Stirred Mill (Perfect Mixing): Difference between revisions

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== Model theory ==
== Model theory ==


{{Restricted content}}
<hide>
{{Model theory (Text, Mill, Perfect Mixing, Population Balance)}}
{{Model theory (Text, Mill, Perfect Mixing, Population Balance)}}


=== Discharge rate ===
=== Discharge rate ===


[[File:StirredMillDimensions1.png|thumb|425px|Figure 2. Schematic of a bottom-fed vertical stirred mill showing key dimensions. The stirrer shown is a screw type with two starts and three turns per start. (After Napier-Munn et al., 1996).{{Napier-Munn et al. (1996)}}]]
[[File:StirredMillDimensions1.png|thumb|425px|Figure 2. Schematic of a bottom-fed, gravity-induced vertical stirred mill showing key dimensions. The stirrer shown is a screw type with two starts and three turns per start. (After Napier-Munn et al., 1996).{{Napier-Munn et al. (1996)}}]]


The discharge rate, <math>D_i</math>, is related to the residence time of pulp in the mill and can be corrected for different volumetric feed rates and mill volumes by first normalising to  
The discharge rate, <math>D_i</math>, is related to the residence time of pulp in the mill and can be corrected for different volumetric feed rates and mill volumes by first normalising to  
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{{Model theory (Text, Ball Mill, Perfect Mixing, Multi-component)|Perfect Mixing|breakage rate}}
{{Model theory (Text, Ball Mill, Perfect Mixing, Multi-component)|Perfect Mixing|breakage rate}}
</hide>


== Excel ==
== Excel ==
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The Perfect Mixing stirred mill model may be invoked from the Excel formula bar with the following function call:
The Perfect Mixing stirred mill model may be invoked from the Excel formula bar with the following function call:


<syntaxhighlight lang="vb">=mdUnit_StirredMill_PerfectMixing(Parameters as Range, Size as Range, MillFeed as Range, OreSG As Range, Appearance as Range, WorkIndexSim As Range, R/D*KnotPositions as Range, R/D*KnotsOrig as Range)</syntaxhighlight>
<syntaxhighlight lang="vb">=mdUnit_StirredMill_PerfectMixing(Parameters as Range, Size as Range, MillFeed as Range, OreSG As Range, Appearance as Range, WorkIndexSim As Range, R/D*KnotPositions as Range, R/D*KnotsOrig as Range, Optional ScalingExponents as Range)</syntaxhighlight>


{{Excel (Text, Help, No Arguments)}}
{{Excel (Text, Help, No Arguments)}}
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S_{\rm Sim}\\
S_{\rm Sim}\\
T_{\rm Sim}\\
T_{\rm Sim}\\
\mathit{WI}_{\rm Orig}\text{ (kWh/t)}\\
{\rm WI}_{\rm Orig}\text{ (kWh/t)}\\
\rho_{\rm B}\text{ (t/m}^{\text{3}}\text{)}\\
(Q_{\rm M,F})_{\rm L}\text{ (t/h)}\\
(Q_{\rm M,F})_{\rm L}\text{ (t/h)}\\
\rho_{\rm L}\text{ (t/m}^{\text{3}}\text{)}\\
\rho_{\rm L}\text{ (t/m}^{\text{3}}\text{)}\\
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\end{bmatrix},\;\;\;\;\;\;
\end{bmatrix},\;\;\;\;\;\;


\mathit{WI}_{\rm Sim}= \begin{bmatrix}
{\rm WI}_{\rm Sim}= \begin{bmatrix}
\mathit{WI}_{1}\text{ (kWh/t)} & \dots & \mathit{WI}_m\text{ (kWh/t)}\\  
{\rm WI}_{1}\text{ (kWh/t)} & \dots & {\rm WI}_m\text{ (kWh/t)}\\  
\end{bmatrix},\;\;\;\;\;\;
\end{bmatrix},\;\;\;\;\;\;


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\end{bmatrix}
\end{bmatrix}
</math>
</math>
:<math>
\mathit{ScalingExponents} = \begin{bmatrix}
e_1\\
e_2\\
e_3\\
e_4\\
e_5\\
e_6\\
e_7\\
\end{bmatrix}^*
</math>


where:
where:
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* <math>Q_{\rm M,F}</math> is the mass flow rate of particles in the feed (t/h)
* <math>Q_{\rm M,F}</math> is the mass flow rate of particles in the feed (t/h)
* <math>\rho_{\rm S}</math> is the Specific Gravity or density of solids (- or t/m<sup>3</sup>)
* <math>\rho_{\rm S}</math> is the Specific Gravity or density of solids (- or t/m<sup>3</sup>)
* <math>^*</math> indicates the <math>\mathit{ScalingExponents}</math> array is optional, the default values are used if omitted.


=== Results ===
=== Results ===
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V_{\rm Media}\\
V_{\rm Media}\\
V_{\rm Slurry}\\
V_{\rm Slurry}\\
\mathit{LF}\text{ (v/v)}\\
{\rm LF}\text{ (v/v)}\\
\tau\text{ (min)}\\
\tau\text{ (min)}\\
\text{R/D* factor (frac)}\\
\text{R/D* factor (frac)}\\
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where:
where:
* <math>\mathit{LF}</math> is the media load fraction (v/v), defined as the fraction of mill volume occupied by media, including void spaces, i.e. <math>\mathit{LF} = H_{\rm b} \big/ H</math>
* <math>{\rm LF}</math> is the media load fraction (v/v), defined as the fraction of mill volume occupied by media, including void spaces, i.e. <math>{\rm LF} = H_{\rm b} \big/ H</math>
* <math>\text{R/D* factor}=D_i^*/D_i</math> is the discharge rate scaling factor
* <math>\text{R/D* factor}=D_i^*/D_i</math> is the discharge rate scaling factor
* <math>Q_{\rm M,P}</math> is the mass flow rate of particles in the mill product (t/h)
* <math>Q_{\rm M,P}</math> is the mass flow rate of particles in the mill product (t/h)
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{{SysCAD (Page, Stirred Mill, Perfect Mixing, Ri/Di)|method=0}}
{{SysCAD (Page, Stirred Mill, Perfect Mixing, Ri/Di)|method=0}}


{{SysCAD (Page, Tumbling Mill, Power)|modelpage={{Name (Text, Company Name)|nospace=1}}*Mill|Nitta=true}}
{{SysCAD (Page, Tumbling Mill, Power)|modelpage={{SysCAD (Text, UnitType Prefix)}}Mill|Nitta=true|Heath=true}}


{{SysCAD (Page, Tumbling Mill, MediaStrings)|modelpage={{Name (Text, Company Name)|nospace=1}}*Mill}}
{{SysCAD (Page, Tumbling Mill, MediaStrings)|modelpage={{SysCAD (Text, UnitType Prefix)}}Mill}}


{{SysCAD (Page, About)}}
{{SysCAD (Page, About)}}
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* [[Stirred Mill (Perfect Mixing, Dynamic)|Dynamic Perfect Mixing stirred mill model]]
* [[Stirred Mill (Perfect Mixing, Dynamic)|Dynamic Perfect Mixing stirred mill model]]
* [[Mill (Herbst-Fuerstenau)| Herbst-Fuerstenau mill model]]
* [[Mill (Herbst-Fuerstenau)| Herbst-Fuerstenau mill model]]
* [[Stirred Mill (Power, Nitta)]]
* [[Stirred Mill (Power, Heath)]]


== References ==
== References ==

Latest revision as of 10:01, 4 December 2024

Description

This article describes an implementation of the Perfect Mixing vertical stirred mill model outlined by Napier-Munn et al. (1996).[1]

The model described here is for steady-state simulation. For dynamic simulation, see Stirred Mill (Perfect Mixing, Dynamic).

Model theory

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Excel

The Perfect Mixing stirred mill model may be invoked from the Excel formula bar with the following function call:

=mdUnit_StirredMill_PerfectMixing(Parameters as Range, Size as Range, MillFeed as Range, OreSG As Range, Appearance as Range, WorkIndexSim As Range, R/D*KnotPositions as Range, R/D*KnotsOrig as Range, Optional ScalingExponents as Range)

Invoking the function with no arguments will print Help text associated with the model, including a link to this page.

Inputs

The required inputs are defined below in matrix notation with elements corresponding to cells in Excel row () x column () format:


where:

  • is the mass flow feed rate of liquids into the mill (t/h)
  • is the Specific Gravity or density of the media in the mill (- or t/m3)
  • is the Specific Gravity or density of liquids in the feed (- or t/m3)
  • is the number of ore types
  • is the number of breakage rate per discharge rate knots
  • is the size of the square mesh interval that feed mass is retained on (mm)
  • , i.e. descending size order from top size () to sub mesh ( mm)
  • is the mass flow rate of particles in the feed (t/h)
  • is the Specific Gravity or density of solids (- or t/m3)
  • indicates the array is optional, the default values are used if omitted.

Results

The results are displayed in Excel as an array corresponding to the matrix notation below:

where:

  • is the media load fraction (v/v), defined as the fraction of mill volume occupied by media, including void spaces, i.e.
  • is the discharge rate scaling factor
  • is the mass flow rate of particles in the mill product (t/h)
  • is the geometric mean size of the internal mesh series interval that mass is retained on (mm)

Example

The images below show the selection of input arrays and output results in the Excel interface.

Figure 3. Example showing the selection of the Parameters (blue frame) array in Excel.
Figure 4. Example showing the outline of the Results (light blue frame) array in Excel.
Figure 5. Example showing the selection of the Size (red frame), OreSG (green frame) and MillFeed (purple frame).
Figure 6. Example showing the selection of the Appearance (pink frame), R/D*KnotPositions (teal frame), R/D*KnotsOrig (blue frame), WorkIndexSim (red frame) arrays in Excel.

SysCAD

The SysCAD interface for steady-state (ProBal) mode is described below. For SysCAD Dynamic, see Stirred Mill (Perfect Mixing, Dynamic).

MD_Mill page

The first tab page in the access window will have this name.

Tag (Long/Short) Input / Display Description/Calculated Variables/Options
Tag Display This name tag may be modified with the change tag option.
Condition Display OK if no errors/warnings, otherwise lists errors/warnings.
ConditionCount Display The current number of errors/warnings. If condition is OK, returns 0.
GeneralDescription / GenDesc Display This is an automatically generated description for the unit. If the user has entered text in the 'EqpDesc' field on the Info tab (see below), this will be displayed here.

If this field is blank, then SysCAD will display the unit class ID.

Requirements
On CheckBox This enables the unit. If this box is not checked, then the material will pass straight through the mill with no change to the size distribution.
NumParallelUnits Input The number of parallel, identical units to simulate:
  • Feed is divided by the number of parallel units before being sent to the unit model.
  • Unit model product is multiplied back by the same value and returned to the SysCAD product stream.
  • All unit model result values are shown per parallel unit.
Method Fixed Discharge The discharge particle size distribution is user defined. Different distributions can be used for different solids.
AG/SAG (Variable Rates) The Variable Rates AG/SAG mill model is used to determine the mill product size distribution. Different parameters can be used for different solids.
Rod Mill (Lynch) The Lynch rod mill model is used to determine the mill product size distribution. Different parameters can be used for different solids.
Ball (Perfect Mixing) The Perfect Mixing ball mill model (steady-state or dynamic) is used to determine the mill product size distribution. Different parameters can be used for different solids.
Stirred (Perfect Mixing) The Perfect Mixing stirred mill model (steady-state or dynamic) is used to determine the mill product size distribution. Different parameters can be used for different solids.
Mill (Herbst-Fuerstenau) The Herbst-Fuerstenau model is used to determine the mill product size distribution. Different parameters can be used for different solids.
PowerModels CheckBox Show alternative mill power model calculations on the Power page.
MediaStrings CheckBox Show media size distributions at recharge equilibrium on the MediaStrings page.
Options
ShowQFeed CheckBox QFeed and associated tab pages (eg Sp) will become visible, showing the properties of the combined feed stream.
ShowQProd CheckBox QProd and associated tab pages (eg Sp) will become visible, showing the properties of the products.
SizeForPassingFracCalc Input Size fraction for % Passing calculation. The size fraction input here will be shown in the Stream Summary section.
FracForPassingSizeCalc Input Fraction passing for Size calculation. The fraction input here will be shown in the Stream Summary section.
Stream Summary
MassFlow / Qm Display The total mass flow in each stream.
SolidMassFlow / SQm Display The Solids mass flow in each stream.
LiquidMassFlow / LQm Display The Liquid mass flow in each stream.
VolFlow / Qv Display The total Volume flow in each stream.
Temperature / T Display The Temperature of each stream.
Density / Rho Display The Density of each stream.
SolidFrac / Sf Display The Solid Fraction in each stream.
LiquidFrac / Lf Display The Liquid Fraction in each stream.
Passing Display The mass fraction passing the user-specified size (in the field SizeForPassingFracCalc) in each stream.
Passes Display The user-specified (in the field FracForPassesSizeCalc) fraction of material in each stream will pass this size fraction.

Mill page

The Mill page is used to specify the input parameters for the mill model.

Tag (Long/Short) Input / Display Description/Calculated Variables/Options
PerfectMixing
HelpLink ButtonModelHelp.png Opens a link to this page using the system default web browser. Note: Internet access is required.
Stirred
MediaStringsP50 CheckBox
  • Only visible if the MediaStrings option is checked.
  • Replaces the MediaSize.Sim user defined value with the MediaSize (All) P50 value from the MediaStrings page.
  • The value of MediaSize.Orig should be determined on the same basis for correct scaling of a changed media charge.
UserExponents Checkbox Indicates whether to use user-defined values for the scaling exponents.
MillDiameter Input The inside liner diameter of the simulated mill.
MillHeight Input The height of the simulated mill.
MediaHeight Input Height of the media charge of the original and simulated mills.
MediaDiameter Input Median diameter of the media in the original and simulated mills.
StirrerDiameter Input Diameter of the stirrers of the original and simulated mills.
StirrerSpeed Input Rotational speed of the stirrers of the original and simulated mills.
StirrerStarts Input Number of starts of the (screw) stirrers of the original and simulated mills.
StirrerTurns Input Number of turns per start of the (screw) stirrers of the original and simulated mills.
WorkIndex Input Bond Ball Work Index of ore in the original mill.
Exponent Input
  • Only visible if UserExponents is selected
  • Allows user to specify values of the scaling exponent for each original/simulated parameter pair.
R/DFunction
NumSplineKnots Input Number of spline knots for the function.
Size Input Spline knot size positions.
Ln(R/D*) Input Values of at each spline knot position.
Results
MillVolume Display Volume inside the mill.
MediaVolume Display Volume occupied by the media in the mill, excluding void space.
SlurryVolume Display Volume of slurry in the mill, including slurry in media void space and above media charge.
LoadFraction Display Volume of media charge, including void space and excluding stirrer volume, as a fraction of mill volume, excluding stirrer volume.
ResidenceTime Display Mean residence time of slurry in the mill.

Ore page

This page is used to define the comminution properties of SysCAD species with the size distribution quality in the project.

Tag (Long/Short) Input / Display Description/Calculated Variables/Options
Appearance
DefaultAppearance

ButtonSetAll.png

Sets all species to the the default Kelsall Appearance function.
OreSpecific CheckBox
  • Ore-specific parameters, allows the Appearance data to be separately input for all species.
  • Default is all species have the same set of single input properties.
  • This option is only available if there is more than one species in the project with the size distribution property.
Appearance Input User-specified Appearance function data for all species with size distribution property.

StirredMillPerfectMixing6.png StirredMillPerfectMixing7.png

WorkIndex
WorkIndex.Sim Input Bond Ball Work Index data for all species with size distribution property.

Ri/Di page

This page displays the scaling factors and breakage rate per discharge rate for each size interval computed by the Perfect Mixing model.

Tag (Long/Short) Input / Display Description/Calculated Variables/Options
Scaling
RDStar/RD Display Value of the factor for discharge rate scaling.
StirrerDiameter Display Value of the stirrer diameter factor for rate scaling.
MediaHeight Display Value of the media height factor for rate scaling.
StirrerSpeed Display Value of the stirrer speed factor for rate scaling.
StirrerStarts Display Value of the stirrer starts factor for rate scaling.
StirrerTurns Display Value of the stirrer turns per start factor for rate scaling.
MediaSize Display Value of the media size factor for rate scaling.
WorkIndex Display Value of the Work Index factor of each ore species for rate scaling.
Ri/DiStar
Size Display Size of each interval in internal mesh series.
MeanSize Display Geometric mean size of each interval in internal mesh series.
Ri/DiStar Display Value of normalised rate for each size interval, for each ore species.
Ri/Di
Size Display Size of each interval in internal mesh series.
MeanSize Display Geometric mean size of each interval in internal mesh series.
Ri/Di Display Value of rate for each size interval, for each ore species.

Power page

This optional page displays the inputs and results for alternative mill power models. The page is only visible if PowerModels is selected on the MD_Mill page.

Tag (Long/Short) Input / Display Description/Calculated Variables/Options
Power
Nitta CheckBox Shows inputs and results for stirred mill power calculations using the Nitta method.
Heath CheckBox Shows inputs and results for stirred mill power calculations using the Heath method.

MediaStrings page

This page displays the inputs and results for grinding mill media string calculations. The page is only visible if MediaStrings is selected on the MD_Mill page.

About page

This page is provides product and licensing information about the Met Dynamics Models SysCAD Add-On.

Tag (Long/Short) Input / Display Description/Calculated Variables/Options
About
HelpLink ButtonLicensingHelp.png Opens a link to the Installation and Licensing page using the system default web browser. Note: Internet access is required.
Information ButtonCopyToClipboard.png Copies Product and License information to the Windows clipboard.
Product
Name Display Met Dynamics software product name
Version Display Met Dynamics software product version number.
BuildDate Display Build date and time of the Met Dynamics Models SysCAD Add-On.
License
File ButtonBrowse.png This is used to locate a Met Dynamics software license file.
Location Display Type of Met Dynamics software license or file name and path of license file.
SiteCode Display Unique machine identifier for license authorisation.
ReqdAuth Display Authorisation level required, MD-SysCAD Full or MD-SysCAD Runtime.
Status Display License status, LICENSE_OK indicates a valid license, other messages report licensing errors.
IssuedTo Display Only visible if Met Dynamics license file is used. Name of organisation/seat the license is authorised to.
ExpiryDate Display Only visible if Met Dynamics license file is used. License expiry date.
DaysLeft Display Only visible if Met Dynamics license file is used. Days left before the license expires.

See also

References

  1. Napier-Munn, T.J., Morrell, S., Morrison, R.D. and Kojovic, T., 1996. Mineral comminution circuits: their operation and optimisation. Julius Kruttschnitt Mineral Research Centre, Indooroopilly, QLD.