# What's New and Changed

## New Models

New Unit Model:

• Solids Recovery Unit : The Solids Recovery Unit can be used to model a variety of solid recovery processes including flotation, magnetic separation and spirals.
• Similar in functionality to the Flotation Cell, the model requires the user to define the primary species or element that is recovered to the concentrate and middlings streams (if connected).
• The user may then specify the recovery and grade or mass pull of the primary species/element.
• The recoveries of secondary species may also be defined by the user.
• Alternatively, the model can be used with PSD and the user can set the recovery to concentrate/middlings of each solid species with a size distribution in each size interval.

New Sub-Model:

## Model Improvements

### Significant Unit Model Improvements

• Feeder - New Operation modes greatly simplifying the use of feeders:
• The simplified modes will remove various options that are not applicable to the selected Operation as well as reducing the species visible on the DSp tab, making it easier to input parameters including stream composition.
For example, if the operating mode is *Liquids*, then Solids and Gases species will be not be displayed in the DSp tab; or if the operating mode is *Steam* then the user does not need to specify the composition it is automatically always steam.
• The new operating modes simplify data entry, reduces complexity of user options shown in the Access window and reduces possibility of incorrect data entry. The General Operation mode retains the full functionality and flexibility.
• The new Operation modes work with Demand functionality. For example using the Link to MakeupSrc Operation mode will allow user to use makeup and demand together as described in this example.
• Where a feeder was used with makeup block to provide the feeder can be simplified significantly with use of Operation mode MakeupSrc Fetch or Link to MakeupSrc with added advantage of being able to use Demand functionality.
• Solvent Extraction - New Method and options:
• Added new Isotherm2 method designed to replace original Isotherm method to better handle user specified McCabe-Thiele phase equilibrium data. See example on how to set up the isotherm.
• Added method to allow user to selectively define which species is included in the elemental concentration count. For example, user can select Fe2+ only, not total Fe. See Example on how to set up and use user defined species with isotherm.
• Added environmental heat loss to the unit.
• Added option for user to load or save the isotherm data.
• Simple Heat Exchanger - Other side - New Approach option for demand calculation.
• The Simple Heat Exchanger now provides feedback for "Hot side", and shows the HotSide and Cold Side approach temperature calculations.
• See Example on how to configure the model using the new approach method.

### Model Enhancements:

• Belt Filter: Added option for user to load or save the wash loss data. Also added example to estimate a wash loss curve based on Simple Filtration Wash Efficiency.
• Feeder: New option (ConnectBlocked) to exclude feeders from crosspage connection list simplifying the workflow for connecting feeders across graphics pages. At the same time marking the feeders as model material inputs or outputs.
• FEM Reactor: New display options for analysis. Improved messages and information for failed convergence. Miscellaneous solver improvements for different conditions.
• Flash Tank: Improve error reporting in the case of a Flash Tank receiving feed with a saturation pressure too high.
• Flash Train Control: This Dynamic mode controller now takes into account heat of reaction in associated shell and tube models.
• Precipitator3: Additional growth rate tuning factor. New option to include Nucleation yield in bound soda calcualtions. New options for dynamic for managing changes in tank volume or contents.
• Makeup Block: new selections for Solids Species, Liquid Species and Vapour Species and better ranging of inputs.
• Unit models with feed Makeup Block now allow the makeup to be the only source of material to the unit.

## User interface

• Added new fields on PlantModel - Project tab page for data entry:
• This allows the user to enter information about the project. It also provides placeholder for two external links, for example, user can add in the hyperlink of a document (in the DescLink field) that would help describe the project. This could be a full web address or a full path of a file on the network or a file on the local computer.
• If a hyperlink points to a web address, then user can click on icon next to the hyperlink to open the web page.
• The hyperlink provided in the DescLink field is tied-in with new menu command View - Project Description.
• This menu command will activate the hyperlink (or other document name with a full path).
• This command can also be activated from graphics page right click context menu
• For distributed SysCAD example projects, this command will open the example project description page on SysCAD Help wiki.
• Added new Menu Command: Help - Example Projects - This command will open the Example Projects page on SysCAD Help wiki.
• Added option to Include All model - for improved usability when selecting unit models from model library dlls:
• For Edit Configuration - Model_Selection step, added new option to always Include All Unit Models for selected dll. This option will include all unit models in dlls which already have at least one model selected. All current (and future) unit models for a dll are then always available.
• For Insert Unit and Change Unit, added "Show All" to allow display of all unit models in dlls. This eliminates the need to close and exit SysCAD, edit the configuration file to include the required model, then re-open the project.
• Expanded Elemental flows section on the EC page to include variables on an Individual Phase basis. This includes:
• Mass Flow/Fraction
• Mole Flow/Fraction
• Mass Concentration (Conc and Conc25)
• Molar Concentration (Mole Conc and Mole Conc25)
• Added new filter criteria for Species Filter
• Expanded species display filter to display species with the largest flows.
• User can filter to show a specified number of species with the largest flows or specify minimum mass fraction.
• New option to copy "partial" unit group tag, for example: P_001.Qo, Tank1.QFeed
• Right click on Access window tab page title has a new context menu to copy the tag providing a convenient way of copying and pasting tags for use in referenced models. This would be the model tag for the first tab page, and the sub-model (eq Qo) for subsequent pages. See Copy Access Window Tab name for more information.
• In Access window Ctrl+C or right click on start of a group of tags (eg Qo...; QFeed...) can now be used to copy the tag for the group. See Copy Access Window group name for more information.
• New Copy Full Tag for PGM, eg: ["P_001.Qo.Qm (t/h)"]
• Right click on an access window tag and select "Copy Tag for PGM" will copy the full tag with the PGM Tag Function syntax already in place. User can use the tag directly inside the PGM file without having to add the [" "] syntax separately.
• New Mouse Action Defaults : Changed Menu command Options | General Options | Mouse Tab | Default2 Mouse Actions
• Double Left Click - opens the Access Window
• Right Click - pop up menu
• Shift + Left Click - Find Connected units (eg cross page connector)
• Improved copy & paste for nested and referenced tags
• Tear simplification. The previous separate Tb_Flange (Tear Block) and Flange (SubClass Tear) associated with a recycle tear have been combined into a single Tear model.
• So there is now a single Access window with all information related to individual Tears in the flowsheet.
• The Flange associated with the stream tear still exists but is now part of the Tear object.
• The new single Tear object is is now directly associated with the tear symbol on the graphics and reporting of tear variables during convergence. The corresponding table of TearTags in Solver Settings has been simplified.
• Add new variables FullDateAndTime and FullDate to View|PlantModelSystem Tab. For excel reports, these tags will export the correct date to match regional date formats.

The following new Add-ons all relate to flexible integration in SysCAD plant models of third party software performing detailed equilibrium and thermodynamic property calculations. The direct integration of these specialist software programs in SysCAD provide a significant range of new and detailed applications in the SysCAD flowsheet simulator for a range of pyromet, hydromet and aqueous chemistry systems. These are currently in BETA. Please contact us for demonstrations or further information.

See PHREEQC Add-On (currently in BETA) for a description of this new add-on. PHREEQC is a computer program that is designed to perform a wide variety of aqueous geochemical calculations. It is developed and maintained by the United States Geological Survey www.usgs.gov/software/phreeqc. PHREEQC unit models:

• PHREEQC Model Configuration - Used to define and view various options for the selected PHREEQC database, including management of mapping of SysCAD species list to species list used in PHREEQC.
• PHREEQC Direct Calc Model - Stand alone unit model to perform side calculations using PHREEQC for predicting aqueous chemistry equilibrium conditions and properties including pH on a user defined PHREEQC stream.
• PHREEQC Side Calc Model - Stand alone unit model to perform side calculations using PHREEQC for predicting aqueous chemistry equilibrium conditions and properties including pH on a SysCAD stream in the current project.
• PHREEQC Reactor - Include this model in a SysCAD stream to use PHREEQC to calculate predicted outlet conditions. Functionality is similar to SysCAD Reaction Block and FEM where for a given feed reactions occur with optional heat exchange. The model can be configured in a number of ways for different purposes.

See ChemApp Add-On (currently in BETA) for a description of this new add-on. ChemApp is a computer program for thermodynamic phase equilibrium calculation primarily in pyrometallurgy using ChemApp and FactSage. It permits the calculation of complex, multicomponent, multiphase chemical equilibria and their associated extensive property balances. ChemApp [1] is developed and maintained by GTT-Technologies [2]. FACTSage [3] is by CRCT ThermFact Inc [4] and GTT-Technologies [5]. ChemApp unit models:

• ChemApp Model Configuration - Used to define and view various options for the selected ChemApp FactSage database, including management of mapping of SysCAD species list to species list used in ChemApp.
• ChemApp Direct Calc Model - Stand alone unit model to perform side calculations using ChemApp for predicting chemistry equilibrium conditions and properties on a user defined ChemApp stream.
• ChemApp Side Calc Model - Stand alone unit model to perform side calculations using ChamApp for predicting chemistry equilibrium conditions and properties including on a SysCAD stream in the current project.
• ChemApp Reactor - Include this model in a SysCAD stream to use ChemApp to calculate predicted outlet conditions. Functionality is similar to SysCAD Reaction Block and FEM where for a given feed reactions occur. The model can be configured in a number of ways for different purposes.

See AQSol Add-On (currently in BETA) for a description of this new add-on. The AQSol program can be used for general phase equilibrium calculations for aqueous solutions. It is developed and maintained by Aqueous Solutions ApS, Søborg, Denmark www.phasediagram.dk. AQSol unit models:

• AQSol Model Configuration - Used to define and view various options for the selected AQSol database, including management of mapping of SysCAD species list to species list used in AQSol.
• AQSol Direct Calc Model - Stand alone unit model to perform side calculations using AQSol for predicting aqueous chemistry equilibrium conditions and properties on a user defined AQSol stream.
• AQSol Side Calc Model - Stand alone unit model to perform side calculations using AQSol for predicting aqueous chemistry equilibrium conditions and properties on a SysCAD stream in the current project.
• AQSol Reactor - Include this model in a SysCAD stream to use AQSol to calculate predicted outlet conditions. Functionality is similar to SysCAD Reaction Block and FEM where for a given feed reactions occur with optional heat exchange. The model can be configured in a number of ways for different purposes.

## Other Improvements

• Increased limit on number of Individual Phases allowed from 32 to 250.
• New Specific Heat equation NASAGlenn_Cp equation available for species database properties.
• Additional tests and warnings during project load for inconsistent Entropy data for species based on user specified S25 and Cp equation.
• Option in the Edit Configuration step 2 to perform entropy data check on project load.
• Additional columns in the $SDB -Thermo1 and$SDB -Thermo2 tabs for H25 and S25 values. Warnings will be given for species with missing H25 and S25 data.
• Added Gibbs Free Energy to stream display under Entropy section.
• Implemented support for larger numbers of species with PSD in projects.
• Potash Properties Utility utility updated with 64 bit version now available.

## Tutorial & Examples

• Updated Tutorial documentation. Please see Tutorial in the Help documentation.
• Example Projects distributed with SysCAD have been updated, including some new Example projects.

## "Under the Hood" Changes

• Reduced memory use for projects allowing even larger projects with more species.
• Moved Belt Filter, Solvent Extraction Unit and Washer from Separ1.dll to Separation.dll.
• Compiled with Microsoft C++ 2017 making use of new features available in C++ and the standard library.
• Significantly enhanced SMDK (SysCAD Model Developers Kit). Expanded list of helper classes and new methods for existing classes.
• Various general and solver speed improvements.

## Changes that may Affect Results

• Thermocompressor model improvements:
• 1D Model - S&K Data - method has been improved by using excess energy to either superheat or condense steam. In most cases this will result in a reduced heatflow and may change the final product temperature.
• Full Steam 1D Model - method has been improved by using excess energy to either superheat or condense steam. In most cases this will result in a reduced heatflow and may change final product temperature and pressure.
• HeatFlow - sign reversed to correctly report Energy Out - Energy In.
• Precipitator3 - Bound Soda calculations correction for Hunter and Fixed% methods.
• Existing projects will retain old calculation methods (and results).
• User would need to tick the option "UseCorrectedBoundSoda" (local to each precipitator unit) to upgrade to the new calculation methods.
• User would need to retune the bound soda factors to re-align the bound soda precipitation values.
• Preciptitator3 - Agglomeration Cutoff fix in Steady State
• This applies to users using Precipitator3 in with PSD Method and Agglom.Cutoff option only.
• Existing projects will retain the original results if no action is taken.
• User would need to tick the "Agglom.UseCorrectedCutoff" option, (local to each precipitator unit) to upgrade to the new calculation methods.
• User would need to check the results and retune as required.
• This will give a correct size distribution curve and also ensures that the model gives the same results as Dynamic projects with the same parameters when run to steady state. See Preciptitator3 for sample results comparison.
• Project using species with missing S25 data may find the stream entropy value may have changed. Species with missing S25 data will be assumed to have value of 0 at 0°C.

## Project Upgrade and Tag Changes

• Thermocompressor tag changes:
Method is now Model
Entrainment.Method is no longer a valid tag. Similar new tag is Method.
Prm.DemandConnection is no longer a valid tag. Similar new tag is Demand.Connection.
EntRatioReqd, AreaRatio, EntRatio, ExpRatio and CompRatio are now dimensionless (previously were fractions).
• Makeup Block changes:
• Selection of elements is now limited to elements which are present in species in the project (instead of complete list). If some elements were previously selected which are not present in the project, the user will receive a warning on load and it will appear as a blank selection in the makeup block configuration.
• Tag changes:
For Product Concentration @25 Model: All tags ending in Conc now end in Conc25.
For Product Molar Concentration Model: All tags ending in ConcMl now end in MlConc.
For Product Molar Concentration @25 Model: All tags ending in ConcMl now end in MlConc25.
• Project will be auto-upgraded to use the new "Tear" formats.