Steady-State Modelling

The starting point for flowsheet selection and process design

We offer steady-state modelling of mineral processing and hydrometallurgical flowsheets in METSIM®, used under licence. Typical processes modelled include comminution, flotation, leaching, solid-liquid separation, precious metal recovery, base-metal solution purification and recovery, reagent regeneration and effluent treatment.

The steady-state mass and energy balance is the basis for all process design and evaluation work, since after all the intention for any plant is to operate at a more-or-less constant rate. For well-understood processes the application of design factors to steady-state flowrates enables equipment to be sized to accommodate likely deviations from this ideal. Less well-understood processes should also be dynamically simulated in a range of scenarios to ensure adequate safety and operating margins are included.

What is Steady-State Modelling?

Steady-state process modelling is the modelling of a chemical process flowsheet with all inputs (feed flowrates, feed stream compositions, process set-points, etc.) held constant in time. Solving this model for conservation of mass and energy provides a steady-state solution for the mass flowrate, chemical composition, temperature and pressure of every stream in the flowsheet.

The level of detail to which a flowsheet is modelled depends on client requirements and is generally related to the level of testwork and engineering undertaken to-date. A flowsheet at concept level can be modelled very quickly and will provide high-level information on major flowrates, water balance, production rates and reagent consumption rates. This data can be quickly linked to client-side economic models allowing rapid evaluation of process options in the early stages of flowsheet selection. A flowsheet at design level will be modelled down to individual service lines (eg gland water to slurry pumps) and must be modelled in a dedicated application capable of handling complex chemistry and hundreds of streams.

We offer steady-state modelling in METSIM®, used under licence. METSIM® is suited to steady-state modelling of complex metallurgical flowsheets and chemistry and is commonly used by the minerals industry. We have been offering our steady-state METSIM® modelling service since 2006.

We are expert users of Microsoft Excel, including VBA programming, and are happy to undertake modelling of simple flowsheets in this environment if preferred by the client.

We combine real-world process experience with specialised mathematical tools to facilitate robust process design.
Director & Principal Engineer, Oliver Kloiber-Deane BEng(Chem) MSc(Math)

Our Services

Steady-State Modelling Dynamic Modelling & Simulation Process Optimisation Operability Studies

Further Info

Fidelity

The degree of fidelity to reality required of a model should be judged carefully: the solution must be sufficiently accurate to correctly answer the questions posed without wasting time modelling features that have no significant impact on outcomes. For this reason process models built over the life of a project typically range from very simple at the desktop-study stage to highly detailed at the engineering and commissioning stages. Models may then continue to be evolved during plant operation in order to optimise the process for new feed-stock, de-bottleneck for greater throughput, etc.

Workflow

Close communication with our client and adherence to client specification documents (process design criteria, process flow diagrams, control philosophy, etc) is our standard approach. Client input is typically required on a range of issues throughout a modelling project. For example process modelling during a flow-sheet development stage often uncovers issues in the process design that had not yet been considered by the design team - commonly water balance, impurities build-up and related effluent treatment issues for hydrometallurgical flow-sheets.

We also find that a period of time spent in the same physical location as the client in the early stages of modelling a complex flowsheet can speed up delivery by removing communication delays.

Deliverables

Our typical deliverable is an electronic file containing process simulation output data and a report that illustrates the model flow-sheet; demonstrates the model's fidelity to the client's design criteria; lists and justifies any assumptions made; and provides a brief analysis of outcomes. If necessary a section will also illustrate any process risks and sensitivities that may have been uncovered. We are also happy to supply the live model files which thereafter allows the client to view and modify the models themselves.

Pricing

Please contact us with details of your job for an obligation-free discussion and a competitive quote. For a well-defined scope of work we are happy to offer a fixed price.

Contact Us

Please contact us for an obligation-free discussion of your needs.

PO Box 3354 Newmarket QLD Australia
info@elementrescon.com.au
+61 (0)408 949 793
elementrescon.com.au