View source for Solids Recovery Unit

[[Category:Models]] [[Category:Size Distribution]]
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This model is available in SysCAD 9.3 Build 138 or later.

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== General Description ==

The Solids Recovery Unit can be used to model a variety of solid recovery processes including flotation, magnetic separation and spirals. The model perfectly mixes all the incoming Feed streams and then, based on the user configuration, calculates the amount, temperature and composition of material reporting to the product streams.

The Solids Recovery Unit is very similar in functionality to the [[Flotation Cell]]. The main difference is that it optionally allows a Middlings stream to be connected. When the Middlings stream is connected, there are two configuration pages and the model works like two Flotation Cells in series.

== Diagram ==

[[Image:Solids Recovery connections.png]]

The diagram shows the default drawing of the Solids Recovery Unit, with all of the streams that can be connected to the unit. The physical location of the streams connecting to the unit is unimportant. The user may connect the streams to any position on the unit.

== Inputs and Outputs ==


{| border="1" cellpadding="5" cellspacing="0"  
|- 
| valign="top" rowspan="2" | '''Label''' || valign="top" rowspan="2" | '''Required<br>Optional''' || valign="top" rowspan="2" | '''Input<br>Output ''' ||  colspan="2"   | '''Number of Connections''' || valign="top" rowspan="2" | '''Description'''
|- 
|  '''Min''' || '''Max''' 
|-
| Feed || 1 Required ||  In || 1 || 20 || The slurry feed/s to the unit
|-
| Concentrate || Required ||  Out || 1 || 1 || Concentrate outlet from the unit.
|-
| Middlings || Optional||  Out || 0 || 1 || Middlings outlet from the unit.
|-
| Tailings || Required ||  Out || 1 || 1 || Tailings outlet from the unit.
|-
| Vent || Optional ||  Out || 0 || 1 || Vent Stream (Vapour only).
|}

== Behaviour when Model is OFF ==

If the user disables the unit, by un-ticking the ''On'' tick box, then the following actions occur:
* The field ''MassFracToTails'' becomes visible and the user may set the fraction of the feed stream that reports to the 'Tailings' outlet.  The default is 100%.
* All streams connected to the unit will flow straight out of the 'Tailings' outlet; unless the user has changed the above field from 100%.  In which case the user defined fraction of the Feed will report to the 'Tailings' outlet, with the remainder reporting to the 'Concentrate' outlet;
* The 'Middlings' outlet (if connected) will not receive any flow while the model is off.
* No separation will occur.
* No sub-models, such as reactions, will occur.

So basically, the unit will be 'bypassed' without the user having to change any connections.

== Model Theory ==

The Solids Recovery Unit is based on user defined variables that define the solids / liquids split.

There are three Recovery methods available in this model:
# Grade & Recovery - The user sets the recovery and grade of the Primary Solid/Element in the concentrate stream.  Primary compounds are always solid species.  
#* The Primary compound/s may defined by either be a specific solid species or an element.  
#* If the user selects ''Elemental'', then:
#*: The user must select a Primary element.  (The recovery and grade will be based on this element.)
#*: The user may also select a Secondary element
#*: The user may then select an element to Exclude from the recovered species.
#*: The species to be recovered '''must''' contain both the Primary and Secondary elements, but '''Not''' the Excluded element.  See the example below. 
#* The user may also specify the grade or recovery of up to 25 additional solid species in the concentrate stream.
# Mass Pull & Recovery - This similar to the Grade and Recovery method where the user sets recovery of the primary solid species or element. But instead of setting the grade of the primary solid species or element, the user sets the mass pull, i.e. the fraction of all solid species which report to the concentrate stream.
#* The user may also specify the grade or recovery of up to 25 additional solid species in the concentrate stream.
# Size Recovery - this is only applicable if the user has size distribution enabled in the project and the solids in the feed to the solids recovery unit have size distributions.  The user then sets the recovery to the concentrate in each individual size fraction for each solid species.

There are also four Concentrate Liquid Split methods available in this model:
# Follow Solids - The split of liquids will be the same as the split of solids. This means that the liquid fraction in the outlet streams will be the same as the feed stream.
# Fraction of Feed Liquids - The user sets the fraction of liquid in the feed that will report to the product stream (Concentrate or Middlings).  
# Liquid in Product - The user sets the required fraction of liquid in the product stream (Concentrate or Middlings).
# Solids in Product - The user sets the required fraction of solids in the product stream (Concentrate or Middlings).

'''Example of Grade & Recovery - Elemental Recovery Method'''

The following example assumes that the only product streams are Concentrate and Tailings as a Middlings stream has not been connected.

The feed stream to the solids recovery unit contains the following solid species:<br>
: Cu<sub>2</sub>S(s), Cu<sub>5</sub>FeS<sub>4</sub>(s), CuFeS<sub>2</sub>(s), CuO(s), Cu<sub>2</sub>O(s), SiO<sub>2</sub>(s), CoO(s) and Ore(s)

The user sets the following:
:* The ''Primary'' element = Cu
:* The ''Secondary'' element = S
:* The ''Exclude'' element = O
:* The ''Recovery'' = 50% and ''Grade'' = 65%.

Then the model will recover to the concentrate 50% of all solid species containing both Cu and S, but not O:
: Cu<sub>2</sub>S(s), Cu<sub>5</sub>FeS<sub>4</sub>(s), CuFeS<sub>2</sub>(s) will be classified as ''Primary'' species.

The remaining solids species will mainly be sent to the tailings, with sufficient material to the concentrate to ensure a grade of 65% Cu in the concentrate.

== Flowchart ==

The following shows the sequence of events in the model evaluation.

[[Image:Solids Recovery Diagram.png]]

<nowiki>*</nowiki> The second split only occurs if the Middlings stream has been connected, otherwise the feed material is split into Vent (if connected), Concentrate and Tailings streams.

== Data Sections ==

=== Summary of Data Sections ===

# '''[[#Solids Recovery Page|Solids Recovery]]''' tab - Contains general information relating to the unit including Evaluation Block settings.
# '''[[Phase Change (PC)|PC]]''' - Optional tab that is visible if EB.Solubility.On and/or EB.PhaseChange@T.On is enabled on the first tab.
# '''[[RB]]''' - Optional tab, only visible if the Reactions are enabled in the Evaluation Block.
# '''[[EHX]]''' - Optional tab, only visible if the EnvironHX is enabled in the Evaluation Block.
# '''[[Evap]]''' - Optional tab that is visible if Evaporator is enabled.
# '''[[MU]]''' - Optional tab, or multiple tabs if more than 1 Makeup is selected.  Only visible if one or more Makeups are enabled in the Evaluation Block.
# '''[[DB]]''' - Optional tab, or multiple tabs if more than 1 Discard Block is selected.  Only visible if one of more Discard Blocks are enabled in the Evaluation Block.
# '''[[#Concentrate Page|Concentrate]]''' - Allows configuration of split to Concentrate stream.
# '''[[#Middlings Page|Middlings]]''' - Optional tab, only visible if the Middlings stream outlet has been connected. Allows configuration of split to Middlings Stream.
#{{ShowQout|Feed|Combined Feed}}
#{{ShowQout|MidsFeed|Feed to Middlings}}
#{{ShowQout|Concentrate}}
#{{ShowQout|Middlings}}
#{{ShowQout|Tailings}}
# '''[[Common Data Sections#Common Data on Info Tab Page|Info]]''' tab - Contains general settings for the unit and allows the user to include documentation about the unit and create Hyperlinks to external documents.
# '''[[Links Table|Links]]''' tab, contains a summary table for all the input and output streams. 
# '''[[Audit]]''' tab - Contains summary information required for Mass and Energy balance. See [[Model Examples]] for enthalpy calculation Examples.

===Solids Recovery Page===
'''Unit Type: SolidsRecovery''' - The first tab page in the access window will have this name.

{|   border="1" cellpadding="5" cellspacing="0" 
|Width=150|'''Tag (Long/Short)'''||Width=140|'''Input / Calc'''||'''Description/Calculated Variables / Options'''
|-
{{Common Data on First Tab Page}}
|-
|  colspan="3" font style="background: #ebebeb"    |

==== Requirements ====
|-
| On || Tickbox || If the model is switched off then no separation occurs and all the feed is sent to the tailings stream. If any vapour is present it is sent to the vent stream if it exists, otherwise it is also sent to the tailings stream.
|-
| MassFracToTails_WhenOff / MassFracToTails|| Input || This field is only visible if the ''On'' tickbox is NOT ticked.  This field allows the user to specify the fraction of the incoming streams that will flow to the tailings outlet when the unit is disabled. The remainder will be sent to the Concentrate outlet. No material will be sent to the middlings outlet.
|-
| ShowQFeed || Tick Box || QFeed and associated tab pages (e.g. Sp) will become visible, showing the properties of the combined feed stream. See [[Material Flow Section]]. This will be prior to any sub-model (e.g. reactions) actions.
|-
| ShowQMidsFeed || Tick Box || Only visible if the Middlings stream outlet has been connected. QMidsFeed and associated tab pages (e.g. Sp) will become visible, showing the properties of the stream after the concentrate stream has been removed, but prior to the splitting of the middlings and tailings streams.  See [[Material Flow Section]].
|-
| TrackStatus ||Tickbox || Enable warning messages if requirements are not met.
{{OperatingP}}
|-
|  colspan="3" font style="background: #ebebeb"    |

==== EB (Evaluation Block) ====
{{EB Evaluation Data Section | Makeups = Yes | Reactions = Yes | EnvironHX = Yes | Evaporation = Yes | Discard = Yes}}
|-
|  colspan="3" font style="background: #ebebeb"    |

=== Options===
|-
{{ShowQout DataSection|Feed | Combined Feed}}
{{ShowQout DataSection|MidsFeed | Feed to Middlings}}
{{ShowQout DataSection|Concentrate}}
{{ShowQout DataSection|Middlings}}
{{ShowQout DataSection|Tailings}}
|-
|  colspan="3" font style="background: #ebebeb"    |

==== Results ====
|-
|  colspan="3" font style="background: #ebebeb"    | The following table displays the flows and compositions of the Feed, Concentrate (Cons), Middlings (Mids) (if connected) and Tailings (Tails) streams. '''Note:''' These are for slurry only, vapours are excluded.
|-
| MassFlow / Qm || font style="background: #ebebeb" | Calc|| The total mass flow of the stream (excluding vapours).
|-
| VolFlow / Qv || font style="background: #ebebeb" | Calc|| The total volume flow of the stream (excluding vapours).
|-
| SolidMassFlow / SQm || font style="background: #ebebeb" | Calc|| The solids mass flow of the stream.
|-
| LiquidMassFlow / LQm || font style="background: #ebebeb" | Calc|| The liquid mass flow of the stream.
|-
| SolidFrac / Sf || font style="background: #ebebeb" | Calc|| The solid fraction of the stream (excluding vapours).
|-
| LiquidFrac / Lf || font style="background: #ebebeb" | Calc|| The liquid fraction of the stream (excluding vapours).
|-
| Temperature / T || font style="background: #ebebeb" | Calc|| The temperature of the stream.
|-
| Density / Rho || font style="background: #ebebeb" | Calc|| The total density of the stream (excluding vapours).
|-
| SolidConc || font style="background: #ebebeb" | Calc|| The solid concentration (mass of solids/density of slurry) of the stream.
|-
| SolidConc25 || font style="background: #ebebeb" | Calc || The solid concentration at 25°C (mass of solids/density of slurry at 25°C) of the stream.
|-
|GridDisplay || Tick Box || This is a global selection, if this is selected, then where available, variables will display in a table format, if not selected, they will be listed in separate groups as a single list. 
|}

===Concentrate Page===

Allows configuration of split to Concentrate stream.

*If the Middlings outlet has NOT been connected, all material not sent to the Concentrate stream will be sent to the Tailings stream.

*If the Middlings stream outlet HAS been connected then all material not sent to the Concentrate stream will be sent to the Other stream. The split of the Other stream between the Middlings stream and Tailings stream will defined on the [[#Middlings Page|Middlings Page]].

{{Solids Recovery Data Section| Tag=Concentrate | Name= concentrate}}

===Middlings Page===

This page is only visible if the Middlings stream outlet has been connected.

Allows configuration of split to Middlings stream. All material not sent to the Middlings stream will be sent to the Tailings stream. 

{{Solids Recovery Data Section| Tag=Middlings | Name= middlings }}

=== Recovery Section ===

If the user selects '''Size Recovery''' as the Recovery Method (in [[#Concentrate Page|Concentrate]] or [[#Middlings Page|Middlings]]), then the '''Recovery''' table will be visible.  This table display the size intervals for all solids species in the project which has its own size distribution.  The user must enter the recovery for each size interval, as shown below:

:{|
|-
| (PSD in Descending Order)  
|-
|[[Image:SolidsRecoverySizeRec138.png]]
|}

In the example shown above, the flotation cell is used to recover Fe3O4 species as can be seen by the higher recoveries specified for this species.  The other species are gangue solids that is recovered to the concentrate in smaller fractions.

== Adding this Model to a Project ==

{{Adding Model to a Project | DllName=Separation | DllSubGroup=Separation | UnitOp=Solids Recovery | Group=Mass Separation}}

== Hints and Comments ==

# If there are some solids species which the user does not want to send to the product stream (concentrate or middlings) at all, then include them as additional solid species with a recovery of 0%.
# It is possible to over-specify the problem, i.e. if the user sets Additional Solid Species to recover to the product, this may prevent the Required Grade or Mass Pull from being met.
#::'''Note:''' The Required Recovery will always be achieved, but the Grade/Mass Pull do depend on feed conditions and the user defined parameters.
# If the Size Recovery Method is selected and there is no PSD Quality data in the feed then the model does not perform any calculations and behaves as if it was off.
# If there is no vent stream, all vapours will be sent to the concentrate stream.
# The user cannot choose the same species as both a primary solid species and an additional solid species or twice as an additional solid species. In either of these cases the model will not run and the user will be given an error message.

== Example Project ==

Please see [[Example_-_04SizeDistribution_Projects#Milling_and_Magnetic_Separation_Project|Milling and Magnetic Separation Project]].