model 251)
A5 Efficiency Curve Variable D50c (Model 251)

This model is an extension of the Efficiency curve (Fixed D50c)
model to include a regression relationship for d50c. The water split
to the fine product remains fixed.

d50c For normal operation the classification size d50c can be related to
Relationship the operating variables according to the equation:
Log10 (d50c) = W * log10 (SW) + X * FW * C / 100 + Y * FPS + Z

. . .(A5.1)
Relationship
Eo(d / d50c) = 100.C.(1+(β.β*.d / d50c)) (exp(α) - 1) /

(exp(α.β*.d/ d50c) + exp(α) - 2) (A5.2)
Eo(d/d50c) = 100.C.(exp(α) - 1) / (exp(α.d / d50c) + exp(α) - 2)
. . . (A5.3)

determines the slope at larger values of d (d close to d50c). Both α
and β are normally constant for given feed solids. The parameter β
* is determined, for given values of α and β, by the condition that:
Eo(1) = 100⋅C / 2
β* is calculated iteratively in the model.
Version 5.1 February 2003 Appendix A5 Page A-37

Efficiency Curve Variable D50c (Model 251) Appendix A
A5.3 Efficiency Curve Variable D50c Model

Showing Default Values
A5.4 Symbols
Symbol Meaning
α reduced efficiency curve sharpness parameter
β reduced efficiency curve dip parameter
β* reduced efficiency curve calculated parameter
W,X,Y,Z regression constants in the d50c equation
d50c size of particle in the feed which has equal probability
of going to fine or coarse product
C % water split to fine product
SW slot width (mm)
FW volume flow rate of water in the feed (m3)
FPS % solids in the feed
Page A-38 Appendix A5 Version 5.1 February 2003

Appendix A Efficiency Curve Variable D50c (Model 251)

As Model 251 is based on a regression equation, extrapolation
beyond the scope of the data used in the regression will decrease
accuracy significantly.
Effect of the The relationship between D50c and Slot Width is defined in Log
log relationship space. This means that the multiplier coefficient W will have a
different effect for slot widths less than and greater than 1.0 mm.
For slot widths less than 1.0 mm a multiplier greater than 1 will
make the calculated D50c value smaller than the slot width.
However, for slot widths greater than 1.0 mm, the effect is
reversed.This can cause unexpected results when changing slot
width.
Screen Wear DSM screens are sensitive to wire wear condition. The screens are
usually reversed on a regular basis. If possible, test data should
record the wear condition. If this is not possible, test at both new
and worn to obtain a range of likely operation.
A5.6 Fitting
PARAMETER MENU
W * Slot
X * FPS
Y * FdWater
Z (int)
Sharpness α
Dip β
C
This is a simple model to fit as it has no scaling capabilities. Fit

the water split, α and d50c. See the comments regarding fitting β in
the cyclone model description (Appendix A2).
Initial estimates of 4 for α and 50% for the water split should be
adequate for most data sets.
An initial d50c estimate of half of the actual screen aperture is
appropriate.
Multiple Data If the data cover a range of feed rates, feed percent solids, slot
Sets widths and screen widths, proceed as follows:
• Fit each data set for α, C and d50.

• Refit with average α and C set constant. That is, force all the
variation into the cut size.
• Use Master/Slave fitting to fit the separation size equation
(A5.1) for W, X, Y and Z.

Efficiency Curve Variable D50c (Model 251) Appendix A
Note: If the slot width does not have a strong effect on d50c, then
the data are very questionable.
A5.7 References
LYNCH, A. J., 1977, Mineral crushing and grinding circuits,
(Elsevier, Amsterdam), pp 124-126.

Appendix A Crusher (Model 400/405)
A6 Crusher (Models 400 and 405)

(Andersen/Awachie/Whiten)
The crusher model considers the crushing process as two
components:
• the selection of particles for breakage, and

• the breakage of the particles so selected.
Selection Clearly, whether or not a particle is selected will depend

principally upon its size relative to the closed-side setting (CSS) of
the crusher and the extent of choke feeding. The size distribution
of the daughter products of breakage will depend principally upon
the initial size of the particle and upon its physical properties.
New feed entering the crusher is classified (or selected). Some
material, predominantly the finer fraction, bypasses the breakage
process entirely and reports directly to the product. The remainder
is broken, and the daughter fragments are then recycled to the
classification step. The new fine fraction exits via the product, and
the coarser material is rebroken.
Perfect Mixing If we think of a crusher as a stagewise breakage process, then we

Model can model it in terms of a steady state balance.
f x
Classification
Function
p
Appearance
A*C*x Function C*x
Figure A6.1: Schematic representation of the crusher model
A schematic representation of the crusher model is given in the

above figure. Mass balance equations may be written about each
node as:
x = f + ACx
(A6.1)
x = p + Cx (A6.2)

Crusher (Model 400/405) Appendix A
where x is a vector representing the amount in each size
fraction in the crusher
f is the feed size distribution vector
p is the product size distribution vector
C is the classification function, a diagonal matrix
describing the proportion of particles in each size
interval entering the crushing zone
A is the appearance function, a lower triangular matrix
giving the relative distribution of each size fraction
after breakage.
Combining (A6.1) and (A6.2) results in the Whiten crusher model

equation:
p = ( I - C ) * ( I - AC ) -1 * f (A6.3)
where I is the unit matrix.
Since the feed and product are expressed as size distributions, and
the properties of the internal classification and breakage
mechanisms are expressed with respect to particle size intervals or
mean sizes, it is convenient to represent these quantities as vectors
and matrices respectively.
Since f is known and p is the desired output, the problem resolves
itself into obtaining estimates of C and A for a particular machine
and feed material. These values can then be manipulated by
simulation to explore the effects of changing machine parameters,
material characteristics or operating conditions upon the product
size distribution.
An important limiting factor in crusher operation is the power
drawn by the machine. This model permits estimates of power
draw to be made for a given condition, so that the simulations can
be constrained by power requirements (by the user). The power
draw can be normalised to experimental data or estimated from
data for similar crushers in the Supplementary Parameters Manual.
Note: a single particle breakage test of the ore is required for either
type of power estimate.


p = (I - C) * (I - A * C)-1 * f
Selection Where C is the classification function (a diagonal matrix) and

where C(x) is the probability of selection for breakage of a particle
of size x and is defined as:
C(x) = 1
(A6.4)
for x > K2
i.e. all particles are broken
 K2 - x K3
C (x) = 1 -  K - K  (A6.5)
 2 1
for K1 < x < K2

C(x) = 0
(A6.6)
for x < K1
i.e. no particles are broken
(x = mean particle size)

An example of the classification functions is given in Figure A6.2.
1.0
K3
0.0
K1 K2
Particle Size x
Figure A6.2 - Classification function, C
The model equations are developed by non-linear regression

analysis of survey data collected over a wide range of operating
conditions, followed by multiple linear regression of the fitted
parameters against the operating conditions. The general form of
these relationships is:
K1 = A0* Crusher gap - A1 * Throughput + A2* Feed coarseness
K2 = B0* Crusher gap - B1 * Throughput + B2* Feed coarseness
K3 = C0 (generally held constant at a value of 2.3)

First For many crusher types performance can be estimated by setting

Approximation K1 to the closed side setting, K2 to the open side setting (or K1
plus eccentric throw). Both K1 and K2 will decrease with particle
interference as the crusher throughput increases to choke feeding.
The breakage severity (t10) will also increase (see A6.6 and
equation A6.11).
The model allows for inclusion of minor variables where more
detailed data are available The equations in the model are of the
form:
K1 = A0* CSS + A1 *TPH + A2 * F80 + A3 LLen + A4 (A6.7)
K2 = B0* CSS - B1 * TPH + B2 * F80 + B3 * LHr + B4 * ET + B5

(A6.8)
K3 = C0 (usually 2.3) (A6.9)
Where Closed side setting CSS

Liner Length LLen
Eccentric Throw ET
Liner Hours LHr
Crusher Feed Rate TPH
Crusher Feed 80% passing size F80
Crusher Product 80% passing size P80
Note that only closed side setting and crusher throw will normally
be used. The other relationships require a very detailed
experimental database.

A6.3 Ore Breakage Characterisation

Andersen The Andersen model uses the results of JK breakage testing of
Breakage Model coarse particles to predict both breakage and crusher power
consumption. This model has been extensively tested on cone
crushers (mostly operating as secondary crushers) over a broad
range of ore types. When the model was developed, only the
pendulum device was available for single particle breakage tests.
However, the JK Drop Weight test is now used as it provides for a
wider range of energies and particle sizes.
The first step is to use the JK breakage test to characterise ore

breakage over a range of input and absorbed energies. The
absorbed energy (per unit mass of particle) is referred to as the
specific comminution energy.
For details of the testing procedure, see Appendix 13.
A6.4 Breakage Distribution Parameter t10

A typical size distribution of product from the JK breakage tester is
given in the figure below. This product size distribution may be
adequately described by a one parameter (t) family of curves
(Awachie (1983); Narayanan and Whiten (1983)). The parameter
t10 is defined as the cumulative percent passing one tenth of the
geometric mean size, Y, of the test particle. The parameter is
shown in the figure below, together with other tn values - t2 and t4,-
which are defined in a similar manner to t10. Using the tn values
(n= 10, 2, 4, 25, 50 and 75), the whole of the size distribution may
be fully described.
Y = Test Particle Size

t
2
t
4
t
10
Y/10 Y/4 Y/2 Y
Particle size mm
Figure A6.3 - Typical pendulum product size distribution

The tn values (n = 10, 2, 4, 25, 50 and 75) for the product size
distributions for nine pendulum tests on hard rock ores from four
major crushing operations at different sites were determined and a
'best-fit' spline curve was drawn through all of the tn data using a
JKMRC multiple spline regression package, MSR. This breakage
distribution information may be conveniently stored as a three
dimensional spline relationship between the breakage distribution
parameter, t10 ( a measure of the amount of breakage or reduction),
the cumulative percent passing a particular relative size, and the
relative size, tn, of the particle being broken. Using the t10 spline
knots 10.0, 20.0 and 30.0, Table A.6.1 gives the cumulative percent
passing the relative sizes t75, t50, t25, t4, and t2 i.e. the cumulative
percent passing the Y/75 size (etc), where Y is the size of the
original particle being broken as shown in Figure A6.4. The
distribution for any intermediate value of t10 is determined by
spline interpolation.
Table A6.1: Appearance Function Data
SIZE RELATIVE TO INITIAL SIZE

T75 T50 T25 T4 T2
Breakage Parameter CUMULATIVE PERCENT PASSING
t10
10.0 2.8 4.0 5.5 22.2 51.4
20.0 5.6 7.2 10.7 43.4 80.8
30.0 8.9 11.3 16.4 60.7 93.0

Figure A6.4: The relationship between t10 and the remainder

of the product size distribution
A6.5 Breakage Parameters

Breakage parameters can be established from regression analysis of
the same data as the classification equations.
t10 = D0*Crusher gap + D1*Throughput – D2* Feed coarseness (F80)

+ D3 (A6.10)
This equation shows the intuitively expected dependence on the

crusher gap, throughput and feed size distribution.
The "feed coarseness" factor is somewhat application dependent.

That is, it will be influenced by crusher liner profile and effective
slope as well as closed side setting and gap.
First Typical cone crusher operation for secondary and tertiary crushers
Approximation will be at a t10 of 15 to 20. For a lightly loaded crusher (size
control on a primary jaw crusher) will operate at a t10 of 5-10. A
high reduction crusher (toothed roll or choke fed tertiary) may
achieve a t10 up to 25.

A6.6 Crusher Power Predictions

Energy - Size The JK breakage test also provides important information on the
Reduction specific comminution energy (kWh/t) required for a fixed size
Relationship reduction, quantified by the breakage distribution parameter t10, for
each particle size broken.
The specific comminution energy, Ecs, defined as the amount of

energy available for breakage, is derived as the energy absorbed
from the drop weight on impact. This energy has been found to
have a linear relationship with the breakage distribution parameter,
t10, but is also dependent on the test particle size. This relationship
is ore-specific and is used to characterise ores and compare the
crushing energy requirements of different ores.
Figure A6.5 shows the energy - size - size reduction relationship

derived from a JK breakage test for a fine-grained, siliceous copper
ore.
1.5
t10 = 30.0
t10 = 20.0
1.2 t10 = 10.0
0.9
0.6
0.3
0.0
10 14 18 22 26 30
Size mm
Figure A6.5 - Energy size reduction relationship
This information as used in the crusher model program in the

spline form is tabulated below. The energy required for a given
reduction increases with a decrease in particle size.
In Model 400, provision is made for data for three particle sizes. In
Model 405, the matrix is extended to accept data for five particle
sizes to match the data available from the JKTech Drop Weight
Test.

Table A6.2 - Energy-Size Reduction Relationship (Spline Form) – Model 400
Reduction
Particle size mm
parameter
t10 14.50 20.63 28.89
Specific comminution
%
energy kWh/t
10.0 0.35 0.30 0.25
20.0 0.80 0.70 0.50
30.0 1.2 1.0 0.80
Table A6.2 - Energy-Size Reduction Relationship (Spline Form) – Model 405
Reduction Particle size mm

parameter
t10 14.50 20.63 28.89 41.10 57.80
% Specific comminution energy kWh/t
10.0 0.35 0.30 0.25 0.20 0.15
20.0 0.80 0.70 0.50 0.40 0.30
30.0 1.2 1.0 0.80 0.60 0.40
Power Prediction A power prediction method has been developed using energy –
Method size-reduction information from the pendulum test (Andersen &
Napier-Munn, 1988) and is also applicable to the Drop Weight test.
Using the ore-specific energy-size-reduction relationship from the
pendulum test, the breakage function, B the classification values Ci
(from the parameter fitting or model regression equations, the
model calculates the total energy required to reduce the feed size
distribution to the product size distribution as if all the feed was
broken in the pendulum or drop weight testing device, i.e. it
defines the energy which would have been used by the breakage
device to achieve the same degree of breakage observed in the
crusher. The sum of the products of the amount of material selected
for breakage in each size fraction, Ci*xi (tonnes) (from equation
(A6.3)), and the Ecs (kWh/t) for each size at the breakage
parameter value t10 (determined from the parameter fitting or model
regression equation (A6.11)), is the total comminution energy
calculated by the model, Pcalc (kWh).

This total model-calculated energy is then regressed against the
actual power draw observed during the plant surveys on a particular
crusher using multiple linear regression analysis, resulting in a
simple equation of the form given below.
Pobs = E1 * Pcalc + E2 (A6.11)
where Pobs is the observed crusher power draw (kW)

Pcalc is the model calculated comminution energy(kWh)
E1 is a constant dependent on the efficiency of the
crusher
E2 is a constant of similar value to the 'no-load' power
draw
The constant included in the regression equation adequately
accounts for the crusher machine power draw (the power required
to overcome machine frictional losses), or 'no-load' power draw as
it is commonly termed. This 'no-load' power appears to vary
slightly with throughput and is a function of both plant power
factor and drive motor efficiency.
Feed rate (t/h) and feed coarseness are usually less significant
variables and a satisfactory model can be obtained by absorbing
these effects into the constant term. These variables are implicitly
included in the pendulum power calculation.
The power regressions developed may be used to predict the power
requirements of crushers operating on different ores after
determining the relationship between the breakage parameter, t10,
test particle size, and the specific comminution energy, Ecs, for the
ore under investigation. The pendulum test should be conducted on
representative ore particles over the range of the crusher feed size.
Where a specific mathematical performance model of the form of
equations A6.7 to A6.10 has been developed from extensive plant
surveys, the power draw may then be predicted for different
operating conditions.
In a design situation, given the feed and the desired product size
distributions, the t10-size-Ecs relationship for the ore to be
processed must be obtained from the pendulum test and this
information used in the model to calculate the total comminution
energy required. The crushing power requirements can then be
determined for a similar crusher from a power regression of the
form of equation A6.11 obtained from another site.

A6.7 Crusher Model (400/405) Printout

Showing Default Values
Model 400
Model 405

A6.8 Symbols
Symbol Meaning
f feed size distribution (vector)
p product size distribution (vector)
A appearance function (matrix)
C classification function (diagonal matrix)
I unit matrix
K1 size below which C = O
K2 size above which C = 1
K3 exponent in the equation for C
CSS closed side setting (mm)
TPH tonnes/hour feed
F80 coarseness of feed, e.g. 80% - 25.4mm
t10 breakage distribution factor
total power consumed in size reduction using the
pendulum (from laboratory tests results)
Ai regression constants
Bi "
Ci "
Di "
Ei "


This is the most general of the crusher models developed at the
JKMRC. It has been extensively tested for large (7ft) cone
crushers. The model provides an excellent description for
individual results for many types of crusher, e.g., jaw, roll, toothed
roll, hammer mill etc., but has not been extensively tested on these
other crusher types.
The feed coarseness relationships are usually based on scalped feed
oversize variations. They could well be different from variations in
scalping screen aperture. This interaction is a subject for
continuing investigation.
For power calculations large particles are apparently softer (see
Table A6.2). The drop weight test is not suitable for particles of
diameter larger than 63mm. Hence, using specific comminution
energies derived on smaller particles will tend to overestimate
required pendulum power.
There is also a physical flow limit for most types of crushers. For
crushers which cause a considerable increase in volume, this limit
is important. Hence for cone or 'Gyra disk' types, check the
simulated flowrates against the design tables for that type of
crusher and the corresponding bowl and mantle. Typical flowrates
are available from standard references such as Mular and Bhappu
(1978), Chapter 11.

A6.10 Fitting the Crusher Model

The model fitting subsystem only analyses one data set at a time.
Hence the actual parameters adjusted are the constant terms in each
of the equations A6.7, A6.8, A6.9 and A6.10.
That is, A4 for K1

B5 for K2
and D3 for t10
PARAMETER MENU
There are two distinct levels of use of the crusher model. The
different uses require different fitting strategies.
Limited Data One data set allows a (somewhat approximate) estimate of product
size for small variations in closed side setting.
For one data set:
fit A4 and B5
with A0 = 1.0, and B0 = 2.0 and (for cone crushers) K3 = 2.3.
Set other A and B values to zero.
Similarly for the breakage function:
fit D3
D0, D1 and D2 are set to zero.
Note that one data set does not provide useful information about
power dependencies.

Extensive Data The model is much more useful with a range of data. This means
5 to 10 data sets covering a range of crusher settings, feed rates and
(if possible) feed sizes.
JKTech can undertake breakage tests to characterize an ore as
shown in Figure A6.3 and Table A6.1 and to determine the size
single particle breakage/power as shown in Figure A6.5 and Table
A6.2.
HP Grinding Note that the value of K3 is generally 2.3 for cone, jaw and
Rolls gyratory crushers only. For other types of crushers, such as
(and others) grinding rolls and hammer mills, it is advisable to fit K3 also, with
2.3 as a good initial estimate
Master/Slave Master/Slave model fitting is available for the crusher model in the
Fitting general release version of JKSimMet.
Model fitting of multiple data sets is complex; assistance from

JKTech consultants is strongly recommended if you intend to
tackle this aspect of the fitting process.
Setting up Master/Slave fitting is detailed in Section 5.6.5

A6.11 Regression Modelling

The procedure is very similar to that for the screen model. Hence,
an efficient test program can be designed to gather screen and
crusher data together.
Fit each test using only constant terms, A1, with all of the other
regression terms set to zero.
Use the ore Specific Appearance and Power Data measured by
JKTech, or use the defaults (average of 4 ore types). Measured
oretype data should give more accurate results for breakage and are
essential for realistic power estimates.
Each data set produces estimates of K1, K2, K3 and A and B.
Set K3 = 2.3
Use a multiple linear regression package to fit each estimate to the
measured variables. If any coefficients plus or minus their
estimated errors bracket zero, try a refit without that variable
included. If the error of prediction improves (i.e., gets smaller),
omit the variable by setting its model coefficient to zero.
A6.12 Model Testing

Import each feed and product into the model and simulate to check
each set. This is quite a complex model and it is not difficult to
make errors.
If any data sets are seriously in error, try to track down the reason.
Check the calculated K1, K2, and t10 against your fitted estimates.
When all else fails (or much earlier, if you prefer), ask JKTech,
who will be happy to assist.
As soon as you have reasonable parameter estimates, you may use
Master/Slave fitting on up to ten data sets at a time to test
secondary crusher model dependencies.

A6.13 References
ANDERSEN, J. A., 1989. M.Sc. Thesis, University of
Queensland, (unpublished).
ANDERSEN, J.A. and NAPIER-MUNN, T.J., 1988. Power
prediction for cone crushers, Mill Operators' Conference,
Cobar.
AWACHIE, S.F.A., 1983, Development of crusher models using
laboratory breakage data, PhD Thesis, University of
Queensland.
MULAR A. L. & BHAPPU, R. B. 1978, Mineral Processing
Plant Design.
WHITEN, W.J., 1984, Models and control techniques for crushing
plants, Control 84, Minl./ Metall.Process
(Am.Inst.Min.Engrs. Annual Meet., Los Angeles, USA,
February), 217-225.

(Blank Page)

Appendix A Rod Mill (Model 410)
A7 Rod Mill (Model 410)

The rod mill model is based on the concept of stages of breakage.
A stage of breakage has three components:
• selection
• appearance
• classification.
That is, each stage is equivalent to breakage, screening and

recirculation.
The mill is considered as a number of segments in order. Each
segment is a stage of breakage.

Diagrammatically a stage of breakage may be considered as:
fj feed vector to stage j
m=C.q+f
(I-S).m
Selection S Diagonal Matrix S
Appearance A Lower Triangular Matrix A

ONE
STAGE OF
BREAKAGE
Contents q Segment contents Vector q
C.q
Classification C Diagonal Matrix C
pj
product vector from stage j
Figure A7.1 A representation of the breakage process in a rod mill

Rod Mill (Model 410) Appendix A
Eliminating m and q by matrix algebra yields
pj = (I-C) . (A.S +I-S) . [I-C⋅(AS+I-S)]-1 . fj
or
pj = X . fj
since AS and C are assumed constant for all stages.
Stages of If there are v stages of breakage in the mill then:

Breakage
p = (X)v ⋅ f (A7.1)
or
p = X⋅X⋅X ... ⋅ f for v times
Non-integer numbers of stages can only be calculated by
interpolation.
Once A, S and C are known, any particular operating condition can
be represented by a value of v.
Feed Rate The key dependence is the variation of stages of breakage v with
mill feed rate F.
Experimentally:
F (v)1.5 = MC
where MC is the mill constant.
The mill constant can also be scaled as detailed later.
Appearance The default Appearance Function is the modified Rosin-Rammler

Function equation:
A(x,y) = (1-e-x/y)/(1-e-1)
Where A(x,y) is the proportion after breakage of particles of initial
size y which are smaller than size x. The appearance A is made up
of vectors of the differences in x for the specified screen interval.
For specific ores, JKTech can measure the appearance function. A
range of appearance functions for various ores is given with the
ball mill model description in Appendix A8.

Classification The classification function C is a diagonal matrix which provides a

Function simple classifier. Each diagonal element gives the proportion of
that size fraction returned to the breakage stage for rebreakage.
The usual values are (for a √2 size distribution)

1.0, 0.5, 0.25, 0.125, 0.063 and so on.
Hence, each stage of breakage in a rod mill will eliminate the top
size fraction from the product.
Selection The selection function, S is a diagonal matrix. It gives the

Function proportions of each size fractions which are selected for
breakage.
S is represented by three parameters XC, SL and IN as shown in

the figure below, and is calculated by:
Si = SL ⋅ Size + IN for Size i > XC
Si = SL ⋅ XC + IN for Size i < XC
and limited if Si > 1.0 then Si = 1.0
and if Si < 0.0 then Si = 0.0
An example of a selection function is given in the figure below.
1.0
SL
Selection
Function
IN
0.0
XC
Size
Figure A7.2 Graph of a rod mill selection function

Scaling The rod mill model is scaled by modifying the mill constant
according to dimensions and operating conditions described below:
Mill Size DSIM2.5 LSIM

FACTA =   ⋅L
 DFIT  FIT
These scale factors only apply for rod mills with normal length to
diameter ratios, that is, 1.2 < simulated L/D < 1.6 and L ≤ 7m.
Media Load Load Fraction (i.e. volume of mill occupied by charge and media at
rest after grinding out)
(1 - LFSIM ) ⋅ LFSIM
FACTB =
(1 - LFFIT ) ⋅ LFFIT
Note 30% < LF < 45%
Critical Speed Fraction Critical Speed
CSSIM
FACTC =
CSFIT
Note 50% < CS < 80%
These factors are applied to the Mill Constant MC of the original

mill to estimate the mill constant of the simulated mill.
MCSIM = MC ⋅ FACTA ⋅ FACTB ⋅ FACTC
The required number of stages of breakage is
MCSIM2/3
vSIM =  F 
 SIM 
Feed Size Coarseness of feed (90% passing size)
 F90FIT 
FACTD = ln F90  / ln 2
 SIM
MCSIM2/3
vSIM =   + FACTD
 FRSIM 

Ore Hardness Work Index

WISIM
FACTE = - 0.8 ln  WI 
 FIT 
 S(I)FIT 
FACTF = ln 1-S(I)  + FACTE
 FIT
FACTG = exp (FACTF)

 FACTG 
S(I)SIM = 1+FACTG
 

A7.3 Rod Mill Model Printout Showing

Default Values

A7.4 Symbols
Symbol Meaning
f feed size distribution (vector)
p product size distribution (vector)
A appearance function (step matrix)
C classification function (diagonal matrix)
S selection function (diagonal matrix)
Si element of selection function S from size i
v number of stages of breakage of original mill
vSIM v for simulated mill
F90FIT 90% passing size for fitted mill feed
F90SIM 90% passing size for simulated mill feed
MCSIM mill constant for simulated mill
MC mill constant for original or fitted mill
SL slope of selection function
IN intercept of selection function
XC Size below which selection function is constant
DSIM diameter of simulated mill
DFIT diameter of fitted mill
LSIM length of simulated mill
LFIT length of fitted mill
LFSIM load fraction of simulated mill
LFFIT load fraction of fitted mill
CSSIM fraction critical speed of simulated mill
CSFIT fraction critical speed of fitted mill
WISIM work index of ore for simulated mill
WIFIT Work index of ore for fitted mill
Note: The fitted mill is the rod mill which provided the
experimental data.

Scaling Note the restrictions for scaling in the section on Model Equations.
Change in Feed The number of stages of breakage is calculated from the feed solids
Pulp Density mass flow. No account is taken of water in the feed. It is assumed
that rod mills operate at 75 to 85 percent solids in the feed.
Effect of Feed There is some doubt about the adjustment of number of stages of
Size breakage according to feed coarseness. Data from some operations
exhibit an effect while data from others do not. If the particles are
large enough and strong enough to resist a rod impact, the
dependence is reasonable.
The scaling effect can be eliminated from open circuit operation by

setting F90FIT (parameter 16) equal to F90SIM (parameter 80).
Mill Speed This dependence is reasonable from 50-80% of critical speed at

industrial mill feed rates.
A7.6 Fitting the Rod Mill Model

PARAMETER MENU
Because the rod mill model is dependent on feed conditions, it is

difficult to fit in closed circuit until the parameters are very good
estimates. Therefore, mass balance a closed circuit rod mill first.
Then fit the discharge using the mass balanced feed rate and sizing.
(Use Whiten SDs for the product size distribution). If an ore
specific breakage function is available, it should be used. The mill
constant (MC) and the three selection function parameters can be
fitted.
For fitting, set the simulated and original mill dimensions etc. to
the same values.

Check the experimental feed 90% passing size and input it. Use a
measured work index if available - an approximate one if not.
This model is fussy about initial estimates and some trial and error
may be needed. These guidelines will help for many cases.
If you are new to the rod mill model use the rod mill example in
Chapter 3 and graph the output to get a feel for how XC, SL and IN
interact and change the shape of the product curve.
Set XC to about half of the top size of the mill feed and MC to
2000. Assume a selection value of 0.1 at XC and 1.0 at the feed
top size. Calculate slope and intercept to suit. Try a simulation
with these values. If the product distribution is approximately the
right shape, (plot as cumulative percent passing both simulated and
experimental products) fit the rod mill constant.
If the shape is very different, increase the assumed selection value
for a steeper product slope and proceed when the slope is similar.
If the fitting program finds a reasonable minimum, - that is, the
mill constant error is less than 20% - change the MC estimate to
the new value and fit the slope. If the sum of squares decreases,
update the SL guess to the fitted value and fit XC and IN also.
A7.7 Reference
LYNCH, A.J., 1977. Mineral crushing and grinding circuits,
(Elsevier, Amsterdam), 51-60.

(Blank Page)

Appendix A Perfect Mixing Ball Mill (Model 420)
A8 Perfect Mixing Ball Mill (Model 420)

This model considers a ball mill as a perfectly mixed tank with
contents described by a vector size distribution s.
The product vector p is produced by a discharge rate di for each size

fraction, where D is a diagonal matrix of rates, that is:
p = D•s (A8.1)
Within the mill, two factors control breakage. The first is the rate
of selection of each size for breakage. The second is the way in
which the selected particles are broken (or appear) in the mill
contents.
Selected = R•s
where R is a diagonal matrix of rates.
Appearance = A•s
where A is a triangular matrix of breakage (appearance)

functions (distributions).
At steady state, the mill feed minus the material selected for
breakage plus the material from breakage minus the material
discharged must equal zero. This can be written as:
f - R•s + A •R•s - D•s = 0 (A8.2)
Discharge Rates For overflow mills and most of the operational range of grate
discharge mills, the discharge elements can be approximated by:
Di = Di* 4 v / (d2 l) (A8.3)
where Di* is close to unity

v is the total volumetric mill feed rate
d and l are mill diameter and length
A typical discharge function is given in Figure A8.1.

*
D
i
0.
Discharge
Log (size)
Screen Size
Figure A8.1 - Typical graph of mill discharge function
Breakage Rates Breakage rates tend to increase rapidly with particle size, with the
increase tapering off at the feed top size.
Log (R )
i
Log (size)
Figure A8.2 - Typical graph of breakage rate factor
Appearance The appearance function A is ore dependent, and can be measured

Function using the drop-weight testing technique developed at the JKMRC.
A table of appearance functions for a variety of ore types and the
associated operating work indices is given in section A8.7. The
standard Broadbent-Calcott appearance function is also included.


Considering equation 8.1 as the elements of each vector and matrix
yields:
i
fi - Risi + ∑ A ij R js j - D is i = 0 (A8.4)
j=1
and:
pi = Disi (A8.5)
Substituting for si yields:

i Rj
Ri
fi - D pi + ∑ A ij pj- pi = 0 (A8.6)
i Dj
j=1
where feed and product are related by R/D for a particular breakage
function.
Equation A8.3 can be used to scale for feed rate and mill
dimensions.
In general, the mill contents s is not known and it is not possible to

separate the R/D* ratio into its components. The R/D* function is
represented internally by a cubic spline function (that is, by a
smooth curve). A number of spline knots (generally between 2 and
4) on the 1n(R/D*) function are fitted.
Scaling Scaling of the ball mill model is achieved by modifying the fitted
R/D* function according to dimensions and operating conditions as
described below.
Mill Diameter The mill diameter d is scaled.
dSIM
FACTA = d 
 FIT 
Note: This factor is in addition to a direct volume effect which is

built into the model.
Load Fraction The load fraction LF is the volume of mill occupied by charge and
media at rest when the load is ground out.
 (1 - LFSIM ) . LFSIM 
FACTB =  
 (1 - LFFIT ) . LFFIT 

Fraction Critical Fraction critical speed is scaled by:

Speed
 CS 
FACTC =  SIM 
 CS FIT 
55% <CS < 78%
Work Index The Work Index is scaled by:
WISIM0.8
FACTD =  WI 
 FIT 
Ball Size Scaling By assuming that the reduction mechanisms of impact and attrition
occur in a ball mill, the following relationships can be derived from
theoretical considerations.
Impact breakage ∝ Db3

Attrition breakage ∝ 1/Db
where Db = ball top size diameter.
Impact breakage is assumed to predominate above a certain size xm
whilst attrition is the main reduction mechanism at sizes below xm.
The size xm is assumed to be equivalent to that at which maximum
breakage occurs. Size xm can be related to ball diameter as
follows:
xm = K . Db2
where K is the maximum breakage rate factor.
The value of K has been found to be of the order of 4.4 E-04. K
can be calculated from the formula above if the value of xm is
known. The graphing facility within JKSimMet allows easy
graphing of the breakage rates to determine this value.
xm (fit) and xm (sim) are both calculated. The smaller of the two is
denoted xm (small) and the larger as xm (large) .
The above relationships are used to scale R/D* values at each
spline knot to account for ball size effects.
The scaling factor for ball size effects depends on the knot position
size.
for knot position size < xm (small)
( 1
FACTE = Db
) = Db FIT
(1Db ) Db
SIM
SIM
FIT

for knot position size≥ xm (large)

2
 Db SIM 
FACTE =  
 Db FIT 
For knot positions between xm (small) and xm (large) linear interpolation

is used.
The effect of ball size is shown in the diagram below.
New xm Old x m
Ball size decreasing
Knot 1 Knot 2 xm Knot 3 Knot 4

Particle Size
Figure A8.3: R/D* Relationship with Ball and Particle Size
Scaling These factors are applied to each fitted 1n (R/D*) knot as follows:
Calculation
R/D*SIM=R/D*FIT•FACTA•FACTB•FACTC/FACTD•FACTE
Scaling Using Where characteristic breakage functions have been measured (i.e.
Breakage pendulum tested) for both ores, these breakage functions may be
Functions used to predict performance. Note that it is not valid to scale this
way from the default breakage function.

A8.3 Ball Mill Model Printout Showing

Default Values

A8.4 Symbols
Symbol Meaning
f feed size distribution vector
p product size distribution vector
s mill contents size distribution vector
A appearance function lower matrix
R breakage rate function diagonal matrix
D breakage discharge function diagonal matrix
D* normalised discharge function
R/D*SIM normalised R/D ratio for simulated mill
R/D*FIT normalised R/D ratio for fitted mill
dSIM diameter of simulated mill
dFIT diameter of fitted mill
LSIM length of simulated mill
v volume flow rate of feed
LFSIM load fraction of simulated mill
LFFIT load fraction of fitted mill
CSSIM fraction critical speed of simulated mill
CSFIT fraction critical speed of fitted mill
WISIM work index of ore for simulated mill
WIFIT work index of ore for fitted mill
Db ball diameter (top size)
DbSIM ball diameter for simulated mill (top size)
DbFIT ball diameter for fitted mill (top size)
K maximum breakage rate factor
xm maximum breakage size.


Change in It is known that the coarse end of the R/D* function does vary with
Coarseness gross changes in the amount of coarse material in the feed stream.
of Feed As the amount of coarse material in the feed is decreased, the
relevant R/D* values increase. This limitation is not considered
significant for changes of less than plus or minus 50% in the
amount of coarse material in the feed.
Critical Speed The critical speed dependence is approximately valid for 55-78%
Range of critical speed and incorrect outside of that range.
Predicting Rates If the ball mill model does not produce any of a coarse fraction (i.e.
at 'Missing Sizes' none in the mill discharge) then the effective rate of grinding is
'infinite'. One way to overcome this problem is to size the mill
contents and expand to the perfect mixing model used for the SAG
mill model.
This is usually not experimentally convenient. Some more

practical approaches are to:
• test the mill at maximum tonnage with coarse feed. If there is
any coarse material in the discharge, the actual rates can be
estimated.
• use a set of rates and knot values from the supplementary
information for a similar mill feed sizing and fit with Work
Index alone the first time. Transfer the coarse rate values from
calc to exp, return the Work Index to its original value and refit
the two smaller rates. This procedure should give reasonable
answers with a coarser feed. Work is proceeding on improving
the ball mill model in this area.
High Mill The perfect mixing mill model only takes account of pulp density
Viscosity or variations as variations in mill volume. Therefore, higher pulp
Pulp Density density will always predict higher grinding rates. In practice, the
rates do improve until pulp viscosity begins to interfere with ball
action and rates decrease rapidly. This onset is difficult to predict
as it is highly ore type dependent. However, effective mill
operation of greater than 50% solids by volume is unlikely and
improbable at greater than 60% solids by volume.
Ball Size Scaling The ball size scaling relies on the R/D* function exhibiting a
maximum. If there is no maximum in the fitted R/D* function,
increasing the ball size will give optimistic results.

Wide Range Size The mill model assumes a constant breakage function for all size
Data fractions. This assumption simplifies the model but experimental
evidence suggest strongly that partial breakage increases in severity
with decreasing size - down to some limiting size. Therefore, if
more than (say) twenty size fractions are considered, an apparent
minimum rate may be produced in the finer ranges. This
phenomenon is more likely to be an artefact of an incorrect
assumption than to have any physical significance. Research work
continues in this area.
A8.6 Fitting the Perfect Mixing Ball Mill

Model
PARAMETER MENU
The ball mill model is well-behaved for model fitting. It can be

fitted in closed circuit with the cyclone model with generally better
results than by fitting each model to mass balanced data. Hence a
good closed circuit fit will also provide a good mass balance
estimate of circulating load.
R/D* Spline Use three knots for normal grinding conditions and four knots for a
Knots wider than usual size range (such as SAG mill discharge or a very
fine product).
Knot To determine an appropriate set of knot positions divide the

Positions number of size fractions covering the feed size distribution by the
number of knots plus one. This will give about equal log size
spaces from both ends and between knots.
Knot Estimates Estimates for the function values at the knot positions are provided
as ln(R/D*) values. A simple ascending series provides a good
first estimate, for example:
0.5 1.5 2.5

Work Index, If you have several sets of data, use an operating Work Index for
Load Fraction each (calculated from mill feed rate, mill power, feed and product
80% passing sizes). If the major variation is hardness only, then
the average knots can be used.
The calculated R/D* values are displayed on the unit data entry
screen. There should be a smooth increase with size. Sometimes
the curve will have a maximum at the coarse end. If there are any
sudden changes or ups and downs, try adjusting the knot positions.
There will often be a bump at a change in size measurement

technique, such as the transition from screen sizing to Cyclosizer
sizing.
Systematic deviations can sometimes be removed by adjusting a

knot towards the largest deviation.
Graph Cumulative When nothing else works, plot the experimental feed and product
Simulated and on a coarse scale (say 0-30%) percent retained against log size. If
Experimental there are any large discontinuities, check your data very carefully,
Product and repeat your sampling if possible.
Master/Slave The perfect mixing ball mill model is well suited to fitting of
Fitting multiple data sets. The ln(R/D*) knot values can be fitted
simultaneously for a number of surveys. Ensure that you use the
same knot positions, and number of knots, for each mill in your
master/slave fitting test.

A8.7 Table of Appearance Functions

This table shows ore-specific appearance function values
determined from single particle breakage tests using JK breakage
testers –pendulum or drop-weight.
Size Interval Ball milling circuits from which the samples were collected:
Massive Massive Porphyry Porphyry Massive
Sulphide Sulphide Hard Soft Sulphide
(Ni) Coarse (Cu) (Cu) Fine
(Pb-Zn) (Pb-Zn)
1 0.000 0.000 0.000 0.000 0.000
2 0.0591 0.0505 0.08586 0.05220 0.1128
3 0.1052 0.0974 0.1248 0.09919 0.1490
4 0.1318 0.1276 0.1387 0.1288 0.1497
5 0.1295 0.1278 0.1278 0.1284 0.1250
6 0.1127 0.1128 0.1076 0.1129 0.09885
7 0.0927 0.09469 0.08722 0.09423 0.07866
8 0.07486 0.07810 0.06960 0.07727 0.06289
9 0.06082 0.06428 0.05540 0.06339 0.04943
10 0.05005 0.05316 0.04428 0.05239 0.03842
11 0.04166 0.04424 0.03574 0.04364 0.03003
12 0.03462 0.03666 0.02899 0.03623 0.02376
13 0.02723 0.02880 0.02278 0.02847 0.01865
14 0.02054 0.02171 0.01743 0.02146 0.01448
15 0.01537 0.01623 0.01325 0.01604 0.01120
16 0.01144 0.01207 0.01004 0.01192 0.00864
17 0.00849 0.00894 0.007581 0.00883 0.00664
Operating Work Index
12.8 9.0 13.6 12.2 15.9
Size Interval Ball milling circuits from which the samples were collected:
Quartzite Porphyry Massive Massive Standard
Sulphide Soft Sulphide Sulphide Function
Low Grade USA (Cu,Pb,Zn) (Pb, Zn, Cu)
(Cu) (Cu)
1 0.000 0.000 0.000 0.000 0.000
2 0.09514 0.05013 0.1171 0.1081 0.193
3 0.1322 0.0970 0.1537 0.1442 0.157
4 0.1417 0.1273 0.1522 0.1472 0.126
5 0.1267 0.1276 0.1247 0.1253 0.101
6 0.1049 0.1128 0.09723 0.1006 0.082
7 0.08477 0.09481 0.07685 0.08050 0.066
8 0.06778 0.07832 0.06131 0.06444 0.053
9 0.05371 0.06451 0.04810 0.05076 0.043
10 0.04244 0.05336 0.03729 0.03958 0.035
11 0.03379 0.04438 0.02911 0.03103 0.028
12 0.02709 0.03677 0.02303 0.02459 0.022
13 0.02127 0.02888 0.01810 0.01929 0.018
14 0.01637 0.02177 0.01407 0.01496 0.015
15 0.01254 0.01628 0.01089 0.01155 0.012
16 0.009565 0.01211 0.008413 0.008888 0.010
17 0.007279 0.008968 0.006483 0.006825 0.008
Operating Work Index:
14.1 10.2 14.1 13.5

A8.8 References
LYNCH, A.J., 1977. Mineral crushing and grinding circuits,
(Elsevier, Amsterdam), 309-312.
WHITEN, W.J., 1976. Ball mill simulation using small
calculators, Proc. Australas. Inst. Min. Metall., 258, 47-
53.
MORRELL, S. 1992. Ball size effects in ball mills. Chapter 2,
End of project report, AMIRA/JKMRC Project P9J.
"Simulation and Automatic Control of Mineral Treatment
Processes".

Appendix A Autogenous & SAG Mill Model (Model 430-431)
A9 Autogenous Mill Model (Model 430) and

Semi-Autogenous Mill Model (Model 431)

The JKMRC has been involved in the development of a model of
autogenous and semi-autogenous grinding for many years. The first
model to provide useful predictions was the Leung model (Leung,
1987). It used ore-specific breakage functions obtained off-line
using a laboratory test procedure. It has largely been superseded by
the Variable Rates model( see Appendix 11). However, because of
its relative simplicity, the Leung model provides a good
introduction to SAG mill modelling.
Caution: The Leung model scales on volume. This is irrelevant for
optimisation but is important for scale up from pilot to full scale
mills of more than 8 to 9m in diameter.
The power model (Morrell, 1991) was added in 1992.
The Leung model has the general structure shown in Figure A9.1.
The appearance function has two components:
• high energy corresponding to impact breakage, determined
from the twin pendulum single particle breakage apparatus, and
• low energy corresponding to an abrasion mechanism,
determined from laboratory tumbling tests.
In both cases the functions are obtained off-line on representative
samples of ore and do not rely on being simultaneously back-fitted
to operating data. The energy levels at which the high energy
appearance function is determined are based on the mean energy in
the mill, which is related to mill diameter.
Discharge rates are determined as the product of the rate at which
the load is presented to the grate, dmax, and the classification at the
grate (which is represented by a simple classification function).
The model iterates to select a value of dmax equal to the fraction of
mill occupied by material of a size less than the grate size, which in
turn is assumed to be a simple power function of feed rate
expressed as a proportion of mill volume.
The model predicts product size distributions and mill loads from a
known feed size and tonnage for a given mill and feed ore. Ball
charge is incorporated through the assumption that balls are
equivalent to mill load particles of equal mass.
Average breakage rates are provided as defaults for both the
autogenous and SAG mill models. Note that these rates are
different and are based on a limited data set.
Usually, breakage rates will be model fitted to plant data.

Autogenous & SAG Mill (Model 430-431) Appendix A
Limitations This model is a significant development of earlier models, and has

/Caution been shown to be successful in describing operating data on full
scale autogenous and SAG mills. Its scale-up capability is limited
to mills up to 8 to 9m in diameter from pilot mills of up to 2m.
The dependency of the model parameters on operating conditions
such as mill speed, percent solids, grate open area, liner
characteristics and pulp rheology was not well established when
this model was developed. Most of these issues are addressed in the
Variable Rates model(A13)
The Leung model is based on data from mills operating at

approximately 70% of critical speed and 60-70% solids by weight
in the feed.
Load
Feed
Product
Breakage Mass Transfer

and Discharge
Breakage Appearance Mass Classification

Rate Function Transfer Function
Function
High Low
Energy Energy
(impact) (abrasion)
Figure A9.1: Autogenous Mill Model Structure
Page A-82 Appendix 9 Version 5.1 November 2001

A9.2 Model Equations- Particle Breakage

Particle Breakage This description follows the structure shown in Figure A9.1.
The model assumes that each size fraction experiences only one
energy level of breakage. (The reality will certainly be a
distribution of energy levels).
High Energy The relationship between the amount of breakage and the input
Breakage energy is described by
t10= A (l - e - b Ecs ) (A9.1)

where t10 is the percentage of the broken particle which will pass
through a screen of one tenth the size of the original particle, and
Ecs is the energy absorbed per unit mass during breakage measured
in kWh/t.
A and b are the parameters which characterize this equation for a
particular ore. A is usually taken as 50. Parameter b is derived
from a drop-weight breakage test of closely sized ore particles.
Required sample size varies according to ore variability. However,
as a guide, about 50 kg of 50 mm material is needed.
Low Energy One or more 3 kg samples of 50 mm natural ore are tumbled for 10
Breakage minutes in a small dry mill at 70% of critical speed. The products
of each run are sized and t10 is measured for each run.
Where 50mm material is not available, other sizes are used and
adjusted using a simple linear model.
The t10 data are fitted to
t10 = a0 + a1 * mean size + a2 * sample mass + a3 * time. (A9.2)
The actual value of the abrasion parameter ta is one tenth (scale

factor only) of t10:
based on top size of 55*38 mm, mass 3 kg and time 10 minutes.

Low Energy The size distributions produced by ores tested to date have a similar
Appearance shape. This shape can be scaled to the ta factor that is the
Function - percentage passing one tenth of the original particle size.
Abrasion
A cubic spline function is used for smooth interpolation.
A 100mm particle is chosen as an example as particles of this size
will typically undergo abrasion rather than crushing breakage.
Parameter ta is taken as 1.0 to make the scaling obvious.
size (mm) % passing
t value scale* 100 100
t1.25 2.687*ta 80 2.687

t1.5 1.631*ta 67 1.631
t10 1.0*ta 10 1.0
t100 0.9372*ta 1 0.9372
t250 0.8070*ta 0.4 0.8070
t500 0.6365*ta 0.2 0.6365
The example shows that most of a 100 mm particle remains
unbroken.
This value of t is assumed to be equal for all size fractions.
Breakage Energy As the charge provides the grinding media, the level of available
energy is related to the coarse fraction of the mill charge.
The average size of the top 20% of the charge is used as the highest
energy reference level.
S20 = (p100 * p98 * p96 ... p80) 1/11 (A9.3)
and the potential energy at the full height of the mill
4
E1 = 3 π (S20)3 ρ g D (A9.4)
where D is mill diameter in metres. An assumption due to Austin

et al (1984) is used to relate other energy levels to E1. Austin et al
provided a rationale for energy levels in mills to be related by
E particle α 1/(x)1.5 (A9.5)
where x is particle diameter.
Hence, the energies experienced by smaller sizes are scaled using
this relationship. This allows an Ecs to be calculated for each size
and t calculated from equation (A9.1).

High Energy Once the energy of breakage is known, the distribution the particle
Appearance breaks into can be described by a cubic spline surface.
Function
(Crushing
Breakage)
spline knots t = 0.0 10.0 30.0 50.0
function values for

t2 0.0 50.53 92.49 96.47
t4 0.0 23.33 61.58 82.86
t10 0.0 10.00 30.00 50.00
t25 0.0 4.975 15.62 25.88
t50 0.0 3.064 9.412 14.71
t75 0.0 2.325 6.893 10.32
For example, for a 50 mm particle, a t of 30 would produce this
distribution.
Size (mm) % passing
50 100
t2 25 92.49
t4 12.5 61.58
t10 5 30.00
t25 2 15.62
t50 1 9.412
t75 0.67 6.893
Combined As noted earlier, the abrasion distribution does not vary with
Appearance particle size while the crushing breakage is highly dependent on
Function particle size.
Hence, abrasion will tend to dominate for coarse particles and

impact for fine particles (from equation (A9.5)).
To generate an appearance function for each size fraction, the high
and low energy appearance functions are combined proportionally.
tLE * a LE + t HE * a HE
a= tLE + t HE (A9.6)
where, aLE' aHE = low and high energy appearance functions

tLE' tHE = low and high energy t values

Equations (A9.1) to (A9.6) combined with the two tables of spline
knots yield a complete appearance function (that is how each
component will break) for each size in the mill load.
Breakage To predict a product from the mill contents and the appearance
Rates function requires only a rate of selection for breakage for each size
fraction of the mill load.
These rates will be inherently scaled because the mill load will be
constrained by mill dimensions and the mill diameter (if the energy
versus breakage assumptions are correct). These rates will
certainly vary if mill speed is changed but this dependence is not
included in the Leung model.
To describe these rates, a five knot spline function is used.
Best fit values to data are tabulated.
Spline knots ln (Rate ln (Rate
(mm) of Breakage) of Breakage)
Autogenous SAG
0.250 2.63 2.176

4.00 4.04 4.444
16.0 3.32 3.577
44.8 1.98 2.753
128 3.37 4.082
These are the default values in each model.
These rates are fitted to customize the model to any particular
operating mill.
SAG Mill The ball charge is approximated by a distribution of equivalent

Modification weight particles added to the mill load for the high energy breakage
calculation (equation (A9.3)). That is, only the appearance
function will be varied by the addition of balls.
This completes the description of the Breakage area of the model.

A9.3 Model Equations (Mass Transfer and

Discharge)
Classification The mill grate is modelled as a very simple classifier. When this
model was developed the relationship between the classification,
discharge and the operating conditions was not well defined.
Hence, the classifier/discharge is assumed to be constant- for other
than minus grate size hold up. A simple form is used.
D=1 x < xm (A9.7)

1n(x) - 1n(xg)
D = 1n(x - 1n(x ) xg > x > xm
m) g
where xm is the particle size below which it will always pass

through the grate if presented to it - that is, behave like water. xg is
the size of the grate through which the largest particles will pass
through.
Pebble Port Pebble port allows a small discharge rate of substantially coarser
Modification particles. This modification affects the classification curve as
shown below.
1.0
fp
x x x
m Size g p
xp is the notional size of the pebble port

fp is the notional fraction open area of the pebble ports compared
with the fraction of grate open area.
Typical values for fp are 2 to 5% ie. 0.02-0.05. While this
modification gives a good description of pebble product, the areas
are notional only and in fact reflect relative discharge rates.
Discharge Rate The quantity of pulp discharged will depend on the quantity per
unit time presented to the grate multiplied by the classification
function.
d = dmax * D (A9.8)

where dmax is the fraction of the load presented to the grate per unit
time and D is the classification function.
The water is assumed to follow the sub mesh particles.
The actual value of D is found iteratively.
The required value satisfies the following empirical mass transfer
law (Austin, 1976).
Mass Transfer The value of dmax is adjusted until the model prediction matches
"Law" the required one. That is, until it lies on the operating line of
L = m1 Fm2 where
m1 = 0.37 (A9.9)
m2 = 0.37
L is the fraction of the active volume of the mill occupied by minus
grate size material and F is the total volumetric feed rate per minute
divided by the active volume of the mill.
Perfect Mixing The perfect mixing model at steady state provides the structure to
Mill Model combine the various components of the model. It relates the
different parts in the following manner.
i
fi - ri si + ∑ rj s j a ij - disi = 0 (A9.10)
j=1
pi = di * si (A9.11)
where fi, si, ri, di and pi are feed rate, contents, breakage rates,
discharge rates and product rate vectors and aij is the combined
appearance function.
The form of equations (A9.10) and (A9.11) allows both the mill
load and the product to be calculated for any mill load and
discharge rate adjusted until equation (A9.9) is satisfied.

Calculation sequence
↓
Calculate breakage rates
↓
Calculate volume of below grate
size material in the mill, L
↓
Calculate discharge rate
↓
If error is acceptable exit else
make correction to Dmax
Mill Load This model is unusual because it uses an internal port to describe
the mill contents. This port is accessible from the model properties
drop down or from the model window. It does not appear as stream
equipment.
Scaling This model is inherently scaled for mill diameter and volume. This
scaling optimistic in capacity as mill diameter is increased. It is
reasonable for mills of up to 8 to 9m diameter.
A9.4 Prediction of AG/SAG Mill Power Draw
The Grinding The gross power draw of the mill is that drawn by the mill
Mill Power motor(s), ie metered power. It is assumed that this has two
components, viz
• net power, ie. the power delivered to the charge

• no-load power, ie. the power to overcome drive train and
bearing losses.
The gross power can, therefore, be represented by the following
equation
Gross Power Draw = No-Load Power + Net Power (A9.12)

The gross power draw is calculated from the fraction critical speed,
ball SG and ball and rock porosity. These data are provided by the
user. The calculations use pulp load data generated by the model
calculations.
The model data entry screen section for the power calculations
include the 'net power adjustment factor'. This is a calibration
constant which varies slightly from mill to mill depending on mill
liner configuration and other factors.
Users are strongly recommended to leave this value set at 1.21.
Other values should not be used unless a comprehensive range of
load vs power data are available.
Net Power Draw From photographic evidence, the charge shapes shown in Figure
A9.2 were assumed to occur in grate discharge mills.
Grate Discharge
o
90
θS
rm
o
θ o
180 0
ri
θT
o
270
Figure A9.2: Simplified AG/SAG Mill Charge Shape
By considering an element in the charge of cross sectional area r ds

dθ and Len, the torque inertia of the element can be represented by
the following equation.
Torque Inertia of Element = gLenρr2 cosθ dθ dr (A9.13)
Power can be defined in terms of torque (τ) and rotational rate (N)
as follows:
Power = 2π Nτ (A9.14)

For grate discharge mills, by integrating between the limits θs and

θT and between ri and rm the net power (Pnet) is given by:
rm θ S
Pnet = 2π gLenρ ∫ ∫N
ri θ T
r r 2 cosθ dθ .dr (A9.15)
No-Load Power The no-load power draw (i.e. that drawn by the mill when
completely empty), is associated with various electrical and
mechanical energy losses. The main ones are motor, gearing and
bearing losses. None of these are fixed over the full mill operating
range. Some, however, may have a fixed component. For
example, bearing losses due to friction will be dictated by the mill's
dead weight (though even this will vary as liners and lifters wear),
and the mill charge weight which will clearly vary with grinding
condition.
To determine the relationship between no-load power and mill

design parameters, data from pilot and industrial mills ranging from
1.7 to 7.2 m in diameter were analysed. However, these no-load
powers are difficult to measure precisely. The problems are power
factor effects at low loads and achieving a completely empty mill.
The parameter Diam3Len N was regressed against no load power
and found to provide a good fit (Figure A9.3). The relationship
developed was as follows with N converted to the fraction of
control speed:
No Load Power (kW) = 2.62 (Diam2.5 Len φ)0.804
Hence, this equation estimates the likely indicated no-load power
for an installed mill.
1000
800
Predicted (kW)
600
400
200
0
0 200 400 600 800 1000
Indicated (kW)
Figure A9.3: Indicated vs Fitted No-Load Power

Power Calculation The most recent JKMRC database currently includes power data
Accuracy from 63 different mills. Details are shown in Table A9.1.
Table A9.1: Data Base Details
Ball Mills SAG Mills AG Mills

Diameter (m) 0.85-5.34 1.80-9.59 1.8-9.50
Belly Length Inside Liners (m) 1.52-8.84 0.59-7.95 0.59-5.18
Length/Diameter Ratio 1.00-1.83 0.33-1.50 0.33-1.0
Percent of Critical Speed (%) 60-83 48-89 72-75
Ball Filling (Vol %) 20-48 3-25 0
Total Filling (Vol %) 20-48 7-38 10-31
Specific Gravity of Ore 2.6-4.6 2.6-4.1 2.7-4.6
Number of Mills 38 20 5
Number of Data Sets 41 28 7
Power Draw (kW) 6.8-4100 14.8-7900 12.5-5500
The power model has been applied to this database and was found
to give excellent results. The standard deviation of the relative
error of the model was calculated to be 6.5% for gross power..
The model therefore requires a knowledge only of mill dimensions
and speed, ball charge, volume occupied by balls and pulp, and the
ore specific gravity. Full details of the model are given in Morrell
(1991).
Because of the industrial database, the prediction of gross power is
the most reliable.
Restrictions This power model assumes the SAG mill grate and pulp lifters do
not limit pulp throughput. For a large diameter mill (say > 7m) in
closed circuit with hydrocyclones or fine screens, this assumption
may not be justified. A build up of fine slurry in the mill will
remove some of the charge imbalance and reduce the actual power
draw.

A9.5 SAG Mill Printout

A9.6 Symbols
Symbol Meaning
aij fraction of size j which breaks into size i

A Ecs model parameter
b Ecs model parameter
dmax discharge rate at xm
di discharge rate of size i
fi feed rate of size i
Ecs Energy absorbed per unit mass during breakage
in each size fraction
E1, particle potential energy at full height of mill
F volumetric feed rate/mill volume
HE High Energy
LE Low Energy
L mill volume fraction of minus grate size
m1, m2 mass transfer parameters
si mill contents of size i
rj rate of breakage out of size j
S20 average size of top 20% of mill load
t10 percentage which passes through a screen
aperture of 10% of the original size.
tp percentage which will pass through a screen of
aperture original size /p
ta abrasion parameter
xi particle size
xg grate size (mm)
xm size below which all will pass through the grate (mm)
g gravitational constant
ρ charge density
r radial position of element

θ angular position of the element

Nr rotational rate at a radial distance r
rm mill radius
ri charge surface radius (see Figure A9.2)
θs angular position of the shoulder
θr angular position of the toe
Diam mill diameter (m)
Len mill length (m)
φ fraction of critical speed.

The model is not valid outside a range of 55% to 75% solids by
weight in the feed.
Mill speed is assumed to be 70% of critical or close to it. However
for small changes in speed (~ ± 5%) a good approximation can be
made by multiplying the rate at each knot by the relative change.
That is, for +5% (ie. 70% increased to 73.5% critical) multiply by
1.05 or add ln (1.05) to the logarithm of the knot value. This
assumes the number of impacts per mill revolution will not change.
In reality more speed will give more lift and a slightly higher
breakage energy.
The classification model is very simple and only dependent on
grate size. The xm parameter is driven by slurry viscosity. For
viscous ores, xm may be up to 1mm. For clean ores (hard rock,
clay free) 0.1-0.2mm is typical.
This model has been tested against a large number of full-scale
operations and a very wide range of pilot plant test data. The
model has provided good predictions for design (Morrison, Kojovic
and Morrell 1989) over a wide range of ore types.
Detailed comparison with pilot plant data has highlighted areas
where the model assumptions are not a sufficiently good
approximation. Known areas to treat with caution are as follows.
The assumption that grinding rates are constant at a given ball load
is not true when
• there are large variations in mill feed sizing
• the mill is taken from open circuit to closed circuit.

Operating The model is numerically stable at any mill load (equation (A9.9)).
Limits Real world mills typically operate with maximum loads of 30 to
35% by volume of charge.
However, they may be limited by motor power at much lower

loads. There is usually a limit on ball load of 5 to 10% because of
mechanical or power constraints.
It is the engineer's responsibility to check these parameters against
the limits for a particular mill.
Feed Sizing The auto/SAG model 'forms its load' from the mill feed. If the mill
feed size distribution is smooth (ie. a reasonably straight line on a
Rosin-Rammler plot), simulated variations in feed sizing give
sensible results. If the coarse end of the feed distribution is
artificially adjusted for the feed is preclassified in some way, then
the S20 assumption that the load can be treated as a single number
becomes unjustified. Hence artificially adjusted top sizes will
cause the model to predict wide variations in performance.
(While these variations are excessive, it should be noted that real
auto mills are also sensitive to feed top size).
Similarly, if those fractions that limit throughput (notional critical

size) are prescreened from mill feed, the model will be optimistic
about increased throughput.
(Once again, real SAG mills will also achieve much higher
throughputs). However, predictions for recycle crusher are quite
realistic.
If mill operation is closed with a fine classifier (DSM screen or
hydrocyclones) there is usually an increase in the observed grinding
rates at 4mm. This means a typical SAG mill may have some 'free'
grinding capacity for particles a few millimetres in diameter.
Where the simulated mill is operating in closed circuit with a
screen, the circulating load will tend to vary more (and the mill
load less) with changes in hardness and feed sizing than the real
mill. However trends will be correct and overall product sizing
should be close.
Mill Power Accurate measurements or estimates of mill dimensions, speed and

ball and pulp load are required for the power calculation. Ensure
that all data used are accurate.

Ball Size Effects Ball effect is estimated by generating an equivalent load of ore
particles. As the top 20% of this load is used to find S20, only the
top one or two ball sizes can have any 'impact' on this calculation.
Manipulating the finer ball sizes (ie. < half top size) have very little
effect. In practice, it does change the fine grinding rates.
Ball Load Effects These have been investigated in some detail at pilot scale. In
general, the harder the ore (low b and low ta) the less the grinding
rates are affected. A soft ore however follows the accepted wisdom
that increasing ball load will produce a coarser product. This may
well be because the increased number of balls are now breaking the
ore particles in the load which were doing the fine grinding.
Discharge Rates Considerable work has been carried out by Morrell (1990) on
factors affecting discharge rates. These effects are also
summarised in Morrell and Morrison (1989). See A11 for details.
Overall, discharge rates will only become a limiting effect in very

high viscosity ores. In this case, operation at a lower pulp density
is recommended. The SAG mill is an effective pump and the
charge will remain relatively 'dry'.
Mill Liner Effects The SAG mill model is valid for correctly designed traditional
'high/low' lifter type action. Wave liners or short lifters do not
provide enough lift to achieve the default rates. If poor lift is
combined with poor discharge, the mill only produces abrasion
with a very fine product at a correspondingly low throughput.
Further The JKMRC now has a substantial database of SAG/auto mill

Developments surveys and breakage characteristics. This data base has been used
to develop the wider range variable rates AG/SAG model described
in Appendix 11
Mill Load The autogenous and SAG mill model does not include an explicit
Limits maximum for the mill load. However, a warning will be flagged if
the total load (ie. balls and pulp) exceeds 35% by volume. An error
will be flagged if the total load exceeds 40%.

A9.8 Fitting the Autogenous and SAG Mill

Models
PARAMETER MENU
XG
XM
Rate 1
Rate 2
Rate 3
Rate 4
Rate 5
These models are complex and calculation intensive. However, any

computer which is suitable for MS Windows 95/98/NT should be
adequate for AG/SAG model fitting.
In the unlikely event that the fit is slow, the Select list may be used
to restrict the scope of calculation or to fix recycle streams as
“feed” streams.
.
Initial Values Use the grate width and 100 µm as initial estimates for xg and xm.
The default breakage rates for auto and SAG will provide a good
guess for each knot value.
Ore Type For accurate results, these are best derived from tests carried out on
Parameters representative samples at JKTech.
For an existing operation, the values provided in the volume of

supplementary information provide some guide to possible values.
Mill Load If a reasonable estimate of load mass and sizing is available, then
fitting with a range of A and b values may provide a way of
estimating these values - that is - use the values which give the best
fit for ratio work.

Mill Load is fitted by inputting it as raw data into the dummy

product stream. If you only have a total mill load estimate (eg.
from bearing pressure), set the size fraction SDs to zero and the
load SDs appropriately. Subtract the weight of balls from this load
for a SAG mill and input it on the model screen.
Closed Circuit If the mill is being operated in closed circuit with hydrocyclones, it
Operation is better to reduce m1 from 0.37 to 0.25. This seems to provide a
better approximation of the mass transfer response for a large
recirculation of material finer than grate size.
Knot Positions The spline knot positions are better left where they are for the
'normal' range of SAG mill feed sizings, 80mm < F80 < 250mm.
However for very fine auto mill feeds, the limiting size fraction
will also be finer and it may help to scale down all the knots. That
is, reduce them by the same ratio. An alternative is to simply fix the
larger knots at their default values.
Hint: If the closed circuit simulation gives a very different

circulating load, check carefully for size biases in the fit or in the
data itself.
Master/Slave The Master/Slave fitting can be used with multiple sets of
Fitting SAG/auto data. Ensure that you are using the same knots positions
for each mill in the test. Similarly, each survey data set to be fitted
simultaneously should have been collected with the same grate and
pebble port size, and ball load.
A9.9 References
AUSTIN, L.G., LUCKIE, P.T. and KLIMPEL, R.R., 1984. The

process engineering of size reduction: Ball Milling,
S.M.E/A.I.M.E., NEW YORK: 561pp.
AUSTIN, L.G., WEYMONT, N.P., PRISBREY, K.A. &
HOOVER, M., 1976. Preliminary results on the
modelling of autogenous grinding. 14th Int. A.P.C.O.M.
Conf. The Penn. State Uni.: 207-226pp.
LEUNG, K., 1987. An energy based ore specific model for
autogenous and semi-autogenous grinding. Ph.D. Thesis,
unpublished, University of Queensland.
LEUNG, K., MORRISON, R.D. and WHITEN, W.J., 1987. An
energy based ore specific model for autogenous and semi-

autogenous grinding. Copper 87. Chilean Institute of
Mining Engineers, Santiago, Chile.
MORRELL, S. 1990. Simulation of bauxite grinding in a semi-
autogenous mill and DSM screen circuit. MEng Thesis,
University of Queensland (unpublished).
MORRELL, S. and MORRISON R.D. 1989. Ore charge, ball load
and material flow effects on an energy based SAG mill
model. SAG Conference, University of British Columbia,
Vancouver.
MORRELL, S., NAPIER-MUNN, T.J. and ANDERSEN, J. 1992. The
prediction of power draw in comminution machines.
Comminution-Theory and Practice, K. Kawatra (ed), SME, Chapter
17, pp. 235-247, 1992.

Appendix A Size Converter Model (490)
A10 Size Converter Model (Model 490)
A10.1 Introduction
The model provides a product size distribution with a user

specified P80. This is achieved by adjusting the feed size
distribution finer or coarser as required.
The model is useful when there is no process knowledge of

upstream comminution devices, or when a size distribution of a
particular size is required for sensitivity analysis.
A10.2 Model Details
The feed to the model is adjusted by moving it sideways on a

Cum % Passing v size plot until the product P80 matches the
specified P80 as closely as possible.
A10.3 Fitting the Size Converter

There are no fittable parameters in this model.
The model is limited in its ability to generate a product which is

coarser than the feed by the coarsest screen available in the feed
combiner and product ports. It is always wise to plot and inspect
the graph of the feed and product to ensure that the shape of the
distribution is reasonable.
Version 5.1 November 2001 Appendix 10 Page A-101

Appendix A Size Converter Model
(Blank Page)

Appendix A Variable Rates SAG Model (435)
A11 VARIABLE RATES SAG MODEL
A11.1 Introduction
The Leung AG/SAG model (A9) typically requires a full scale plant or
pilot mill survey combined with ore breakage testing to generate a set of
grinding rates. However research in the mid 1990’s using a large
database of pilot and full scale milling tests has lead to the development
of a correlation between model grinding rates and mill operating
conditions. A further correlation between mill feed sizing and ore
breakage characteristics has also been developed. These two correlations
now allow mill performance to be predicted for a wide range of mill sizes
and operating conditions. Hence the model can be used to evaluate
optimisation strategies in existing plants and to investigate (and
compare) grinding circuit configurations at the pre-feasibility stage thus
reducing the cost of pilot testing.
The underlying model is still identical with that developed by Leung et al

(1987) except that
• grinding rates have been related to mill diameter and operating
conditions, and
• A model which includes grate geometry (but does not
incorporate pulp lifter capacity) now describes slurry holdup.
This approach was reported by Morrell and Morrison, 1996.

If you are new to SAG mill modelling, it is strongly recommended
that you work through Appendix 9 (the Leung model) before
attempting to use the Variable Rates model.
The VR model interface has been slightly revised for Version 5
mostly to make recycle effects easier to specify.
A11.2 Scaling Approach
A large proportion of AG/SAG model users either carry out pilot

scale tests and wish to predict full scale operation or carry out full-
scale tests and wish to predict performance at different operating
conditions. The variable rates model has been implemented to
facilitate this scaling process as in the rod and ball mill models.
The variations in rates also depend on recycle and feed sizing.
Hence, this model allows the user to select appropriate streams for
recycle data.
For model fitting, the original and simulated cases will usually be
identical. This is considered in detail in section A11.6.
A 11.3 Slurry Holdup Model
The transport of slurry through the mill is described by a function which

relates the hold-up of slurry, grate design, grate open area and mill speed

Variable Rates SAG Model (435) Appendix A
to the volumetric discharge rate through the grate (Morrell and

Stephenson, 1996):
Jp = k Q0.5 γ-1.25 A-0.5 φ0.67 D-0.25 (A11.1)
where
Jp = fractional slurry hold-up
D = mill diameter (m)
2
A = total area of the grate apertures (m )
φ = fraction of critical speed
3
Q = volumetric flowrate out of the mill (m /hr)
γ = mean relative radial position of the grate apertures
γ =
∑ ri ai
rm ∑ ai
ai = open area of all holes at a radial position ri

rm = radius of mill inside the liners.
Classification by the grate is related to the effective grate aperture by a

simplified classification function. For illustrative purposes a conceptual
view of the weighted radius model is shown in Figure A11.1.
0.75 - 0.8 0.85 - 0.95
Figure A11.1: Weighted Radius For Two Grate Designs

A11.4 Variable Rates Model
Relationships between the operating conditions and changes in the

breakage rate distributions within the JKMRC’s pilot mill database
(Mutambo, 1993) were developed. These results were augmented with
results from full-scale mill data in cases where the pilot mill database
contained little or no variation in the parameter of interest e.g. mill
speed. To indicate the extent of the pilot mill database, Table A11.1
summarises its details.
Table A11.1: Pilot Mill Database Details
Range
New Feed F80 (mm) 35-140
Ball load (%) 0-12
Recycle load (%) 0-500
No. different ores 16
No. tests 52
The breakage rate distribution is described within the model using cubic
splines (Ahlberg, 1967). This gives rise to five breakage rate values each
of which relate to a particular particle size and which together
characterise the entire breakage rate distribution. The five standard
particle sizes chosen are 0.25, 4, 16, 44 and 128mm which have
associated with them breakage rates which are labelled R1, R2, R3, R4
and R5 respectively.
1000
R5
Breakage rate (hr^-1)
100
R2 R4
R1
R3
10
1
0 0 1 10 100 1000
Size (mm)
Figure A11.2: Characterisation of the Breakage Rate Distribution
These rate curves exhibit a characteristic shape. The coarser (R5 and
R4) rates relate to abrasive breakage while the finer rates R1 and R2
exhibit similar characteristics to those of coarse ball milling, ie.
predominantly impact breakage. The pronounced dip in the rates at R3 is
associated with the critical size which may limit mill throughput by
building up to excessive levels. Typically it is in the 25-75mm range and

varies with particular combinations of feed sizing, breakage

characteristics and the magnitude of the breakage energy developed in
the mill.
To determine the relationship between operating conditions and the

breakage rate distribution, the breakage rates R1-R5 were regressed
against operating conditions. The resultant equations were of the
following form:
Ln (R1) = (k11 + k12Ln(R2) - k13Ln(R3) + JB (k14 - k15F80) - DB)/Sb

……(A11.2)
Ln (R2) = k21 + k22Ln(R3) - k23Ln(R4) - k24F80 (A11.3)
Ln (R3) = Sa + (k31 + k32 Ln(R4) -k33 Rr) /Sb (A11.4)
Ln (R4) = Sb(k41 + k42 Ln(R5) + JB(k43 - k44F80 (A11.5)
Ln (R5) = Sa +Sb(k51 +k52F80 + JB (k53 -k54F80) - 3DB) (A11.6)
where
Sa = rpm scaling factor
= Ln (simulated mill rpm/23.6)
Sb = fraction of critical speed scaling factor
= simulated mill fraction of critical speed/0.75
DB = ball diameter scaling factor
= Ln (simulated ball diameter/90)
JB = % of total mill volume occupied by balls and
associated voids
Rr = recycle ratio
= (tph recycled material_-20+4mm)
(tph new feed) + (tph recycled material -20+4mm)
F80 = 80% passing size of new feed (mm)
kij = regression coefficients
The regression coefficients for equations (A11.2)-(A11.6) are given

below and are based on the JKMRC current database at mid 1996. As
more data are collected and our understanding of the various factors
increases, these coefficients are likely to be modified.
Table A11.2: Regression Coefficients
j k1j k2j k3j k4j k5j

1 2.504 4.682 3.141 1.057 1.894
2 0.397 0.468 0.402 0.333 0.014
3 0.597 0.327 4.632 0.171 0.473
4 0.192 0.0085 -- 0.0014 0.002
5 0.002 -- -- -- --

It can be seen from the equations that the finer size rates are functions of
the rates of the coarser sizes. Hence R1 is a function of R2 and R3 etc.
The rates can be considered as falling into 2 groups which represent the
grinding media and product size fractions. Hence the grinding media
group contains the rates R4 and R5 (related to particles >30mm) the
magnitude of which affect the throughput. The product group
incorporates rates R1, R2 and R3 (related to particles < 30mm) and the
magnitude of these affects the final product size. It is of particular note
that the rates are interrelated in a complex manner and are best
understood by graphing the entire breakage rate distribution.
A11.5 Effect of Key Parameters

The variable rate model allows the effects of a number of key parameters
to be considered independently.
It is worth mentioning that ‘original’ does not provide a basis for
scaling in this model as it does in rod and ball mill models. It
provides a marker to allow the user to see how much the rates have
varied from the original case.
Ball Load The effect of changing ball load on the breakage rate distribution is
illustrated in Figure A11.3.
10000
0% balls
1000
4% balls
Breakage rate (1/hr)
8% balls
100
10
1
0 1 10 100 1000
Size (mm)
Figure A11.3: Effect of Ball Load on Breakage Rate Distribution
The resulting relationship is as expected in that by increasing the ball

load the breakage rates increase at coarser sizes but reduce at finer sizes.
This has the effect of predicting higher throughputs at coarser grinds as
the ball load is increased. However, it is commonplace to operate at too
high a ball charge often because of historical experience with softer,

oxidised, surface ore. As the ore becomes harder it may well be possible
to replace balls with ore as grinding media for more power effective
operation.
Makeup Ball No significant dependence of the breakage rates on ball size was found in
Size the pilot mill database. The SAG model does account for ball size
changes in terms of the energy provided during impact. It does this by
changing the mean grinding media-size, which in turn changes the
‘energy level‘ of the mill. This ‘energy-level‘ term is used to determine
the specific energy of impact. As the ball size is increased, therefore, the
specific energy increases and hence for a given impact event a finer
product size distribution occurs. However, as the ball size is increased
the number of grinding media per tonne of charge will decrease. As the
breakage rate is related to the number of impacts provided by the grinding
media then a reduction in the breakage rate may be expected to occur. To
account for this a ball scaling factor is used. Figure A11.4 illustrates the
effect of the ball size correction factor on the breakage rate distribution.
It should be emphasised that it is usually argued that a coarser ball size

will give a higher throughput but with a coarser grind. In practice,
experiments with full-scale mills are sometimes inconclusive and mill
operators see little or no effect when experimenting with ball size. This
may be due to the counter-effect of reduced numbers of balls providing
higher breakage energies when increasing ball size. The model predicts
such a response by increasing the breakage energy and reducing the
breakage rate. In some instances the one effect may outweigh the other,
in which case a response will be noted. Over some ranges of ball sizes,
however, little or no effect will be seen.
1000
100
10
94mm balls
125mm balls
1
1
10
1000
0.01
100
0.1
Size (mm)
Figure A11.4: Predicted Effect of Changing Ball Size

Feed Size F80 The effect of F80 was found to be the most difficult one to evaluate as it
Effects for SAG interacted with the ball charge level. At relatively high ball charges (10%
Milling or more) high F80 values were detrimental as evidenced by the reduction
in the breakage rates illustrated in Figure A11.5.
10000
f80=75;Jb=10%
1000 f80=125;Jb=10%
Breakage Rate (1/hr)
100
10
1
0 1 10 100 1000
Size (mm)
Figure A11.5: Effect of F80 on Breakage Rate Distribution - (SAG

mill)
Feed Size F80 However in the case of autogenous grinding the pattern is different. In
Effects for this case a higher F80 promotes breakage in the coarser size fractions
Autogenous (Figure A11.6). This is to be expected when it is considered that in
Milling autogenous milling large rocks are required to break ore in the R5 size
range (128mm). As the F80 increases, this will typically result in more
coarse rocks in the charge able to break R5-size ore and hence R5 will
increase. In SAG mills running with higher ball charges, the rock
component of the grinding media plays a lesser role in dictating the
breakage rate and contributes more to the rock ‘burden’ which has to be
ground down. Feeds with F80 values and hence more coarse feed rocks,
can thus be expected to reduce the breakage rate.
Caution needs to be exercised, however, as it has been found that the F80
is not always a good indication of the feed size distribution. This is
particularly noticeable with autogenous mills whose performance may
fluctuate considerably yet maintain a reasonably constant F80. In such
cases the distribution changes systematically with performance and that
typically higher proportions of 25-50mm material in the feed result in
lower feedrates, ie. less sub-grate size material is present in the feed and
more near size material has to be broken.

1000
f80=75;Jb=0%
f80=125;Jb=0%
Breakage Rate (1/hr)

100
10
1
0 1 10 100 1000
Size (mm)
Figure A11.6: Effect of F80 on Breakage Rate Distribution - (AG

mill)
Effect of Recycle Recycle loads broadly fall into 2 categories viz.:

Load
1. Coarse recycles from trommels, vibrating screens and recycle
crushers which typically comprise only -20 + 4 mm material
and have P80 values of the order of 8 - 12mm,
2. Fine recycles from hydrocyclones and DSM screens which are

predominantly –4 mm material and have P80 values of the order
of 0.2 - 0.5 mm.
It has been found that the amount of recycled material in the -20 + 4 mm
size range is inversely related to the amount of breakage that this
material is subjected to. This can be explained if one considers that these
rocks are broken by coarser rocks and balls whose frequency does not
appreciably change with changes in recycle load. However as the
amount of recycled -20 + 4 mm rock increases, the amount of this size
material in the load will increase. As the breakage rate in a given size
class is related to the ratio of the number of coarser rocks and balls to the
number of rocks in the given size class, then increasing the -20 + 4 mm
recycle will result in a drop in the breakage rate in this size range (R3
size = 16 mm). The changes in the breakage rate distribution as the
coarser recycle increases is illustrated in Figure A11.7. Interestingly,
recycle of fine material ie. –4 mm did not correlate with any of the
breakage rates. This may be related to the breakage mode of this
material which is believed to be dominated by attrition.
Where the material has been recycle crushed, it is considered to have

similar properties to new feed and is not included as -20 +4 mm recycle.

1000
100
10 Rec=0
Rec=.05
Rec=.1
1
1
10
1000
100
0.1
Size (mm)
Figure A11.7: Effect of Recycle Load on Breakage Rate Distribution

Recycle Control in For the most part, the Version 5 model is identical with the
V5 Variable Rates SAG model in Version 4. There are, however, a
couple of important differences which relate to control of recycle
of –20 +4mm material on the grinding rates.
As for V4, the User inputs new feed rate tonnes per hour and 80%
passing size for Simulated and “Original” mills.
Recycle Options – In Version 4, there are two implied switches.

The first is “Fixed Recycle”. If the User inputs a Fixed Recycle
tonnage, all simulations will use this value to calculate the recycle
ratio.
Version 5 uses this implied switch as well i.e. the fixed recycle
tonnage value is set to zero to allow for simulated recycle.
The second implied switch in Version 4 is to select one (or more)

recycle streams from the flowsheet. In version 5, this switch is
now explicit as “Use Recycle in Calculations”. If this switch is
set to one, the actual recycle is now calculated by the model as the
difference between –20 +4mm in new feed (specified by the user)
and in the total feed to the SAG mill.
Hence the User uses the Ore Feeder size marker to estimate % -
20mm and % -4mm and enters the difference into the appropriate
field on the SAG model.
Comment. The effect of recycle has always been difficult to

model and it also the subject of current research. It provides
some compensation for recycle material ‘survivors’ being likely
to be somewhat ‘harder’ than new feed particles in the same size
fraction.
However, if the recycle stream is crushed, new flaws will be
generated and the original feed properties retained. Therefore it is
recommended that ‘Use Recycle …. ‘ be turned off when a
recycle crusher is used, with the following note of caution. If K1
is larger than 4mm, a proportion of recycle crusher feed will not
be crushed. The bypassed –20 +4mm can be compensated for by
iteratively adding the ‘new’ –20 +4mm in the crusher product to
the new feed % of –20 +4mm.
Excessive fine recycle may make this model unstable. However,

excessive fine recycle will often make real AG/SAG mills
unstable and it a consequence of a realistic model.

Mill Speed/Mill The breakage rate is related to the number of size reduction events
Diameter per particle, per unit time and is hence a frequency. This in turn
must be related to the frequency with which the mill rotates (rpm).
A scaling factor is therefore applied to account for changes in the
rotational rate. For a given fraction of critical speed the rpm
decreases with mill diameter0.5 and hence this scaling factor will
also change with mill diameter. All else being equal, therefore, a
larger diameter mill will have a lower breakage rate than a smaller
unit. However it is pointed out that the JKMRC model inherently
scales on the basis of breakage energy which it relates to mill
diameter. Therefore, whereas a larger diameter mill will have a
lower breakage rate it will have a higher breakage energy.
In a given mill as the rpm changes, apart from the rotational rate,
the shape of the grinding charge will also change in line with the
fraction of critical speed (Morrell, 1996). Typically as the fraction
of critical speed increases the charge is subjected to increased lift
and hence impact breakage is enhanced. It is at the expense of
attrition breakage which is normally associated with cascading
motion and which is prevalent at lower speeds. To account for
these effects a further scaling factor is applied which is based on
the fraction of critical speed. Figure A11.8 illustrates the predicted
changes in the breakage rate distribution as speed is changed.
10000
85% Cs
75% Cs
1000
65% Cs
100
10
Size (mm)
Figure A11.8: Predicted Effect of Changing Speed on the Breakage
Rate Distribution
Mill Power The variable rates model allows the user to specify the conical slope
inside the liners of each mill end. The mill power estimate includes
the conical ends (Morrell, 1996).

A11.6 Parameter Fitting the Variable Rates

Model
Fitting Single Model fitting the variable rates model is quite similar to fitting the
Data Sets Leung model (A9). The defaults for the original mill grinding rates
are all set to zero, ie. the intercepts of the rate equations (Table
A11.2) are included in the model.
Hence the fitted rates indicate how far the measured mill is
operating from “typical” conditions. The recommend strategy is to
first fit xg and xm with the grinding rate intercepts set to zero. If
the mill has pebble ports, set the initial pebble port size to the
largest measured particle in the mill discharge. If the xg and xm fit
is plausible, add the pebble port size (PPSize). Use the measured
open areas for pebble ports and grates and the measured weighted
radius/mean relative radial position for the grates. Note that the
grate open area includes grates and pebble ports. The recycle
streams are selected from the unit menu.
The measured recycle rate (-20 +4 mm) should also be entered as

data. (When this field is zero, the calculated recycle is used. This is
appropriate for simulation).
The new feed size (F80) should be noted and entered for both
Sim(ulated) and Org(inal) mills as should all of the other measured
mill data.
If the xg, xm and PP (pebble port) size fit is plausible, adjust the
scale factors on Breakage Rate “Constants” to 0.1 and include them
in the next fit.
The open area fractions (Grate OA) can be selected to fit. They are
only suited to matching wear conditions and should not be fitted
together with grate or pebble port sizes as the parameters are likely
to interact quite severely.
Given good data and ore characterisation this model will often
predict the measured results quite well and model fitting is very
simple.

Remember – xg, xm and PP size are all square mesh equivalent

sizes. Therefore, aperture shape and particle shape will interact. A
slabby particle will appear much larger to a square mesh screen
than to a slotted grate aperture!
Fitting Multiple A comprehensive pilot test program will produce data over a range
Data Sets of operational conditions. For sophisticated users, the variable rates
model allows several sets of pilot data to be analysed
simultaneously.
The first step is to analyse each set by using its own select list. This
should identify any data problems. Then add each data set onto a
combined select list for master slave fitting.
One of the pilot data sets is selected as a base case. For this set,
simulated and original inputs are the same. For the other sets,
change the simulated mill conditions as required (eg. Ball load)
and use the base case original mill conditions in all tests. Add all
of the measured load and product streams to the model fit data list.
Use the master/slave capability to simultaneously fit, xg, xm, PPort
size and grinding rate intercepts to all data sets at once.
Notes:
• a fast computer (Pentium 166 or better) is required for three or
more SAG data sets
• Multi-fit capability is not available in Version 5. However, the
number of fittable sets of port data will be expanded in later
releases.
This approach can also be used to simultaneously analyse several

sets of operating plant data, even between different sizes of mills
treating similar ores.
In either case, a good overall fit indicates a model which can be

used for prediction over a wide range of operating conditions.
A poor overall fit, particularly if the grinding rates are lower than
typical (negative intercepts) may indicate shortcomings in data
collection. More seriously, it may also indicate more significant
problems such as poor liner design or inadequate pulp transport
capacity (i.e. pulp lifters).
Larger rates may indicate particularly good practice or at the coarse

knots, decreasing ore competence at coarser sizes.

A11.7 Using the Variable Rates Model for

Simulation and Design
This model is quite complex and a good appreciation of both the

model and SAG mill operations are recommended before use for
design.
Comprehensive industrial research work over the last decade has

built up the database for this model and exposed some conceptual
weaknesses which are being addressed with two new models.
However, the variable rates model is now a powerful tool for data
analysis, circuit evaluation and AG/SAG mill design.
The following points should be noted.
Recycle Streams Up to three recycle streams can be selected from the model menu.
These should be recycles which actually go into the mill, eg.
Recycle crusher product, not feed. The “Fixed Recycle” input
should be set to zero for simulation to allow the calculated flow of
-20 +4mm to be used. (Input the measured flow for model fitting).
Where the material has been recycle crushed, it is considered to

have similar properties to new feed and is not included as -20 +4
mm recycle.
NB: V5 handles recycle loads differently from V4. See pages 108-
109 for details of the differences.
Load Limits The feed trunnion diameter indicates the maximum volumetric load
limit. If the simulated mill limits at a lower level than the actual
mill, reduce this diameter.
Beyond a certain load, the power model is unlikely to be reliable

and the power estimates are set to zero.
Grate Flow The flow correlation detailed in A11.3 provides a maximum flow
Limits (Mass estimate at the simulated mill load. The user may enter a design
Transfer maximum load level for which a maximum flowrate estimate is also
“Law”) calculated. These estimates relate to flow through the grate. They
assume that the pulp lifters can remove all of the grate discharge.
This is not always true for mills operating in closed circuit with
cyclone or fine screens.
If the simulated flow exceeds the maximum, the mill will likely fill
up with fines and go into overload as the slurry pool reduces impact
breakage. This effect is not simulated by the model.
Feed Size The F80 values for new feed for both simulated and original mills are
Considerations entered by the user.

For design, a reasonable estimate of F80 is often difficult. Power

based equations typically divide by the feed size so the assumption
becomes unimportant but real mills are sensitive to feed sizing as
are accurate models.
The JK database shows reasonably systematic dependence of

AG/SAG F80 (crusher P80) with all hardness measures. The harder
an ore, the coarser the resulting crusher product at the same crusher
closed side setting. The best correlation is with the JK abrasion
parameter ta.
For a design case, the F80 of the feed can be estimated from the
measured ta with a standard deviation of about 10% of the primary
crusher closed side setting.
F80 (mm) = {css - 78.7 - 28.4 ln (ta)} (A11.7)

s.d. = 0.1 css.
This is not a perfect answer, as the size distribution slope also

varies as shown below.
100
10
Coarse/hard ore
Fine/soft ore
1
.01 .1 1 10 100 1000
Size (mm)
Figure A11.9: Typical AG/SAG mill feed sizings
The size converter model (see Appendix A10) can be used to adjust
from a similar ore to the target range for simulation.
(Note that it is also possible to conduct a test in a pilot adit to

estimate the likely run of mine size distribution. This distribution
can be fed to the crusher model to predict the mill feed distribution.
Contact JKTech for assistance with test blast design.)

This model does not take account of the variation in breakage

energy at different mill loads. Therefore pilot and industrial
operation should be measured at realistic operating loads (ie.
>20%).
As noted earlier, pulp lifter capacity may limit before maximum

grate capacity is reached.
The single number grate characterisation (Mean relative radial

position) is a useful approximation. However, it should be used
with actual grate designs, not hypothetical variations which may
not be able to be manufactured. As the database of very large mills
expands, it is becoming apparent that the charge in a large coarse
feed mill restricts the maximum circulating load. Hence for mills
11m in diameter (or larger) treating coarse feed, the simulated
circulating load should be restricted to 25% of new feed rate. This
can be done by reducing the grate open area parameter. This is an
area of continuing research at JKMRC.
With the large database of SAG mill test work, it is clear that
maximum throughput does not always correspond to maximum
mill power draw or maximum mill load.
For hard ores, maximum throughput requires sufficient impact
energy at the toe of the charge. Hence the maximum throughput (at
maximum discharge coarseness) will often occur between 20 and
30% volume mill load.
Research at JKMRC is developing models which will account for

this effect and others such as the difficulty of removing pebbles for
crushing from very large mills. For mills of larger diameter than
10m, a maximum recycle crusher flow of less than 25% of new
feed rate is recommended as a constraint on simulations. (Mills
with very fine feed and large grates may exceed this estimate)
Manipulating the SAG mill feed size distribution by pre-crushing is

another way of shifting the throughput/product relationship for hard
ores.
A limitation has been found on the accuracy of the response of the

rate equations to changes in F80, particularly if the new feed F80 is
outside the range of the data base. The recommended F80 for use
in the model is calculated from the equation:
F80 = 71.3 – 28.4 * ln (ta)
This F80 value should be used as the Reference F80 value on the
Recycles tab in the Variable Rates SAG Model equipment window.

A11.9 Variable Rates SAG Model Printout


A11.10 References
Ahlberg J H, Nilson, E N & Walsh, J L, 1967. The Theory of Splines

and Their Applications. Mathematics in Science and Engineering,
38, Academic Press, New York and London
Andersen J S, 1989. Development of a Cone Crusher Model. M.Eng.Sc

Thesis, University of Queensland.
Leung. K, Morrison R D & Whiten W J, 1987. 1987. An Energy Based

Ore Specific Model for Autogenous and Semi-autogenous Grinding
Mills. Copper 87, Santiago Chile.
Morrell, S. 1996. Power Draw of Wet Tumbling Mills and its

Relationship to Charge Dynamics. Part I: A Continuum Approach to
Mathematical Modelling of Mill Power Draw. Trans. Instn.
Min.Metall, 105, C43-53.
Morrell S & Stephenson I, 1996. Slurry Discharge Capacity of

Autogenous and Semi-autogenous Mills and the Effect of Grate
Design. Int. J. Miner. Process. (In press).
Morrell S & Morrison R D, 1989. Ore Charge, Ball Load and Material
Flow Effects on an Energy Based SAG Mill Model. Presented SAG
1989, University of British Columbia. Editors. Mular & Agar.
Morrell S & Morrison R D, 1996. AG and SAG Mill Circuit Selection

and Design by Simulation. SAG 96, edited Mular, Barrett and
Knight, Vancouver 769-790.
Mutambo. J, 1993. Further Development of an Autogenous and Semi-

autogenous Mill Model. M. Eng Sci. Thesis. University of
Queensland (unpublished).
Needham T M & Folland G.V. 1994. Grinding Circuit Expansion

at Kidston Gold Mine. Presented at SME Annual Meeting,
Albuquerque, New Mexico. February 14 -17.

(Blank Page)

Appendix A High Pressure Grinding Rolls (Model 402)
A12 High Pressure Grinding Rolls (402)
A12.1 Introduction
The high pressure grinding rolls crusher(HPGR) - also known as

the roller press or roller mill - was invented by Klaus Schönert in
Germany as an outcome of his fundamental research on rock
fracture (Schönert 1988). The device has been most widely used in
cement clinker grinding in Europe, but is beginning to find
application also in mineral processing. One of the first such
applications was in diamond ore processing in Southern Africa and
latterly in Australia, where it was shown that the device offered
some degree of selective liberation of the diamond from the host
rock. However the claimed advantage for most mineral processing
operations is the very high reduction ratio achieved, and the
favourable specific energy consumption, compared to conventional
technologies. Some evidence has also been reported for
downstream benefits such as reduced grinding strength and
improved leachability due to microcracking (Knecht 1994).
Potential applications therefore include preparation of material for

fine grinding, replacement of tertiary crushing, rod milling and
primary ball milling in primary grinding, and the attainment of
enhanced leaching performance. The general principle is
illustrated in Figure A12.1.
Figure A12.1: The high pressure grinding rolls (roller mill)
Schönert’s research has shown that the most efficient way to

fracture a rock mechanically is to load it between two opposing
platens until it fails. One way to do this at a high throughput is to
compress a bed of such particles between two contra-rotating
driven rolls. In industrial practice these rolls can be very large, up
to 2.8 m in diameter. One roll is mounted on fixed bearings, and
the other can move linearly against a hydraulic ram or (in small
machines) a spring.

High Pressure Grinding Rolls (Model 402) Appendix A
The hydraulics are set to deliver a particular pressure to the bed of
particles passing through the machine, compressing it to a density
greater than 70% by volume. This pressure, which usually exceeds
50 MPa, controls the size reduction in the machine.
The material leaves as a compressed cake (flake), which may have

to be disagglomerated prior to further processing. Particular care
must be taken to do this correctly when determining a product size
distribution.
The preferred method is to break-up the cake using a 2 or 3mm

screen, take representative samples and then to use an ultrasonic
bath to deagglomerate the particles. Deagglomeration can be
completed in either water or acetone but preferably the latter. The
objective is to produce a repeatable size distribution without
additional comminution.
A12.2 Model Structure
Underlying the structure of the size reduction model are three

assumptions about the inherent breakage mechanisms that occur in
HPGRs. As shown in Figure 12.2.
Pre-crusher If particles are bigger than a certain critical size they will be broken
directly by the roll faces as would occur in a conventional rolls
crusher. The breakage in this zone can be considered as analogous
to a ‘pre-crusher’, the products from which may subsequently pass
to a region where a bed under compression has formed. The
boundary between the pre-crusher and bed compression regions is
defined by a critical gap (xc).
Edge Effect Breakage at the edge of the rolls is different to that at the centre and
Crusher conforms more to that experienced in a conventional rolls crusher.
This is the so-called ‘edge effect’ which defines the proportion of
relatively coarse particles usually seen in HPGR products. Its
existence has been explained by the pressure gradient across the
width of the roll and the static confinement of the ore at the edges
of the rolls which the cheek-plates provide.
Compressive At some point away from the edges of the rolls, and extending
Bed Crusher upwards from the area of minimum gap (xg) to an area bounded by
the critical gap (xc), is a compression zone where breakage
conditions are similar to those experienced in a compressed packed
bed.
From a modelling viewpoint these assumptions can be

accommodated in the conceptual structure shown in Figure A12.2.
Feed firstly passes to the ‘pre-crusher’. Particles greater in
diameter than the critical gap (xc) are crushed below this size in a
single particle breakage mode. The products from this breakage

then combine with feed particles which are smaller than xc. A
proportion is then diverted to another single particle crusher stage
where all particles greater than the minimum gap (xg) are crushed
to below this size. The remainder are diverted to a compression
stage where all particles greater than xg are crushed below this size
but in a compressed bed mode.
All products then combine to produce the final HPGR product.
Feed to the HPGR
Precrusher:
conventional rolls crusher;
gap = x c
Splitter: determines the

fraction affected by the
"edge" phenomenon
Compressive bed Edge effect

breakage crusher; crusher: conventional
gap = x g rolls crusher; gap = xg
Combiner
Product from the HPGR
Figure A12.2: Schematic Structure of the HPGR Model
A12.3 Breakage Processes
HPGR Model The model contains three breakage processes and one splitting
process between the edge and compressed bed zones. For the
breakage processes the JKSimMet crusher model is used to
describe the size reduction. Four model parameters are required for
each breakage process: K1, K2 and K3 and t10. The first three are
used to describe the probability that a particle will be broken whilst
the t10 is used to describe the product size distribution that results.
For a detailed model description, refer to Appendix 6.3.
t10 Definition The t10 is defined as the percentage passing one tenth of the
original particle size in the product after breakage. Other tn
parameters can be similarly obtained from a product size
distribution, eg. t2 is the percentage passing one half of the original
particle size. From breakage tests the t10 and a number of other tn
values are determined from the breakage products. These values
are stored in tabular form in the model which, given a value of t10,
uses spline interpolation to determine the associated tn values and
hence reconstructs the entire product size distribution.

Pre-crushing For the pre-crushing process, breakage of particles is assumed to be
in single particle mode in which rocks are nipped directly by the
faces of the rolls, similar to a conventional rolls crusher. The
parameters used to describe crushing in this zone are determined
from tests conducted in a conventional (non-HPGR) laboratory
rolls crusher and single particle breakage tests, and remain constant
in the model fitting and scale-up. The parameter K2 is set as the
critical gap, xc, which is expressed by Morrell et al (1997)
0.5
 4 ρ g Dx g 
x c = 0.5 {(D + x g ) (D + x g ) 2 -  } (A12.1)
 ρc 
where xg is the working gap, D is roll diameter, ρc is bulk density

of feed and ρg is flake density.
xc
αc D
xg
Figure A12.3: HPGR Schematic Showing Compression or Nip Angle
In the edge zones rock breakage is also assumed to take place in

single particle mode. The parameters used to describe crushing in
this zone are the same as that in the pre-crushing, except K2 which
now takes the value of the working gap (xg).
Compressed Bed In the compressed bed crushing zone, on the other hand, size
Breakage reduction is assumed to be similar to that experienced by a bed of
particles in a piston press. The parameters used to describe size
reduction are determined from tests in a laboratory or pilot scale
HPGR machine combined with breakage tests in a piston press.
The piston press tests provide information on the relationship
between size reduction and energy input in a compressed bed.
They also provide a description of the characteristic shape of the
product size distribution. If the piston press tests are not available,
then the results from the single particle Drop Weight test may be
used to determine the Compressed Bed Breakage Function (Section
A12.4)
The parameter K2 for the compressed bed crushing is the

working gap xg, whilst K1 is set as zero.

The parameters K3 and t10 are fitted to the laboratory scale

HPGR test data. These are the only two breakage parameters
required to be fitted to laboratory data.
Edge Crushing The last sub-process in the model is the split to the edge and
Bypass compressed bed zones. The edge zones are associated with the
drop in pressure that is experienced towards the edge of the rolls.
Their extent is assumed to be a function of the working gap. The
fraction of feed which is crushed in the edge zones (f) can therefore
be expressed as:
xg
f = g L (A12.2)
where g is split factor and L is the roll width. Using pilot scale
HPGR test results where sizing data of both pure flake and total
product were available, the split factor g was found to be
approximately constant with a value of 3.4. In physical terms this
means that the edge effect zone extended from the edge of the roll a
distance equivalent to 1.7 times that of the working gap. By sizing
the pure flake and total products from lab/pilot test results f can be
determined experimentally. Recent work suggests that the fraction
of material being subjected to edge crushing is usually about 10%.
Thus, the model may be simplified by manipulating g (split factor)
to ensure that 10% of the feed reports to the edge crushing zone.
A12.4 Compressed Bed Breakage Function

The product size distributions produced at different energy inputs (or
reduction ratios) can be characterised by a family of “t” curves.
Measurement and analysis for impact breakage are detailed in
Appendices 6.3 and 6.4.
This approach can be extended to predict required breakage power and

scaled to net crushing power using an efficiency factor., typically - 1.25
(Appendices 6.5 and 6.6).
Single particle t10 t75 t50 t25 t4 t2

impact breakage 10.0 6.05 7.94 12.60 46.70 74.60
data. 20.0 8.33 10.90 17.30 62.60 90.30
30.0 10.0 13.10 20.70 74.50 99.20
This approach can be extended to compressive breakage by using a piston

press to compress closely size fractions ( ( 2 ) in a controlled manner.
4
The resulting products are sized and fitted to a spline surface. This
surface can be regenerated by the model from a matrix of spline function
values. These values are input to the model as

Compressed Bed t10 t75 t50 t25 t4 t2

Breakage Test. 10.0 4.04 6.48 7.51 17.65 35.44
30.0 13.53 19.71 22.24 41.35 58.36
50.0 23.02 31.91 38.00 52.37 69.01
It can be clearly seen that these breakage models are different. The
power requirements can also be characterised with particle size
dependence if required and also related to motor power (Section A12.6).
A12.5 Throughput
Throughput is controlled principally by roll dimensions, speed and
profile, and material characteristics such as size hardness and
particle-roll friction (and thus nip-angle). The profile and material
of the roll surface is important in controlling both wear and
machine performance, and various options are offered by the
different manufacturers.
The rolls throughput can be theoretically expressed as

Q = 3600 U L xgf ρg (A12.3)
where
Q = mass throughput (tph)

U = circumferential velocity of the rolls (m/s)
L = length of rolls (m)
xgf = working gap (m) – from the flake thickness
measurements
ρg = flake density (t/m3)
It is realised that A12.3 does not take into account the slip between
feed material and the rolls surface, nor does the feed characteristics
(particle size and size distribution, moisture, etc). Figure A12.3
shows the deviation between the measured throughput and the
calculated one using Equation A12.1 for Primary diamondiferous
ore treated through a 100 mm Polysius laboratory scale HPGR. It
is obvious that Equation A12.3 over-predicts the HPGR throughput
at high rolls speed, which may indicate that slip exists in the HPGR
operation at these speeds.

12
0.38 m/s
10 1.50 m/s
2.50 m/s
3.10 m/s
8
tph (measured)
6
0
0 2 4 6 8 10 12
tph (calculated)
Figure A12.4: Deviation of the Throughput Calculated from Equation

A12.4 for Diamondiferous Ore Treated through a Laboratory HPGR at
Various Speeds
To correct for the slip effect it is considered that for a specific feed
the slip is a function of the rolls speed and the dimensionless
working gap which is defined as xg /D, where D is the rolls
diameter.
Qm
Figure A12.4 plots the correction factor c (c = Q , where Qm is
c
the measured throughput and Qc is the calculated by Equation
A12.3) versus the product of the speed and the dimensionless gap
xg
(U* D ) for the Diamondiferous ore using the laboratory HPGR
data. A linear regression on the plot was obtained and Equation
A12.3 was accordingly modified as:
Q = 3600 U L xg ρg c (A12.4)
where c is the correction factor determined from Figure A12.2.
Recent work by Schonert (2000) suggests that under normal

operating conditions, slip does not occur in the compression zone.
If normal operating conditions are assured, then the correction
factor should be set to 1.0.

2.0
1.5
c = Qm / Qc
1.0
0.5
0 0.01 0.02 0.03 0.04 0.05 0.06
U * (Xg / D)
Figure A12.5: Throughput Correction Factor for Diamondiferous Ore

Treated through a Laboratory Scale HPGR
15
LAB (D = 0.25 m)
KHD (D = 0.80 m)
POLYSIUS (D = 0.71 m)
10
Q (predicted tph)
0
0 5 10 15
Q (measured tph)
Figure A12.6: Prediction of Throughput for Two Pilot Scale HPGRs from
Equation A12.4 with Model Parameter c Calibrated Using Laboratory
Scale HPGR data
Using Equation A12.4 with c determined from Figure A12.5 the

throughput of a laboratory scale HPGR (D = 0.25 m) and two pilot
scale HPGRs (KHD, D = 0.8 m; Krupp Polysius, D = 0.71 m) was
predicted. A comparison between the calculated and the measured
throughputs is given in Figure A12.6. The rolls speeds varied from
0.29 m/s to 3.1 m/s, rolls length from 0.1 m to 0.21 m, rolls
diameters from 0.25 m to 0.80 m, and working gaps from 3 mm to
23 mm. The throughput model prediction is seen to be good.

A12.6 Power Draw
Conventional The impact size reduction model contains an energy balance

Crusher Power equation (Andersen and Napier-Munn, 1988) which ensures that the
energy for size reduction is compatible with that provided by the
motor. The t10 parameter is related to the specific energy used by
the machine and will follow a curve described by the equation:
t10 = A (1 - e-bEcs) (A12.5)
where A and b are parameters and Ecs is the specific energy.
HPGR Crusher In the size reduction model the two parameters K3 and t10 were
Power fitted to the laboratory scale HPGR power data. It was found that
the fitted t10s for 24 sets of Diamondiferous ore tests under various
rolls speeds and feed size conditions fell on a t10 - Ecs master
curve, as shown in Figure A12.7
Equation A12.5 was hence fitted to these data to generate the A, b

parameters, which are used for the scale-up as will be
demonstrated in the next section. In JKSimMet, the points for t10 =
10, 30 and 50 are placed in the Compressive Breakage Specific
Community Energy Matrix.
100
A = 100, b = 0.2084
80
60
Fitted T10 (%)
40
9.5 mm feed, 0.38 m/s speed
20 9.5 mm feed, 3.10 m/s speed
A,b fitted to Lab
0
0 2 4 6 8 10
Ecs of motors (kWh/t)
Figure A12.7: The Fitted t10 vs Specific Energy Ecs for Diamondiferous
Ore Treated through a Laboratory HPGR
A power coefficient kp is required which relates the measured

power to that predicted by the model for size reduction. This
model uses the specific energy (kWh/t) and associated t10 values
from the piston press breakage experiments. From these it
calculates the overall specific energy in a piston press. The

difference between this value and that observed from the motor is
accommodated by kp, ie. kp is the ratio of the observed to the
theoretical piston press specific energy. This coefficient has been
found to be reasonably constant over a range of specific energies
but increases rapidly beyond a certain limiting value. This is
shown in Figure A12.8 for the 24 sets of data.
4.0
Power coefficient of HPGR 3.5
3.0
2.5
2.0
0 2 4 6 8 10
Ecs of motors (kWh/t)
Figure A12.8: Relationship between Power Coefficient (kp) and Specific

Energy for Diamondiferous Ore Treated Through a Laboratory Machine .
Where kp = Observed power/Piston Power
Power Draw vs The prediction of the working gap xg is also required for simulation.
Working Gap The working gap depends on pressure and power draw.
Working This relationship is developed from the laboratory/pilot scale test.

Gap/Specific The specific motor energy is plotted against the working gap.
Energy
Relationship The parameters ρc and ρg in Equation A12.2 are functions of feed
type, operating conditions (eg working pressure) and the roll
surface (eg smooth, chevroned, studded). Therefore, provided the
pilot scale or the full scale machines are operating under similar
conditions to the laboratory unit, then xg will be proportional to the
diameter of the rolls. The principal dependence of the working gap
will be on the working pressure, with the gap reducing as the
pressure increases. As working pressure is directly related to
specific energy, then it will be found that as the specific energy
increases the gap will decrease. An example of this is shown in
Figure A12.9 for Diamondiferous ore treated through a laboratory
machine.

Working gap (mm)

5
2
0 2 4 6 8 10
Specific energy of motors (kWh/t)
Figure A12.9: Relationship between Working Gap and Specific Energy for
Diamondiferous Ore Treated Through a Laboratory Machine

A12.7 HPGR Model Printout

A12.8 Fitting the HPGR Model
SpFact
K1H
T10H
Power Coeff. H
Split Factor (g) This factor determines the proportion of material which is crushed
(SpFact) in bypass mode. This is usually 1.7 times the effective gap width
on each side for a default value of 3.4. (Section A12.3)
Setting the split factor to zero and running a simulation generates

the size distribution expected from pure compression crushing, ie.
“pure flake” and may be compared with (or fitted to) an actual
sample taken from the centre of the roll discharge.
Pre and Edge Using the same feed material as for the pilot/lab HPGR test,
Crusher Model laboratory roll crusher is operated at close to the nipping gap and
Parameters the working gap of the HPGR.
(K1H & T10H)
The Whiten/Awachie/Anderson crusher model (Appendix 6) is
used to derive K1 and t10 where K2 is the crusher gap and K3 is set
at 2.3.
The ratio K1/K2 is the input to the pre crush and edge effect model
along with the fitted t10 values. It is unlikely that power can be
measured with sufficient accuracy in this test to justify using other
than the default power factor of 1.25.
Throughput As noted in Section 12.5, throughput is strongly controlled by

Relationship geometry at low throughputs and by slippage at high throughputs.
Pilot or laboratory scale tests can be used to derive the slope and
intercept for the slip correction factor Cp.
The model defaults are for smooth rolls. It is highly likely that
different roll surfaces will generate different correction factors.
Compressed Bed Breakage within the compressed bed is assumed to be uniform and
Breakage (t10 able to be described by a single parameter t10 . The t10 parameter
HPGR) will increase as the reduction ratio increases. In compression, all
particles are assumed to be able to be selected for breakage ie. K1 =
0 and every particle larger than the working gap will always be
broken, ie. K2=cacluated Working Gap.
Power Model The HPGR model takes a somewhat circuitous approach to power
Fitting modelling. As noted in Section 12.6, the combination of piston
press tests and laboratory/pilot scale HPGR produces a relationship
between the compressive bed t10 and net motor power (Figure
A12.7).

Developing this relationship requires some modelling using the
Andersen/Whiten model (A6). The objective is to find a t10 for
each data set with K2 set to the working gap and K3 a constant
value over all sets. To do this, enter all sets of data into one test,
master slave K3, set K2 to working gap and fit each of the t10
values. This provides a set of t10 values which can be plotted
against the motor power per tonne (Ecs) corrected for no load and
the power drawn by pre-crush and edge crushing (as in Figure
A12.7). Equation A12.5 is fitted to this data with A=100 and Ecs
values calculated at t10 =10, 30 and 50 for input into the
Compressed Bed Breakage Matrix.
This relationship allows compressive power draw to be calculated

(as in Section 6.6) for any set of K1, K2, K3 and t10 values. Figure
A12.7 shows the power coefficient (observed motor power divided
by calculated “piston” power) for a range of energy inputs
expressed as power per tonne.
If this model was ideal, the coefficient would be constant. Between

zero and 5 kWh/t it is approximately constant at, say, 2.5 and
increases rapidly at high powers (ie. the crusher becomes less
energy efficient). More energy is converted into heat and does not
result in further comminution.
A12.9 Scaling the HPGR Model
To predict the performance of pilot scale and full scale HPGRs the
model is firstly calibrated using the results from the laboratory,
conventional rolls, single particle breakage and piston bed
breakage test. Figure A12.10 illustrates the scale-up procedures.
Also shown in Figure A12.10 are the values of the parameters
obtained from the calibration, which have been used to predict the
two pilot scale units and one full size machines treating a
Diamondiferous ore (Morrell, Shi and Tondo, 1997).

Input data
Rolls dimension: diameter, length
Select rolls speed, required specific energy Ecs
Feed size distribution
Bulk density of feed, flake density
Working gap: chose the lab working gap by Ecs from Figure 12.9,
multiplying the gap by the ratio of full scale to lab rolls diameters
Nipping gap calculated from Equation 12.1
Throughput calculated from Equation 12.4
Power draw = Ecs required x throughput
Pre-crusher
Single particle (parameters from the conventional rolls
breakage test test)
(using a drop weight K1p=0.64 K2p
device) K2p = nipping gap
K3p = 1.0
K3p = 1.0
t10p = 12.04
Mass Splitter
Fraction split to the edge effect
crusher is calculated by Equation
12.2 in which γ = 3.4
as determined from the KHD tests
Bed breakage test HPGR

Edge Effect Crusher k1h = 0
(using a piston press
(parameters from the K2h = working gap
device)
conventional rolls test) t10h calculated from Equation 12.5
K1e = 0.64 K2e in which A = 100, b = 0.2084
K2e = working gap determined from lab tests
K3e = 1.0 Power coefficient
t10e = 12.04 determined from
Figure 12.8
Calculated power = N Adjust K3

observed power ?
Combined Product
Figure A12.10: Schematic of the Model Algorithm and Scale-up Procedure
The full scale-up procedure is implemented in JKSimMet. When

running the simulations of pilot scale or of full scale machines, the
parameter K3 for the compressed bed crushing zone is
automatically adjusted until the model predicts the same power
draw as was originally chosen for the simulation. As a result, the
calculated power draw is identical to that observed, and the product
size distribution is predicted based on this power consumption.
In the simulation the maximum throughput of a scale-up HPGR is

calculated using the throughput model (Equation A12.4) with the
correction factor c determined in the laboratory unit with similar
rolls surface on the same type of ore. The required power is then
calculated from the maximum throughput and the specific energy

selected. The model is iterated until the breakage power, which is
the sum of the power used in the three sub-processes of pre-
crushing, compressed bed crushing and edge effect crushing,
matches the required power. The overall product size is then
predicted based on the breakage power.
Roll Surface Tests using a Krupp Polysius pilot roll (rolls diameter 0.71 m), with
4 mm profiles (on the rolls) resulted in a considerably larger
working gap than was observed for the KHD pilot tests using
smooth rolls. Therefore, laboratory tests must be conducted with a
rolls surface similar to that proposed on the full scale machine.
Limited Data As only limited production scale data were available, the models
Base need to be further tested and validated against more real data in the
future, and their capabilities explored in case studies.
Power Coefficient Ideally, this coefficient should be constant. A better understanding and
(kp) (possibly) a better representation need to be developed.
A12.11 Nomenclature
αc - nip angle (degree)

γ - split factor
ρc - bulk density of feed (t/m3)
ρg - flake density (t/m3)
c - correction factor for rolls throughput
D - rolls diameter (m)
Ecs - specific energy (kWh/t)
f - fraction of feed which is crushed in the
edge zones
g - split factor
K1,K2,K3 - size reduction model parameters
kp - power coefficient
L - rolls length (m)
Qm - measured mass throughput (tph)
Qc - calculated mass throughput without
correction tph)
t10 - size distribution parameter
U - rolls circumferential speed (m/s)
xc - critical gap (m)
xgf - working gap (m).

A12.12 Acknowledgments
This model was developed with the financial support of the

sponsors of the AMIRA P428 project (Application of High
Pressure Grinding Rolls in Mineral processing) including the
Centre for Mining Technology and Equipment (CMTE).
Considerable assistance was also provided by the staff at KHD and
Krupp Polysius, as well as the staff and students at the JKMRC and
CSIRO, Division of Mineral products.
A12.13 References
Andersen J S and. Napier-Munn T J, 1988. Power prediction for

cone crushers. Proc. 3rd Mill Ops Conf, Cobar, Aus. Inst. Min.
Met.
Andersen J S, 1988. Development of a cone crusher model. M.

Eng. Sc. Thesis, University of Queensland (JKMRC).
Fuerstenau D W, Shukla A and. Kapur P C. 1991. Energy

consumption and product size distributions in choke-fed, high
compression roll mills. Int. J. Miner. Process., 32: 59-79.
Kapur P C, 1972. Self - preserving size spectra of comminuted

particles. Chem. Engng. Science, 27: 425-431.
Knecht, J, 1994. High pressure grinding rolls, a tool to optimise

treatment of refractory and oxide gold ores. Fifth Mill Operators
Conf. Roxby Downs, Oct, 51-59 (AusIMM, Melbourne)
Morrell, S, Shi F & Tondo, L. 1997. Modelling and scale-up of

High Pressure grinding rolls. IMPC Aachen.
Morrell S, Lim, W, Shi F and Tondo L. 1997. Modelling of the

HPGR crusher. SME Annual Conference, Denver, Colorado.
Comminution Practices Symposium, Ed Kawatra, 117-126.
SchÖnert K. 1988. A first survey of grinding with high

compression roller mills. Int J of Min Proc, 22, 401-412.
SchÖnert K.and Sander, U., 2000. Pressure and shear on the roller
surfaces of high pressure roller mills, Proc. XXI IMPC, Rome,
Italy, Sect A4, 97 - 103.
Tondo L, 1996. Modelling of HPGR crushers. M. Eng Science

Thesis, University of Queensland (unpublished).
Whiten W J, 1972. The simulation of crushing plants with models

developed using multiple spline regression. J. South Afr. Inst. Min.
Metall. 72: 257-264.

(Blank Page)

Appendix A Simple Degradation (Model 480)
A13 Simple Degradation (Model 480)
A13.1 Introduction
The concept of a degradation model has its origins in iron ore and
coal operations where particles may undergo significant size
reduction during mechanical handling such as dropping on to a
stock pile from a conveyor or perhaps at a conveyor transfer
point.
A13.2 Model Structure

The model structure is a simple representation of a single drop
which results in the particles being broken to a specified t10 value.
The breakage distribution parameter, t10, characterises the size
distribution of the broken product. More details of this parameter
and the concepts behind it are given in Appendix 6.4.
The appearance function data which are discussed in Appendix

6.4 are required for the degradation model and are derived from
the JKMRC Drop Weight test. This test is described in Appendix
15.
Breakage The breakage distribution parameter, t10, is entered as a model

Distribution parameter. It must be calculated by the user and is generally
Parameter (t10) based on the Energy – Size Reduction relationship for the
particular ore derived from the JKMRC Drop Weight test.
Specific The Specific Comminution Energy in a drop is a function of the

Comminution height of the drop and can be calculated using the following
Energy equation:
Ecs = 0.00272 * h (A13.1)
Where:
Ecs = specific comminution energy (kWh/t)
h = height of the drop (m)

Simple Degradation (Model 480) Appendix A
Energy – The relationship between Specific Comminution Energy and size

Size Reduction reduction represented by t10 is also one of the results of the
Relationship JKMRC Drop Weight test. The relationship is of the form:
t10 = A * ( 1 – exp( - b * Ecs )) (A13.2)
Where:
t10 = Breakage Distribution Parameter
A & b are ore characteristic parameters
Conditioning In most cases, the damage inflicted by a second drop is less than
that inflicted by the first drop. This effect is known as
conditioning. Of course, the height of each drop is important as
well as the number of drops.
Effectively, the particles become a little more resistant to impact

after each successive drop. The amount of this effective increase
in resistance depends on the ore type and on the drop heights.
This effect can be included in the simulation by an appropriate

reduction in the b value used in equation A13.2. For an ore which
is only a little affected by conditioning, a reduction of b to 75% of
its starting value is typical. For an ore which is significantly
affected by conditioning b is typically reduced to 40% of its
starting value.

Appendix A Simple Degradation (Model 480)
Example The A and b values from the JKMRC Drop Weight test for the
example ore are 50 and 0.5 respectively.
For a drop height of 20 m, from equation A13.1:
Ecs = 0.00272 * h
= 0.00272 * 20
= 0.054 kWh/t
and from equation A13.2
t10 = A * ( 1 – exp( - b * Ecs ))

= 50 * ( 1 – exp( - 0.5* 0.054))
= 1.33
this value of t10 is then entered into the model.
For a second 20 m drop of an ore which is strongly affected by

conditioning, b is reduced to 0.2 (40% of 0.5) and
from equation A13.2
t10 = A * ( 1 – exp( - b * Ecs ))

= 50 * ( 1 – exp( - 0.2* 0.054))
= 0.54
this value of t10 is then entered into the model for the second drop.
Use for the The degradation model can be used to represent a lightly loaded
Vertical Shaft Vertical Shaft Impactor. In this case, the energy of an impact is
Impactor calculated from the velocity of the particle imparted by the rotor.
This energy must be converted to units of kWh/t before equation
A13.2 can be applied.
For example, for a VSI with a rotor diameter of 0.6 m spinning at

2000 rpm, the energy imparted to a particle leaving the rotor at its
peripheral speed is:
Ecs = 0.5 * m * v2 / ( 3600 * m )

= 0.5 * v2/ 3600
= 0.5 * ( π * 0.6 * 2000 / 60 )2/ 3600
= 0.55 kWh/t
Where:
m = Particle mass (which cancels out)
v = peripheral velocity of rotor (m/s)
3600 is the conversion factor for kWh/t
The Ecs value is substituted into equation A13.2 to calculate t10

for use in the model.

Simple Degradation (Model 480) Appendix A
A13.3 Degradation Model Printout
A13.4 Fitting the Degradation Model

This is a very simple model to fit, the only fittable parameter being
t10.
A typical range of starting estimates for degradation by drop is 0.2
to 0.8 depending on amenability to degradation and drop height.
A typical range of starting estimates for the VSI is 5 to 20
depending on rotor diameter and speed and ore type.

It is recommended that the ore specific appearance function is
measured by a Drop Weight test rather than using the default
values. Although the variation of the crusher appearance function
data in the JKTech data base (of ores subjected to Drop Weight
testing) is not particularly large, ore specific values will provide
better results.
If several drops actually occur, it may be better to simulate these as
separate drops than as a single drop of the total accumulated drop
height, particularly if conditioning is likely.
It should also be noted that ores which are particularly susceptible
to degradation are also likely to be degraded during the process of
screening to determine the size distrbution, thus making the size
distributions somewhat doubtful.

Appendix A Splitters (Models 810, 811, 812, 870)
A14 Splitters (Models 810, 811, 812, 870)
A14.1 Introduction
These models provide splitters of varying complexity, from a

simple mass split to two (810) or three products (870),
independent mass splits of solids and water (811) and a split
generating a specific volume flow rate to one product (812).
A14.2 Model Details
A14.2.1 Simple Mass Split – Two Products (810)

The feed to this model is split into two streams with size
distributions and pulp densities identical to the feed. The
controlling parameter is the Fraction Split to Top Product. The
top product is the upper product on the equipment icon and is
marked with a T. The parameter range is 0.0 – 1.0.
A14.2.2 Simple Mass Split – Three Products

(870)
The feed to this model is split into three streams with size
controlling parameters are the Fraction Split to Top Product and
the Fraction Split to Bottom Product. The top product is the
upper product on the equipment icon and is marked with a T. The
parameter range is 0.0 – 1.0.

Splitters (Models 810, 811, 812, 870) Appendix A
A14.2.3 Simple Mass Split – Two Products –

Water and Solids (811)
distributions identical to the feed. The controlling parameters are
the Fraction Split to Top Product (Water) and Fraction Split to
Top Product (Solids). The top product is the upper product on the
equipment icon and is marked with a T. The parameter range is
0.0 – 1.0.
A14.2.4 Fixed Volume Split – Two Products

(812)
controlling parameter is the Volumetric Flow Rate to Top Product
(m3/h). The top product is the upper product on the equipment
icon and is marked with a T. Should the volumetric flow rate of
the feed stream be less than the required flow to the top product,
the entire feed stream is directed to the top product.

Appendix B Error Messages
APPENDIX B
Error Messages
Version 5.1 February 2003 Appendix B Page B-1

JKSimMet Error Messages Error Messages
B. ERROR MESSAGES
These messages occur during operation of JKSimMet. The display
warns that an error has occurred and provides the error number.
The descriptions provided here give more information about the
possible cause of the error message.
ERROR 58 Not enough size distribution data in the feed to an equipment item
for spline interpolation to work. Check combiner ports with Exp
TPH Solids values > 0.0 with limited or no Exp Size Distribution
data.
One of the combiner ports of one of the equipment items on the
select list has Exp TPH Solids greater than zero but limited or no
size distribution data. Thus JKSimMet is not able to perform the
required Spline Interpolation. Either add some size distribution
information or zero the Exp TPH Solids.
ERROR 110 Hydrocyclone - SPOC predicts roping.

The results of the simulation violate the SPOC roping constraint
indicating that under the simulated conditions, the hydrocyclone is
likely to be roping. See Section A2.5 for more details. The
simulation results may be unreliable.
ERROR 111 Plitt et al constraint predicts roping.

The results of the simulation violate the Plitt et al roping constraint
indicating that under the simulated conditions, the hydrocyclone is
likely to be roping. See Section A2.5 for more details. The
simulation results may be unreliable.
ERROR 120 No data in a stream or streams. Please correct.

One of the streams you have selected in the Balance List contains
no data.
ERROR 121 Two or more streams have different sieve series. Please correct.
For Mass Balancing with GSIM format data, all selected streams
must have the same screen series.
ERROR 122 Sum of % component does not equal control value. Please
correct.
If you have specified a component sum (on the active
COMPONENT LIST) your assays must total this sum or less. A
component sum of zero turns off this constraint. Normally a
REMAINDER TERM is added to achieve the sum in the
experimental data. To force a constraint, omit one of your
categories and it will be the remainder term.
Page B-2 Appendix B.1 Version 5.1 February 2003

Error Messages JKSimMet Error Messages
ERROR 123 No COMPONENT LIST is currently selected. Please select or
enter one.
You must have a current Component List before attempting to
mass balance data. Either select one you have already created or
create one.
ERROR 124 No BALANCE LIST is currently selected. Please select or enter

one.
You must have a current Balance List before attempting to mass
balance data. Either select one you have already created or create
one.
ERROR 125 Modifications to flowsheet detected. Please check your current

data.
Modifications have been made to the flowsheet since the last mass
balance. You should check that your selected streams are still
correct.
ERROR 126 No stream input to unit. Please check current SELECT list.
One of the units selected for inclusion in the balance has no input
stream. You should check that input streams are selected for all of
the selected units.
ERROR 127 No stream output from unit. Please check current SELECT list.
One of the units selected for inclusion in the balance has no output
stream. You should check that output streams are selected for all of
the selected units.
ERROR 128 Stream is not connected to unit. Please check current SELECT list.
One of the selected streams is not connected to any selected unit.

You should check that all selected streams are connected to
selected units.
ERROR 129 No unit/node is currently selected. Please check current SELECT

list.
There are no units selected on the SELECT list. At least one unit
and its associated streams must be selected to run a mass balance.
ERROR 130 Morrison solution error. See Morrison solution error Section 6.10.
The simple solution has not worked correctly. Check your data
carefully and then read section 6.10. If you can find no data
problems, try increasing the number of steps. Note that only one
flow rate should be tightly constrained - not all of them.
ERROR 131 Morrison solution convergence error. Please increase step number
Version 5.1 February 2003 Appendix B.2 Page B-3

See also Error 130.
ERROR 132 Consistent assays convergence error. Please increase step number.
Check the SELECT screen to see that the step count has reached its
nominated maximum. If so you may increase that count by a few
steps. Caution: such long searches indicate poorly defined flows
or some variation of the middlings problem. Refer to section 6.10.
ERROR 133 Adjusting sum convergence error. Please increase step number.
See also Error 132.
ERROR 134 Main loop convergence error. Please increase step number.
See also Error 132.
ERROR 135 Negative balance flow rates.
See also Error 132.
ERROR 136 Balance size distributions cal. err. Increase adj. sum step number.
See also Error 132.
ERRORS 137-139 are reserved for later versions.
ERROR 140 No Model-Fit data are selected. Fitting requires data.

No data have been selected on which to do the Model-Fit. Select
some and try again.
ERROR 141 No Model-Fit parameters are selected. Fitting requires parameters.

No parameters have been selected on which to do the Model-Fit.
Select some and try again.
WARNING 142 Model-Fit data include a stream with no experimental data.

One or more of the streams selected for the Model-Fit has no
experimental data entered for it. It is ignored. Enter the necessary
data before attempting the Model-Fit again or remove the stream
from the data list.
WARNING 143 Model-Fit data do not include this stream. Normal editing only.
The Stream selected is not included for Model-Fit. Therefore, the
extra information cannot be edited.
ERROR 144 Model-Fit data do not contain any streams. Fitting requires data.
No streams are selected for Model-Fit. The list of streams, whose
data must be fitted, is empty.
WARNING 145 Poor convergence of fit. Check SDs / data.

The Model-Fit has not been able to make effective use of the data
given. Try different SDs or reject some of your data.
Check your circuit and unit details also. Rerun the survey.
ERROR 146 No streams in the circuit have data. Please add some.
None of the Streams selected for the Model-Fit have data entered
for them. At least one stream must have data. See ERROR 51.
ERROR 147 No parameters are selected for fitting. Please select some.
Model fitting works by adjusting parameters of models until
simulated results match experimental data. You must specify at
least one parameter to adjust.
ERROR 148 There are too many streams on the circuit. Please simplify!
Please simplify the circuit or break it into two circuits, The Model-
Fit function has strict limits on the number of units and streams
allowed. Please reduce the number you have selected, then try
again. Refer to the manual for the current limits (there is a limit of
10 units, 20 streams).
ERROR 149 There are too many units on the circuit for fitting. Please simplify.
The Model-Fit function has strict limits on the number of units and
streams allowed. Please reduce the number you have selected, then
try again. Refer to the manual for the current limits (there is a limit
of 10 units, 20 streams).
FAULT 150 An illegal parameter is selected. It won't be fitted.

This error should never occur. Please make a note of the error
number and what you were doing, and contact JKTech.
ERROR 151 Constant residual error during fitting. Check

SDs/parameters/scales.
See ERROR 154. The model fit gauges its success by a
diminishing error between experimental and simulated data. The
error was not changing with different parameter values. SDs,
scales or the initial parameter estimates may be responsible.
ERROR 152 Fitting is not getting anywhere. Try again with better guesses.
The Model-Fit has not been able to make effective use of the data
given. Please enter new parameter guesses and try again.
FAULT 153 Model fit array sizes were in error.

This error should never occur. Make a note of the error number
and what you were doing, and contact JKTech.
ERROR 154 No errors were calculated. Only non zero SDs contribute an error.

The errors between experimental and simulated data are combined
with each values SD. A zero SD implies the value should be
ignored. If all SDs are zero, fitting has no data.
WARNING 155 No SDs have been entered on a stream. Unit SDs are assumed.
See ERROR 154.
ERROR 156 You have duplicate data entries. Please remove duplicate.
If you want one stream to have a greater significance reduce its
SDs.
ERROR 157 You have duplicate parameter entries. Please remove duplicate.
Each parameter entry is independently adjusted. This becomes
nonsense if one parameter is repeated.
ERROR 158 Only two parameters may be fitted per stream. Please correct.
There are only two independent parameters for a stream. See
ERROR 157.
ERROR 159 Only one water parameter may be fitted per stream. Please correct.
Once stream's water parameters are independent. See ERROR 157.
All water parameters control the water content of a stream. There
is only one way this may be selected. See Error 157.
WARNING 160 A new stream was selected.

Model-fitting is complex. It thus tries to select streams
automatically when it starts. Occasionally this changes the
selections you have made. The warning is then issued.
WARNING 161 A new unit feed stream was selected.

Refer to WARNING 160 above.
WARNING 162 New Model Fit data were selected.

WARNING 163 New Model Fit parameters were selected.

ERROR 164 That unit doesn't have experimental data suitable for model-fitting.
The unit selected has no parameters and can not be fitted.
ERROR 165 No units in the circuit have data. Please add some.
None of the units in the circuit have data. You must supply some.
WARNING 166 A new unit was selected.

The currently selected unit does not appear in the Parameter List
WARNING 167 The coarsest particles in the feed to the AG/SAG mill are in a size
range either finer than 200 mm or coarser than 300 mm. This
affects the calculation of energy values and the results of
simulations using this feed are likely to be unreliable. Please
modify your feed size distribution.
The energy calculations in the Variable Rates SAG model were
based on data from mills with the top size of the feed in the region
200 – 300 mm. Simulating with feeds outside this region using the
default rates will be unreliable.

(blank page)

Appendix C JK Breakage Testing
APPENDIX C
JK BREAKAGE
TESTING
Version 5.1 February 2003 Appendix B Page C-1

JK Breakage Testing Appendix C
C JK Breakage Testing
C.1 Drop Weight Test Procedure
This section provides a brief description of the drop weight test

procedure.
To characterise ore breakage at different energy levels, the
JKTech method uses two complementary techniques:
1. To characterise breakage at moderate to high energy levels
(i.e. impact breakage), a drop weight device is used.
2. To characterise breakage at low energy inputs (i.e. the
abrasion component of breakage), a tumbling test is used.
C.2 Impact Breakage Testing

The JK drop weight device comprises a steel drop-weight which
is raised by a winch to a known height. A pneumatic switch
releases the drop weight which falls under gravity and impacts
the rock particle which is placed on a steel anvil. The device is
enclosed in perspex and incorporates a variety of features to
ensure operator safety. By varying the height from which the
drop weight is released and the mass of the drop weight, a very
wide range of energy power inputs can be generated. A
schematic drawing of the device is given in Figure C.1.
Perspex
enclosure
5kg lead
weights
Guide rail
Adjustable
height (energy)
Rock
Steel anvil
Large concrete base
Figure C.1: Schematic of the Drop Weight Device
Page C-2 Appendix C Version 5.1 February 2003

Appendix C JK Breakage Testing
After release of the drop weight, it descends under the influence
of gravity and impacts the target particle. The particle is broken
by the impact. The drop-weight is brought to rest at a distance
above the anvil approximately equal to the largest product
particle. The difference in distance between the initial starting
point and the final resting place of the drop-weight is used to
calculate the energy that is expended in breaking the particle.
The following equation is used:
Ei = Mg(h - xM) (C.1)
Where:
Ei = energy used for breakage
M = drop-weight mass
g = gravitational constant
h = initial height of the drop-weight above the anvil
xM = final height of the drop-weight above the anvil.
Providing the drop-weight does not rebound after impact, the

application of equation (C.1) is valid. Where rebound occurs an
additional term is required to account for the energy re-
transmitted to the drop-weight. Rebound has been seen to occur
only at elevated input energies. This energy will be measured
during the testwork programme. It is likely, however, that its
magnitude will be relatively small and can be ignored with only a
minimal loss in accuracy.
The assumption is made that all the energy provided is utilised in
the breakage of the particle. Thus
Ecs = Eis = Ei / m (C.2)
where:
Eis = specific input energy
Ecs = specific comminution energy
m = mean particle mass
To test an ore type, the original 100 kg sample is sized into

selected fourth-root-of-two size fractions. Ten to thirty particles
are required in each size fraction for each energy level, depending
on particle mass. Typically fifteen size/energy combinations are
selected. The input energy levels for a particular test are
designed to suit ore hardness.
Version 5.1 February 2003 Appendix C Page C-3

JK Breakage Testing Appendix C
The breakage products of all particles for each size/energy
combination are collected and sized. The size distribution
produced is normalised with respect to original particle size. For
a wide range of energy input, particle sizes and ore types, the
relative size distributions remain similar in shape and can be
described by a single point on the distribution. The JKTech
convention is to use the percentage passing one-tenth of the
original particle size. This is referred to as the “t10”.
In the manner described above, a set of t10 and Ecs values are
produced for the 15 energy/size combinations.
C.3 Abrasion Breakage Testing

It is possible to characterise low energy (abrasion) breakage with a
miniature drop weight and repeated impacts. However, Leung
(1987) demonstrated that a tumbling test of selected single size
fractions could produce a similar result with less experimental
effort.
The standard abrasion test tumbles 3 kg of -55 +38 mm particles
for 10 minutes at 70% critical speed in a 305 mm by 305 mm lab
mill fitted with four 6 mm lifter bars. The resulting product is then
sized and the t10 value for the product is determined.
The mean particle size of the original size fraction 55 x 38 mm is
45.7 mm. The t10 size is:
1/10 x 45.7 = 4.57 mm.
Page C-4 Appendix C Version 5.1 February 2003

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steady state

In no event will JKTech Pty Ltd be liable for direct, indirect,

Copyright © 1987 - 2003 JKTech Pty Ltd

JKTech Pty Ltd

Telephone - (07) 3365 5842 International: +61 7 365 5842

ABOUT THIS MANUAL vi

Version 5.1 February 2003 Contents Page i

Page ii Contents Version 5.1 February 2003

Version 5.1 February 2003 Contents Page iii

All Trade Marks acknowledged

Page iv Contents Version 5.1 February 2003

Version 5.1 November 2001 Acknowledgements Page v

Page vi Acknowledgements Version 5.1 November 2001

ABOUT THIS MANUAL

If you are new to computing or JKSimMet:

If you are familiar with JKSimMet simulation techniques:

If you wish to fine tune JKSimMet to your own requirements:

Version 5.0 December 1999 About this Manual Page vii

Page viii Version 5.0 December 1999

Version 5.1 November 2001 Chapter 1 Page 1-1

1.1 About JKSimMet

JKSimMet performs steady state simulation of a range of

New process models can readily be incorporated into JKSimMet by

Page 1-2 Section 1.1 Version 5. 1 November 2001

The main features of JKSimMet are:

JKSimMet has been designed primarily as a powerful aid to an

It is important at the outset to understand what JKSimMet will and

This point is amplified at the beginning of Chapter 4, and the

Version 5. 1 November 2001 Section 1.1 Page 1-3

1.2 Equipment Requirements

• Processor speed 400MHz minimum

Printer An MS Windows 95,98, ME, NT or 2000 compatible printer:

Operating MS Windows 95,98, ME, NT(4 sp5 or later) or 2000

Pointing Device Microsoft Mouse or functional equivalent.

Equipment A wide range of equipment combinations has been successfully

Page 1-4 Section 1.2 Version 5. 1 November 2001

1.3 Cautionary Tales

It is recommended that you make a backup copy of the files on the

Read.Me Any modifications to procedures since the production of this

Learn by JKSimMet is a program which is rich in capabilities and easy to

Once you are a proficient user of JKSimMet, you will be creating

Windows Backup Alternatively, Project Data Files(*.JKSM5) only need be backed

Version 5. 1 November 2001 Section 1.4 Page 1-5

1.4 Program Structure

Process Models of the following units are supplied:

Custom Contact JKTech if you are interested in adding other models to

Page 1-6 Section 1.4 Version 5. 1 November 2001

1.5 JKSimMet Support

Documentation Three levels of documentation are supplied:

Courses JKTech offers regular courses in simulation technology at various

Extended Continuing backup support is provided by JKTech either through a

Restrictions A standard licence for the use of JKSimMet permits operation of

Distribution of copies of JKSimMet to other company sites is not

Version 5. 1 November 2001 Section 1.5 Page 1-7

Page 1-8 Section 1.5 Version 5. 1 November 2001

Version 5.1 November 2001 Chapter 2 Page 2-1

2.1 Contents of the Package

The manual contains information on the installation and

Page 2-2 Section 2.1 Version 5.1 November 2001

2.2 Computer Hardware/Software

• Processor speed 400MHz minimum

Printer Any MS Windows 95, 98, ME, NT or 2000 compatible printer.

Operating MS Windows 95, 98, ME, NT(V4 sp5 or later) or 2000

Pointing Device Microsoft Mouse or functional equivalent.