Intro to JKSimMet

1. James Didovich 2014
JKSimMet V6
3
JKSimMet
OVERVIEW

2. James Didovich 2014
JKSimMet V6
4
JKSimMet Overview
• JKSimMet is a package developed by the JKMRC/JKTech
for the modelling and simulation of comminution circuits.
• It includes models for crushers, autogenous mills, ball
mills, rod mills, screens, and hydrocyclones.
• It is a closed package: you can not add your own
process models.
• There is detailed information on the models included
with JKSimMet in the user manual.

3. James Didovich 2014
JKSimMet V6
5
JKSimMet Overview
Mass Balance
Model Fit
Simulate
Flowsheet Design
Data Input
Model Fitting
Simulation
Mass Balancing
Results Analysis

4. James Didovich 2014
JKSimMet V6
6
JKSimMet References
JKSimMet V6 Help Files
(HELP FILE)
JKSimMet V6 User Manual
(PDF)
Mineral Comminution Circuits: Their Operation and Optimisation
(Published by JKTech)

5. James Didovich 2014
JKSimMet V6
7
JKSimMet User Manual
• Part I – Overview
• Part II – Changes from Version 5
• Part III – Installing JKSimMet
• Part IV – Learning JKSimMet
• Part V – Using JKSimMet
• Part VI – Mass Balancing
• Part VII – Model Fitting
• Part VIII – Model Descriptions
Read Once
JKSimMet 101
MODELS REFERENCE
JKSimMet Reference

6. James Didovich 2014
JKSimMet V6
8
JKSimMet Help File

7. James Didovich 2014
JKSimMet V6
9
JK Blue Book
CONTENTS
Ch 1 Introduction
Ch 2 Models of Comminution Processes
Ch 3 Mineral Liberation
Ch 4 Rock Testing
Ch 5 Surveying Comminution Circuits
Ch 6 Crushers
Ch 7 AG and SAG Mills
Ch 8 Rod Mills
Ch 9 Ball Mills
Ch 12 Screens & Hydrocyclones
Ch 13 Optimisation of Comminution Circuits

8. James Didovich 2014
JKSimMet V6
10
Steps to Building a Circuit Simulation
5. Review results.
1. Draw the flowsheet.3. Setup the models.
2. Setup the feed.
4. Run the simulation.

9. James Didovich 2014
JKSimMet V6
11
JKSimMet
FLOWSHEETING

10. James Didovich 2014
JKSimMet V6
12
Starting with JKSimMet
• 1. Create a new ‘Project’ and save it.
• 2. Press No when prompted about V5 icons
• 3. Should now have a blank project on screen:
V5 used bitmap icons;
V6 uses vector images.
Can’t mix so need to
make a decision. Best
just to go with ‘No’.

11. James Didovich 2014
JKSimMet V6
13
JKSimMet Flowsheeting
Flowsheet drawing area
List of Flowsheets in project
List of models available

12. James Didovich 2014
JKSimMet V6
14
Ex F1: Sandbox Flowsheet
Experiment with:
1. Adding models to the drawing area by dragging and
dropping;
2. Connect models using streams (red ports are outputs,
blue ports are inputs – connect red to blue);
3. Adjust stream lines to be aesthetically pleasing (right
click ‘Add/Remove stream node’).
4. Name the flowsheet ‘Ex F1: Sandbox’

13. James Didovich 2014
JKSimMet V6
15
SAVE
• Save, and save often.
• JKSimMet can often crash seemingly right when you
have significant unsaved changes.
• Network licenses can cause increased frequency of
crashes (compared to a local dongle).
• Become OCD about saving!
• CTRL + S does not work. Must use the disk icon.

14. James Didovich 2014
JKSimMet V6
16
Ex F2: Ball Mill Circuit
Experiment with:
1. Adding nodes to streams
(right click ‘Add node to stream’)
1. Resizing units
(drag and drop)
2. Changing unit orientations
3. Naming streams and equipment
(double click on unit/stream)
4. Adding autolabels
5. Adding water feeders where
appropriate for this circuit
NOTE:
A JKSimMet flowsheet must have at
least one ‘feed’ unit and one ‘final
product’

15. James Didovich 2014
JKSimMet V6
17
Ex F2: Ball Mill Circuit

16. James Didovich 2014
JKSimMet V6
18
Ex F3: SABC Circuit
Draw the following circuit:
• Ore is fed into a SAG mill.
• SAG mill has a pebble crusher (closed with a
screen on SAG Discharge).
• SAG Discharge screen U/S feeds a cyclone
cluster.
• Cyclone underflow feeds a ball mill in closed
circuit.
• There are water additions to the SAG feed,
Cyclone Feed, and Ball Mill Feed.
Experiment with
adding Info Blocks to
your flowsheet

17. James Didovich 2014
JKSimMet V6
19
Ex F3: SABC Circuit

18. James Didovich 2014
JKSimMet V6
21
JKSimMet
SIMULATE I

19. James Didovich 2014
JKSimMet V6
22
Steps to Building a Circuit Simulation
5. Review results.
1. Draw the flowsheet.3. Setup the models.
2. Setup the feed.
4. Run the simulation.

20. James Didovich 2014
JKSimMet V6
23
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Clone your Ex F3: Flowsheet Layout Design

21. James Didovich 2014
JKSimMet V6
24
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
Required Feed Size Distribution:
Screen Aperture WEIGHT
mm %
190 0.0
165 0.0
140 4.1
125 4.3
100 23.9
63.0 23.6
45.0 12.2
31.5 3.0
25.0 0.5
19.0 2.2
13.2 8.4
9.50 4.7
6.70 3.0
4.75 2.0
3.35 1.2
2.36 1.1
1.70 0.8
1.18 0.8
0.850 0.5
0.600 0.5
0.425 0.4
0.300 0.3
0.212 0.3
0.150 0.2
0.106 0.2
0.075 0.2
0.053 0.2
0.038 0.1
-0.038 1.3

22. James Didovich 2014
JKSimMet V6
25
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
Setting the Ore Feed Rate
Set to 500 tph

23. James Didovich 2014
JKSimMet V6
26
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
Feed Sieve Series
• JKSimMet uses one master sieve series for
the entire simulation.
• However survey data from the lab will use
different sieves for different streams.
• JKSimMet allows each stream can have a
custom sieve series.
• JKSimMet will then convert all streams to
the master series by interpolation.

24. James Didovich 2014
JKSimMet V6
27
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
The Root 2 button is a quick
way to set a sieve series.
Add sieve series here
Specify which series
each stream is to use
here
TIP: Entering a size of 0 will delete all size fractions below.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD

25. James Didovich 2014
JKSimMet V6
28
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD

26. James Didovich 2014
JKSimMet V6
29
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Feed Needs:
1. Feed Rate
2. Feed Size Distribution
• Feed Sieve Series
• Feed PSD
PRESS Transfer to perform the
conversion to master sieve
series.

27. James Didovich 2014
JKSimMet V6
30
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Ball Mill
Hydrocyclones
Water addition
Need to specify models for:
SAG Mill
SAG Discharge Screen
Pebble Crusher

28. James Didovich 2014
JKSimMet V6
31
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Water Feeders
Use a simple model to set a specified % solids in the
downstream unit.
Parameter SAG Ball Mill Cyclone
Req. %S 65 70 30

29. James Didovich 2014
JKSimMet V6
32
Ex SIM1: Simple Models
SAG, BALL, PEBBLE CRUSHER
Simple model that creates a product PSD by moving
it sideways on a Cum % Passing vs size plot to give a
user specified product P80.
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.

30. James Didovich 2014
JKSimMet V6
33
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
SAG, BALL, PEBBLE CRUSHER
Simple model that creates a product PSD by moving
it sideways on a Cum % Passing vs size plot to give a
user specified product P80.
Parameter SAG Pebble Ball Mill
Req P80 (mm) 10.0 5.00 0.500

31. James Didovich 2014
JKSimMet V6
34
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
SAG Discharge Screen, Hydrocyclone
Efficiency (partition) curve that describes what
fraction of a particular particle size reports to the
product stream.
• The underflow and overflow curves
are complementary.
• Traditionally the underflow curve is
used for efficiency curves
• JKSimMet uses the overflow curve
given that this is the product
stream in a grinding circuit
classifier.

32. James Didovich 2014
JKSimMet V6
35
Ex SIM1: Simple Models
1. Draw the flowsheet.
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
SAG Discharge Screen, Hydrocyclone
Efficiency (partition) curve that describes what
fraction of a particular particle size reports to the
product stream.
Efficiency Curve:
𝐸0
𝑑
𝑑50𝑐
= 𝐶.
1 + 𝛽 ⋅ 𝛽∗
⋅
𝑑
𝑑50𝑐
⋅ 𝑒 𝛼
− 1
𝑒
𝛼⋅𝛽∗⋅
𝑑
𝑑50𝑐 + 𝑒 𝛼 − 2
Parameters
• Sharpness of Efficient Curve – α
• Initial Dip in Efficient Curve – 𝛽
• Water Split to Fine Product (%) - 𝐶
• Corrected d50c (mm) – 𝑑50𝑐
(𝛽∗
is calculated internally and is not a parameter)
For more on Efficiency curves see:
1. JKSimMet Manual – pp. 346
2. JK Blue Book – pp. 276
Alpha Beta

33. James Didovich 2014
JKSimMet V6
36
Ex SIM1: Simple Models
1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
SAG Discharge Screen, Hydrocyclone
Parameter SAG Disch
Screen
Cyclones
Alpha 1.5 2.5
Beta 0 0
C (%) 90 75
d50c (mm) 10 0.10

34. James Didovich 2014
JKSimMet V6
37
Ex SIM1: Simple Models
1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
PRESS START TO
RUN SIMULATION
PRESS THE
SIMULATE ICON

35. James Didovich 2014
JKSimMet V6
38
Ex SIM1: Simple Models
1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
DO NOT TRUST A BLACK BOX
This is where you use your subject matter knowledge to review
and interpret the results.
• Do they make sense?
• Are they realistic?
• What needs to be improved/changed/corrected?
JKSimMet Tools:
1. Data Blocks
2. Graphing
3. Reports (Export to Excel)

36. James Didovich 2014
JKSimMet V6
39
Ex SIM1: Simple Models
1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Data Blocks:
• What is the final product P80?
• What is the circulating load in the ball mill circuit?
• What are the reduction ratios for each comminution
machine?
• Are there any concerning numbers?
(HINT: Pebble crusher tph, ball mill % solids)

37. James Didovich 2014
JKSimMet V6
40
Ex SIM1: Simple Models
1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Graphs:
• Can’t print from JKSimMet, can copy to
clipboard and paste into Word, Excel,
PowerPoint etc.

38. James Didovich 2014
JKSimMet V6
41
Ex SIM1: Simple Models
1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Graphs:
• Plot all the feed/products for comminution machines (SAG,
Ball, Pebble)
• Plot Feed/US/OS for Cyclone
• Plot Fresh Feed – SAG Screen US
• Plot SAG Screen US – Final Product
• Plot Fresh Feed – Final Product
Review Graphs:
• What do these charts tell you?
• Where is the most size reduction taking place?
• Which machines are working harder than others (too hard?)?

39. James Didovich 2014
JKSimMet V6
42

40. James Didovich 2014
JKSimMet V6
43

41. James Didovich 2014
JKSimMet V6
44
Ex SIM1: Simple Models
1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Reports:
• Allows you to export data for analysis in Excel
(Can’t view reports within or print from JKSimMet)

42. James Didovich 2014
JKSimMet V6
45
Ex SIM1: Simple Models
1. Draw the flowsheet
2. Setup the feed.
3. Setup the models.
4. Run the simulation.
5. Review results.
Baseline Scenario 1 Scenario 3Scenario 2
• This has described the process of running a single simulation.
• Having reviewed the results of the model we can then:
1) make appropriate changes to our model parameters, our feed, our circuit configuration;
2) rerun the simulation; and,
3) compare the results.