Dense Medium Cyclone (Dunglison)
Description
This article describes the Dunglison (1999) model for dense medium cyclones.[1] The model is applicable to both minerals (e.g. iron ore, diamonds) and coal separations.
The Dunglison model is a comprehensive description of dense medium cyclone performance, and does not have any parameters that require calibration or "fitting" to plant or laboratory data.
Model theory
Flowrate and pressure
Volumetric flow rate
Feed inlet pressure
Medium split
Medium:Ore ratio
Medium viscosity
Shear rate
Shi viscosity model
Medium classification
Pulp-split function
Underflow and overflow densities
Medium properties
Ore partitioning
Pulp-split function
Cut density and Ecart Probable
Particle velocity
Centrifugal acceleration
Hindered settling velocity
Feed medium density adjustment
Excel
The Dunglison dense medium cyclone model may be invoked from the Excel formula bar with the following function call:
=mdUnit_DMCyclone_Dunglison(Parameters as Range, Size as Range, Density As Range, Feed as Range, MediumSize as Range, MediumDist 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:
- specifies the flow-pressure calculation mode to apply (0 = Compute flow rate at specified pressure, 1 = Compute pressure at specified flow rate)
- is the volumetric flow rate of medium in the cyclone feed (m3/h)
- specifies the type of solid media (0 = Atomised FeSi, 1 = Milled FeSi, 2 = Magnetite)
- is the temperature of the medium (deg. C)
- is feed solids mass flow rate by size and ore type (t/h)
- is the particle density (t/m3)
Results
The results are displayed in Excel as an array corresponding to the matrix notation below:
where:
- (m) is the geometric mean size of a medium particle in size interval (mm)
- is mass flow rate of solids to the underflow (sinks) stream (t/h)
- is mass flow rate of solids to the overflow (floats) stream (t/h)
- is the actual partition of all mass to the sinks stream, computed as (frac)
- is the actual partition of all particles of size to the underflow (sinks) stream, computed as (frac)
- is the actual partition of all particles of density class to the underflow (sinks) stream, computed as (frac)
Example
The images below show the selection of input arrays and output results in the Excel interface.
SysCAD
MD_DenseMedium 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 MassFracToSinks option appears below. |
| MassFracToSinks | Input | Only appears if the On field above is not checked. Specifies the fraction of feed mass that reports to the sinks stream when the model is off. |
| NumParallelUnits | Input | The number of parallel, identical units to simulate:
|
| Method | Partition (User) | The partition to sinks for each size interval and species is defined by the user. |
| Partition (Rho50-Ep) | The partition to sinks for each species and size interval is defined by the Rh050-Ep model. | |
| Partition (Pivot) | The partition to sinks for each species and size interval is defined by the Pivot model. | |
| Partition (Stochastic) | The partition to sinks for each species and size interval is defined by the Stochastic model. | |
| Drum (Baguley) | The Baguley dense medium drum model is used to determine the partition of solids to sinks and floats for each species and size interval. | |
| Cyclone (Dunglison) | The Dunglison dense medium cyclone model is used to determine the partition of solids to sinks (underflow) and floats (overflow) for each species and size interval. | |
| Options | ||
| ShowQFeed | CheckBox | QFeed and associated tab pages (eg Sp) will become visible, showing the properties of the combined feed stream. |
| ShowQSinks | CheckBox | QSinks and associated tab pages (eg Sp) will become visible, showing the properties of the sinks stream. |
| ShowQFloats | CheckBox | QFloats and associated tab pages (eg Sp) will become visible, showing the properties of the floats stream. |
| 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. |
Cyclone page
The Cyclone page is used to specify the required model method and associated input parameters.
| Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
|---|---|---|
| DMCyclone | ||
| HelpLink | Opens a link to this page using the system default web browser. Note: Internet access is required. | |
| Mode | Compute Flow | The model computes the cyclone volumetric flow rate at the specified feed inlet pressure. |
| Compute Pressure | The model computes the feed inlet pressure required to achieve the specified feed volumetric flow rate. | |
| Parameters | ||
| FeedPressure / Pi | Input / Display | Feed inlet pressure of the cyclone |
| CycloneDiameter / Dc | Input | Diameter of the cylindrical section of the cyclone. |
| ApexDiameter / Du | Input | Diameter of the cyclone apex (underflow) discharge. |
| InletDiameter / Di | Input | Diameter (equivalent) of the inlet to the cyclone. |
| Medium | ||
| MediumSolids | Input / List | Specifies which species should be considered as the medium solids by the model.
|
| MediumType | Atomised FeSi | The dense media is atomised ferrosilicon. |
| Milled FeSi | The dense media is milled ferrosilicon. | |
| Magnetite | The dense media is milled magnetite. | |
| Feed.Medium.VolFlow / QfMed | Input / Display | The volumetric flow rate of feed medium to the cyclone. |
| CorrectMediumDensity / Rhocm | Input / Display | The density of the correct medium. |
| MediumSolidsDensity / Rhom | Input / Display | The density of the medium solids. |
| MediumTemperature / T | Input / Display | The temperature of the feed medium. |
| Liquids | ||
| LiquidsSeparMethod | Split To Sinks (User) | Liquids are split to sinks by a user-defined fraction of liquids in the feed. |
| Split To Sinks (Model) | Liquids are split to sinks by a fraction determined by the selected model. | |
| Sinks Solids Fraction | Sufficient liquids mass is recovered to the sinks stream to yield the user-defined sinks solids mass fraction value (if possible). | |
| Sinks Liquids Fraction | Sufficient liquids mass is recovered to the sinks stream to yield the user-defined sinks liquids mass fraction value (if possible). | |
| SinksSolidsFracReqd / Sinks.SfReqd | Input | Required value of the mass fraction of solids in the sinks stream. Only visible if Sinks Solids Fraction is selected. |
| SinksLiquidsFracReqd / Sinks.LfReqd | Input | Required value of the mass fraction of liquids in the sinks stream. Only visible if Sinks Liquids Fraction is selected. |
| LiqSplitToSinks / Sinks.LiqSplit | Input/Display | The fraction of feed liquids recovered to the sinks stream. |
| Results | ||
| Feed.SolidMassFlow / Mf | Display | Mass flow of ore solids in cyclone feed. |
| Feed.OreDensity / RhoOre | Display | Mean density of all ore solids in cyclone feed. |
| Feed.Medium.SolVolFrac / Cvf | Display | Volume fraction of solids in feed medium. |
| Feed.Medium.Density / Rhof | Display | Density of feed medium to cyclone. |
| Feed.VolFlow / Qf | Display | Volumetric flow rate of feed to cyclone. |
| MediumOreRatio / MO | Display | Medium to ore volume ratio. |
| Feed.OreSolVolFrac / PhiOre | Display | Volume concentration of ore in cyclone feed. |
| Feed.MedSolVolFrac / PhiMed | Display | Volume concentration of medium solids in cyclone feed. |
| MediumSplitToUF / Rm | Display | Fractional split of feed medium to underflow (sinks) stream. |
| MediumSolSplitToUF / RmSolids | Display | Fractional split of feed medium solids to underflow (sinks) stream. |
| MediumLiqSplitToUF / RmLiquids | Display | Fractional split of feed medium liquids to underflow (sinks) stream. |
| MediumVelocity / Vc | Display | Velocity of medium in the cyclone. |
| PressureHead / Head | Display | Pressure head to cyclone feed in multiples of cyclone diameter (Dc). |
| ShearRate / GammaDot | Display | Shear rate of medium in cyclone. |
| MediumP80 | Display | 80% passing size of the medium solids. |
| MediumP20 | Display | 20% passing size of the medium solids. |
| ApparentViscosity / mu | Display | Apparent viscosity of medium in cyclone. |
| AccelRadius / Radius | Display | Radius of centrifugal acceleration. |
| InletVelocity / Vinlet | Display | Velocity of cyclone feed at inlet. |
| InletVelLossFactor / alphaInlet | Display | Inlet velocity loss factor. |
| TangentialVelocity / Vt | Display | Tangential velocity of flow in the cyclone. |
| CentrifugalAccel / ac | Display | Centrifugal acceleration of flow in the cyclone. |
| ReynoldsNumber / Rec | Display | Reynolds Number of flow in the cyclone. |
| MedIneffExponent / bMed | Display | Medium inefficiency exponent. |
| UF.Medium.SolVolFrac / Cvu | Display | Volume fraction of solids in underflow medium. |
| UF.Medium.Density / Rhou | Display | Density of medium in the underflow. |
| OF.Medium.Density / Rhoo | Display | Density of medium in the overflow. |
| OreIneffExponent / bOre | Display | Ore inefficiency exponent. |
| CoarseCutDensity / Rho50c | Display | Cut density of coarse particles in cyclone. |
| CutDensityParameter / c | Display | Cut density parameter. |
| CutDensity / Rho50 | Display | Unsized cut density (Rho50). |
| EcartProbable / Ep | Display | Unsized Ecart Probable (Ep). |
| Imperfection / I | Display | Unsized partition Imperfection (I). |
MediumSz page
The MediumSz page is used to specify the size distribution properties of the dense medium solids.
| Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
|---|---|---|
| MediumSz | ||
| NumMediumSizes | Input / Display | Number of medium solids particle size intervals. |
| Size | Input / Display | Size of each interval in medium mesh series. |
| MeanSize | Display | Geometric mean size of each interval in medium mesh series. |
| WtMedium | Input / Display | Mass fraction of medium solids per size interval. |
| YiMedium | Input / Display | The partition to underflow (sink) of medium solids per size interval. |
| All | Input / Display | Actual overall recovery of all medium solids to underflow (sinks). |
Partition page
The Partition page is used to display (or specify) the partition by species/component/element/individual phase and size values.
| Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
|---|---|---|
| Distribution | ||
| Name | Display | Shows the name of the SysCAD Size Distribution (PSD) quality associated with the feed stream. |
| IntervalCount | Display | Shows the number of size intervals in the SysCAD Size Distribution (PSD) quality associated with the feed stream. |
| SpWithPSDCount | Display | Shows the number of species in the feed stream assigned with the SysCAD Size Distribution (PSD) quality. |
| Partition | ||
| Method | Model / User | Select model-calculated or user-defined partition to separate each solids species type. |
| Density | Display | Density of each solid species. |
| Size | Display | Size of each interval in mesh series. |
| MeanSize | Display | Geometric mean size of each interval in mesh series.
|
| All (All column) | Display |
|
| Partition | Display |
|
| All (All row, All column) | Display |
|
| All (All row, per species) | Display |
|
| CmpPartition | ||
| Components | Hides or shows component partition table. | |
| Size | Display | Size of each interval in mesh series. |
| MeanSize | Display | Geometric mean size of each interval in mesh series. |
| All (All column) | Display |
|
| CmpPartition | Display |
|
| All (All row, All column) | Display |
|
| All (All row, per component) | Display |
|
| ElePartition | ||
| Elements | Hides or shows element partition table. | |
| Size | Display | Size of each interval in mesh series. |
| MeanSize | Display | Geometric mean size of each interval in mesh series. |
| All (All column) | Display |
|
| ElePartition | Display |
|
| All (All row, All column) | Display |
|
| All (All row, per element) | Display |
|
| IPhPartition | ||
| IPhases | Hides or shows individual phases partition table. | |
| Size | Display | Size of each interval in mesh series. |
| MeanSize | Display | Geometric mean size of each interval in mesh series. |
| All (All column) | Display |
|
| IPhPartition | Display |
|
| All (All row, All column) | Display |
|
| All (All row, per individual phase) | Display |
|
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 | Opens a link to the Installation and Licensing page using the system default web browser. Note: Internet access is required. | |
| Information | 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 | 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. |
Medium solids
This model allows the user to designate any single SysCAD solids species in the project as the medium solids. Alternatively, no medium solids may be specified (default: "-").
The selected option determines how the medium solids species is treated by the model:
- Default: -:
- The medium properties required by the model (Feed.Medium.VolFlow, CorrectMediumDensity, MediumSolidsDensity, MediumTemperature, and Size/WtMedium) are specified by the user.
- All solids species in the feed stream that possess the PSD property are partitioned by the model based on their size and density characteristics.
- The All partition values shown on the Partition page include contributions from all species.
- All solids species in the feed stream that do not possess the PSD property are split by the model based on default behaviour (see Additional notes).
- [Species Name]:
- The medium properties required by the model (Feed.Medium.VolFlow, CorrectMediumDensity, and MediumSolidsDensity are determined by the properties of the selected medium solids species and all liquids in the feed.
- If the SysCAD heat calculations are enabled (Edit, Project Settings, Heat Calculations), the MediumTemperature is determined by the mixed temperature of all feed streams. Otherwise, MediumTemperature is user-specified.
- If the selected medium solids species possesses the size distribution property (PSD):
- The Size/WtMedium properties are determined by the PSD of the medium solids species in the feed stream.
- The selected medium species is partitioned according to the medium classification (YiMedium) determined by the model.
- The partition-by-size values for the medium species on the Partition page are displayed as zeroes.
- The All partition values on the Partition page exclude the medium species.
- If the selected medium solids species does not possess the PSD property:
- The Size/WtMedium values are user-specified.
- The selected medium solids species split to the sinks stream is determined by the RmSolids model parameter.
Additional notes
- Solid species that do not possess a particle size distribution property are split according to the overall mass split of the default particle size distribution species selected in the SysCAD Project Configuration.
- If the default particle size distribution species is not present in the unit feed, the overall split of all other species with particle size distributions combined is used, as determined by the model.
- Gas phase species report directly to the tail/floats stream without split.
See also
External links
- Met Dynamics - Dense Medium Separator (help.syscad.net)
- Gravity, Dense Medium, and Magnetic Separation Example project (help.syscad.net)
References
- ↑ Dunglison, M.E., 1999. A general model of the dense medium cyclone. PhD thesis, The University of Queensland, Julius Kruttschnitt Mineral Research Centre.

