International Journal of Mineral Processing 104-105 (2012) 1116

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International Journal of Mineral Processing

journal homepage: www.elsevier.com/locate/ijminpro

The use of simulation for process diagnosis: Application to a gravity separator

Claude Bazin a,, Gracia Mfudi Payenzo a, Mathieu Desnoyers b, Claude Gosselin b, Guy Chevalier b
a
Department of Mining, Metallurgy and Materials Engineering, Laval University, Canada
b
ArcelorMittal Mines Canada, Pelletizing Plant, Port-Cartier, QC, Canada

a r t i c l e i n f o a b s t r a c t

Article history: The operation of mineral processing equipments is affected by natural disturbances coming from changes of
Received 12 September 2011 the ore feed characteristics and operating practices. A method to quantify the impact of natural disturbances
Received in revised form 11 October 2011 and equipment operating practices on plant performances is described in this paper. The method that is
Accepted 6 November 2011
based on process simulation is applied to an industrial hydraulic classier. For the studied process it was
Available online 21 November 2011
found that most of the variation observed in the production results is due to the operation of the classier
Keywords:
rather than changes in the feed mineral composition and particle size distribution.
Gravity concentration 2011 Elsevier B.V. All rights reserved.
Iron ores
Classication
Modeling
Mass balancing

1. Introduction
The operators of mineral processing plants are often required to
reduce the variability of process performance indices such as the ne-
ness of grind for a grinding circuit, the recovery or the grade of a o-
tation concentrate. The variability of a process output variable may
have three main sources, natural disturbances that affect the ore
feed characteristics, the operation of the plant itself and errors on
the measurements used to calculate the plant performance indices.
Measurement errors are unavoidable and their amplitude may be es-
timated by repeated measurements of one variable. Data reconcilia-
tion (Hodouin et al., 1989) can be used to attenuate the variation in
the estimated performance indices due to measurement errors. The
variability due to operation includes the way the equipments are op-
erated and the quality of the consumables (reagent, water) re-
quired for the process. A problem due to the operation may be
attenuated by training practices and control strategies. If the problem
is caused by variations in the feed characteristics blending of the ore
or stocking ores in different bins and feed forward control may atten-
uate the impact on the variation of the process performances. In any
case it could be strategic for some processes to identify whether the
source of variability in a process performance is due to the changes
in the feed characteristics or caused by operating practices.
In this paper process simulation is used to help in the identica-
tion of the source of variability in a process. The process used to illus-
trate the method is the upgrading of an iron oxide concentrate in a
Corresponding author. Tel.: + 1 418 656 5914; fax: +1 418 656 5343.
E-mail address: claude.bazin@gmn.ulaval.ca (C. Bazin).
hydraulic classier (Wills, 1992; Hearn, 2002; Das et al., 2009;
Kumar et al., 2009). Production results indicate that the recovery
and concentrate grade exhibit a signicant variation about the target
values for these performance indices. Simulation was used to identify
the sources of the variability observed in the production results.
The rst part of the paper describes the operation of a hydraulic
classier and the second part discusses the application used for the il-
lustration of the proposed method. The following section describes
the methodology used for data acquisition and processing. The last
section describes and illustrates the proposed diagnosis method.
2. Hydraulic classier operation
A simplied drawing of a hydraulic classier is shown in Fig. 1. The
material to be classied is fed onto a screen with water to achieve a
target feed solids concentration. The slurry is distributed on the top
of the classier and particles are allowed to settle toward the classi-
er cone where a pinch valve is used to control the ow of settled
solids. Fluidization or teeter water is added above the cone to provide
the upward ow of water used to entrain the light and ne particles
toward the overow while heavier (coarse and dense) particles settle
to the underow. The operating principle of the classier is a compe-
tition between the terminal velocity of a particle and the velocity of
the raising water that is mainly conditioned by the uidization
water (Das et al., 2009). The main operating variables for a classier
are the opening of the pinch valve on the underow stream and the
ow rate of uidization water. The bed density is measured by a pres-
sure sensor located above the injection of uidization water (see
Fig. 1) and is used to control the opening of the pinch valve.

0301-7516/$ see front matter 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.minpro.2011.11.009
12 C. Bazin et al. / International Journal of Mineral Processing 104-105 (2012) 1116
Fig. 1. Hydraulic classier.
The separation of minerals in the classier can be described using
partition or separation curves similar to those observed for a hydrocy-
clone processing an ore consisting of minerals of various specic
gravities (Lynch, 1977). A partition curve describes the proportion
of a mineral species in a size interval of the feed to a separator that re-
ports to a particular output stream of the separator. The underow
stream is used for the hydrocyclone and the hydraulic classier. Ex-
amples of mineral partition curves observed for a hydrocyclone and
a hydraulic classier are shown in Fig. 2.
3. Hydraulic classier for iron oxide concentrate
The method described in this paper is applied to a hydraulic clas-
sier used in the pelletizing plant of ArcelorMittal Mines (Canada) of
Port-Cartier, Quebec Canada. The hydraulic classier is used to up-
grade an iron oxide concentrate produced by spiral classier (Bazin
et al., 2011) by removing light silica minerals. The production of
low silica content iron oxide concentrate implies to reduce the silica
content of the spiral concentrate assaying 3.5% to 5.0% SiO2 to less
than 1.2%. The upgraded concentrate is then processed to produce
iron oxide pellets for the steel producers.
The hydraulic classier used in the pelletizing plant is manufac-
tured by Linatex and some dimensions of the equipment are given
in Fig. 1. The solids feed rate to the classier varies from 170 to
270 t/h and the feed slurry density is usually controlled at 45% w/
w solids. The uidization water addition rate ranges from 1200 to
2500 l/min. The feed, overow and underow streams of the classier
are sampled on a 2 hour basis to obtain 12 hour composite samples of
these streams. The samples are assayed and the results are used for
the control of the classier and daily production reports. Some pro-
duction results for low silica content pellets are given in Table 1.
The solids recovery to the underow varies between 70 and 90%
with a target 80% recovery. The classier overow contains from
45% to 65% iron is reprocessed in a secondary circuit to recovery
some iron to reduce losses.
The results of 150 days of production of low silica pellets are
shown on the grade and solids recovery map of Fig. 3. The weight re-
covery in the underow exhibits a signicant dispersion around the
targeted 80%. There is also some distribution about the target 1.2%
SiO2 for the enriched concentrate. Excluding the measurement errors
there are two possible sources for that observed dispersion of the pro-
duction data:
The variation of the classier feed mineral composition and mineral
size distribution,
The operation of the hydraulic classier.
 C. Bazin et al. / International Journal of Mineral Processing 104-105 (2012) 1116 13

44 88 176 350 700

100

MASS FRACTION TO CUF

0.9

% reporting to underflow
80
0.7
60
Hematite
0.5
a) primary 40
0.3 Over-all
Maximum
Pyrite 20 Average Quartz
0.1 Non-sulphides
Minimum
0
270 150 65 35 20 10 100 1000
400 200 100 48 28
PARTICLE SIZE, mesh Particle size (um)

Hydrocyclone partition curves (Laplante Hydraulic classifier for iron oxide (this study) (SG of
and Finch, 1984) (SG of pyrite = 5 g/cm3; SG hematite: 5 g/cm3; SG of quartz = 2.7 g/cm3)
of non-sulphides = 2.7 g/cm3)

Fig. 2. Effect of mineral specic gravity and particle size on the partition curves of a hydrocyclone and a hydraulic classier. Hydrocyclone partition curves (Laplante and Finch,
1984) (SG of pyrite = 5 g/cm3; SG of non-suldes = 2.7 g/cm3). Hydraulic classier for iron oxide (this study) (SG of hematite: 5 g/cm3; SG of quartz = 2.7 g/cm3).

Simulation was used as an aid to identify the impact of the varia- the total concentration of ilmenite feldspar and garnet varies be-
tions of the feed composition and of the operating conditions on the tween 0.98% and 1.53%. For the considered sampling campaigns
variability of the hydraulic classier production results. more than 99% of the SiO2 assays variation is explained by the change
of the quartz content. This is readily observable in the measured SiO2
4. Data acquisition and process analysis content also reported in Table 2.
Hydraulic classiers separate the particles according to their size
Seven sampling campaigns were conducted on different days and and density. Hence the size distribution of the minerals in the feed
hydraulic classiers operating steady state during the production of is strategic to assess the operation of these equipments. The estimat-
low silica concentrate. Samples of the feed, overow and underow ed quartz and hematite size distributions expressed as weight
streams were collected during 90 minutes. The purpose of the cam- retained for the considered sampling campaigns are shown in Fig. 4.
paigns was to assess the range of variation of the feed composition Although the sampling campaigns were conducted on different days
and mineral partition curves in the classiers. Each sample was and on different hydraulic classiers the estimated mineral size dis-
assayed and sieved using Tyler screens ranging from 20 to 150 tributions are similar from one campaign to another one. Hematite
mesh (0.850 to 0.106 mm). The ore retained within each size interval mineral particles are located in the coarser size intervals than quartz
was assayed for iron, SiO2, Al2O3 and TiO2. particles. This last characteristic enhances the selectivity of the classi-
The data processing is carried out using a least squares data reconcil- er against quartz that is not only ner than hematite but also lighter
iation algorithm that also performs mineral reconstruction using the el- with a specic gravity of 2.7 compared to 5.0 g/cm 3 for iron oxide.
ement and oxide assays and estimation of the mineral partition curves The variations of the mineral contents (Table 2) and of the mineral
in the classier (Bazin et al., 2011). The iron oxide concentrate consists size distributions (Fig. 4) in the feed of the classier traduce the nat-
mainly of hematite (Fe2O3). Quartz (SiO2) is the major gangue mineral ural variability of the feed which could be responsible for the varia-
followed by feldspars, ilmenite and garnets. In this application the min- tion in the operating results shown in Fig. 3. The effect of the
erals are assumed liberated although composite particles of quartz and classier operating conditions is assessed through the variation of
hematite are observed in the size intervals above 0.5 mm. Accounting the mineral partition curves for the 7 considered sampling cam-
for locked particles in the data processing is possible but it is not neces- paigns. The estimated partition curves for hematite and quartz are
sary for the diagnosis objective of this analysis. shown in Fig. 5. The hematite mineral partition curve is shifted to-
The estimated mineral contents of the iron oxide concentrate ward ne size indicating the effect of specic gravity on the separa-
feeding the classier for the 7 considered sampling campaigns are tion carried out by the classier. Hematite particles that are coarser
given in Table 2. The quartz content varies from 2.90% to 4.65% and
90
Good grade Improve grade
Weight recovery in the

Table 1 and recovery

Operating results for the production of low silica iron oxide pellets. 85
underflow (%)

Variable Average Minimum Maximum SD

Feed composition 80
% Fe 66.44 65.70 67.20 0.29
% SiO2 4.46 3.22 5.59 0.43 Improve grade
% Al2O3 0.30 0.24 0.39 0.03 75 and recovery
Improve
% TiO2 0.15 0.06 0.30 0.04 recovery
+ 0.850 mm 6.04 4.20 8.20 0.76
0.106 mm 9.30 6.60 19.30 0.57 70
1 1,1 1,2 1,3 1,4 1,5 1,6
Performance
% SiO2 in the classifier underflow
Weight recovery (%) 79.99 61.00 91.00 4.36
% SiO2 in upgraded concentrate 1.21 0.86 1.89 0.14
Fig. 3. Observed SiO2 content of the enriched concentrate and weight recovery ob-
% Fe in classier overow 56.44 46.00 63.00 2.77
served from daily production report.
14 C. Bazin et al. / International Journal of Mineral Processing 104-105 (2012) 1116

Table 2 100

% reported to underflow
Estimated mineral contents from sampling of the classier feed.
80
Sampling Mineral contents Lab assays
campaign %SiO2
Hematite Quartz Ilmenite Feldspars Garnet 60
1 94.62 4.26 0.32 0.43 0.37 4.59
2 94.37 4.65 0.28 0.65 0.05 4.96 40
Quartz
3 95.62 3.01 0.34 0.61 0.42 3.45
4 95.33 3.14 0.32 0.79 0.42 3.66 20 Hematite
5 95.83 2.90 0.27 0.58 0.42 3.32
6 95.09 3.62 0.28 0.57 0.44 4.05 0
7 94.23 4.57 0.19 0.57 0.44 4.99 10 100 1000
Average 95.01 3.74 0.29 0.60 0.37 4.15 Particle size (um)
Minimum 94.23 2.90 0.19 0.43 0.05 3.32
Maximum 95.83 4.65 0.34 0.79 0.44 4.99 100

% reporting to underflow
80

60
than 250 m mostly report to the underow while quartz particles of Hematite
the same size are rejected to the overow.
40
Maximum
5. Diagnosis of the classier operation using simulation 20 Average Quartz
Minimum
Results of the sampling campaigns provide typical variations in 0
10 100 1000
the classier feed characteristics and classier operating conditions Particle size (um)
as traduced by the mineral partition curves. The proposed diagnosis
method is based on the generation of random feed compositions Fig. 5. Mineral partition curves in the hydraulic classier. a) Partition curves for the 7
and mineral partition curves that are used simulate the classier op- campaigns. b) Average and extreme values.
eration. The analysis of the simulation results provides information
concerning the factors responsible for the process variability.

5.1. Principle of the simulation The feed rate of each mineral in each size interval is calculated
using the following:
The input variables for the simulation are the following:
wm;i;F W F g m;i;F xm;0;F 1
The solids feed rate to the classier (WF);
The mineral contents (xm ; 0 ; F) in the classier feed stream (hema-
tite, quartz, feldspar, garnet);
The weight fraction of mineral m retained in the size interval i is
The weight retained of the minerals in the feed stream (gm ; i ; F);
noted gm ; i ; F and xm ; 0 ; F is the mineral content of the feed. The ow
The partition curve of the minerals (Sm;i).
of each mineral in each size interval is then multiplied by the corre-
sponding partition value to obtain the ow of this mineral in the clas-
35 sier underow as follows:
Weight retained (%)

30
wm;i;U Sm;i wm;i;F 2
25
20
The solids weight recovery to the underow is given by
15 Quartz
10 WU 1 NM NS
RU m1 i1 wm;i;U 3
5
Hematite WF WF

0
10 100 1000 The mineral content in the classier underow is calculated using
Size (um)
1 NS
xm;0;Z i1 wm;i;U 4
35 WU
Weight retained (%)

30
The mineral assays are readily converted into elemental and oxide
25
species (FeTot, SiO2, Al2O3, TiO2) assays using the mineral composition
20 Quartz (Bazin et al., 2011).
15
10 5.2. Random process simulation
Hematite
5
The method used to analyze the sensitivity of the classier to the
0 variations in the feed composition and mineral partition curves con-
10 100 1000
sists of generating random feed composition and mineral partition
Size (um)
curves that belong to the observed variations of the actual process
Fig. 4. Size distributions of hematite and silica minerals in the classier feed. a) Observed (Table 2, Figs. 4 and 5) and to pass this data through Eqs. (1) to (4)
values for the 7 campaigns. b) Average, minimum and maximum. to simulate the process response to these variations. A random
 C. Bazin et al. / International Journal of Mineral Processing 104-105 (2012) 1116 15

Weight recovery to underflow (%)

number following a Gaussian distribution with an average and a 90
Simulated
standard deviation is generated using (Law and Kelton, 2000) data

q 85
z~ 2  lnU 1 sin2U 2 5

80

The variable z~ is a random number following N ; . The vari-

ables U1 and U2 are two random numbers that follow a uniform distri-
bution between 0 and 1. These numbers are readily generated by a
computer using a random generator function.
Several hundred of random data for the variables of interest can
then be generated and used to simulate the classier operation by
solving Eqs. (1)(4). The simulated variation of the estimated weight
recovery and upgraded concentrate silica content is used to assess the
impact of the varied input variable on the process output variables.
The analysis is similar to an error propagation analysis in a calculation
(Hodouin et al., 1989).
5.3. Impact of the variation of the mineral content in the classier feed
The analysis is conducted through the simulation of the classier
responses to 150 different concentrations of the 5 minerals in the
classier feed. The variation of the feed composition follows the one
observed from the sampling campaigns (Table 2). The simulations
are performed using the average mineral size distributions in the
classier feed (Fig. 4b) and the average mineral partition curves
(Fig. 5b).
The simulation results are presented in Fig. 6 with the plant pro-
duction data (Fig. 2) as the estimated weight recovery as a function
of the simulated silica content in the classier underow, i.e. the
upgraded iron oxide concentrate. Results show that the variation of
the mineral contents is not sufcient to explain the dispersion ob-
served for the weight recovery although it can explain part of the ob-
served variation of the %SiO2 content in the classier underow.
5.4. Variation of the mineral size distributions in the classier feed
The next studied variable is the size distribution of the minerals in
the classier feed. For the simulation the mineral contents of the feed
and the mineral partition curves are kept constant to their average
values observed for the sampling campaigns (see Table 2 and
Fig. 5b). Random values of the weight retained for the mineral size
distributions in the classier feed are generated using Eq. (5). The
simulation results, shown in Fig. 7, indicate that changes of the min-
eral size distributions within the range of observed variations during
the sampling campaigns are not sufcient to explain the dispersion in
the production data. The simulated effect is even less than that due to
a change in the feed composition.
Weight recovery to underflow (%)
75
Production
data
70
1 1,1 1,2 1,3 1,4 1,5 1,6
% SiO2 in classifier underflow
Fig. 7. Effects of random variations in the mineral size distributions of the classier
feed.
5.5. Effect of variation in the mineral partition curves of the classier
The last simulation uses the average mineral contents (Table 2)
and mineral size distributions (Fig. 4b) in the classier feed with ran-
dom changes of the partition curves according to the variations ob-
served in Fig. 5. The results shown in Fig. 8 indicate that the
variability observed for the production data is probably caused by
changes of the classier operating conditions rather than changes of
the feed characteristics. This last result is an indication that efforts
should be put in the development of control strategies for the classi-
ers as well as techniques for real time monitoring of the classier
performance as the bed density may not be sufcient for a tight con-
trol of the classier.
6. Conclusion
Several sampling campaigns were conducted on hydraulic classi-
ers used to upgrade an iron oxide concentrate by removing ne
quartz particles. The samples were used to assess the variability of
the feed composition as well as the variability due to the operating
practices of the mineral partition curves in the classiers. These
data were used in a sensitivity analysis to identify the source of ob-
served variability in the hydraulic classier performances. Results of
the analysis show that most of the variability in the weight recovery
observed from the production data is probably caused by the operat-
ing conditions of the classier. Work is in progress to develop a phe-
nomenological simulator of the classier to help in studying various
control strategies for the classiers. The methodology described in
this paper can be readily applied to assess the sources of variability
in the production results of otation and other concentration
processes.
Weight recovery to underflow (%)

90 90
Simulated Simulated
data data

85 85

80 80

Production Production
75 75 data
data

70 70
1 1,1 1,2 1,3 1,4 1,5 1,6 1 1,1 1,2 1,3 1,4 1,5 1,6
% SiO2 in classifier underflow % SiO2 in classifier underflow

Fig. 6. Effects of random variations of the mineral content of the classier feed. Fig. 8. Effects of random variations in the mineral partition curves of the classier.
16 C. Bazin et al. / International Journal of Mineral Processing 104-105 (2012) 1116
Acknowledgements
The authors acknowledge the assistance of Violaine Ouellet, Jean-
Pierre Ct, Khadija Bouchha and the plant technicians for the data
processing, planning and realization of the sampling campaigns. The
authors acknowledge ArcelorMittal Mines Canada for the nancial
support and permission to publish the paper.
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