Introduction To METSIM

1.0 SOFTWARE INSTALLATION

METSIM for Windows is either downloaded form the METSIM web site or from CD. The web
site contains the latest version of the software.

1.1 Download from Web Site

To download use the following instructions:

ftp://www.metsim.com/pub/METSIM1704.zip

Unzip the file to create a METSIM executable file.

Note: METSIM Versions are defined as follows

The first two digits define the year 16 is 2008, 17 will be 2009 an so on. The second two digits
relate to the month of issue 01 = January, 02 = February, 03 = March to 12 = December.

1.2 Installing METSIM

Insert CD in the CD drive

In Windows, go to START, then RUN.
Choose CD drive and Browse.
Select METSIM.EXE and run it.
Follow the installation instructions.
METSIM will be loaded automatically.

Install the USB Key on a USB port.

1) Download: ftp://www.metsim.com/pub/METSIM1704.zip
Or Insert CD in the CD drive
In Windows, go to START, then RUN.
Choose CD drive and Browse.
2) Run: METSIM1704.exe
3) Download: ftp://www.metsim.com/pub/Black USB Driver.zip
Or from the CD
4) Run: Black USB Driver.exe
5) Copy: “SentinelKeyW.dll” to C:/METSIM directory.
6) Install: Black USB Key
7) Wait for: USB Key to be located and activated.
8) Run; METSIM from Start Menu/Programs/METSIM

On completion of installation, the program can be run using the METSIM icon located in the
programs list. On initiation, the user license details appear on the screen, with expiration date
for Maintenance. Once this is acknowledged the METSIM Screen Interface appears. If the
security key is not installed or functioning properly, the program will revert to a demo version.
The Screen Interface has Drop Down Menus and Task Bar Buttons along the top, a palette for
entering the flowsheet and unit operation module Screen Object buttons down the right side of
the palette. As METSIM is a typical windows program, the Mouse is used to access and initiate
menus and routines.
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Note if the license date code is earlier than the current version on the web site or CD, the
user will not be given access to the program and it will default to demo mode.

To re-install METSIM first uninstall the program using the WINDOWS – Add/Remove
program routine located under Settings – Control Panel. Then follow the instructions above.

2 SCREEN INTERFACE

On OK in the METSIM message window the METSIM Main Interface Screen appears.
The screen displays Drop down Menus and Task bar Buttons along the top, a drawing area or
palette to enter the flowsheet and unit operation and controller buttons down the right side
of the palette area.

2.1 Drop down Menus

The drop down menus contains programs used to create, build, develop, analyse and save
flowsheet models i.e.:

Files Handling
Setup parameters for Flowsheet palette
Input setup for selection and definition of flowsheet options
Components routines for building, editing model component lists.
Weather data input for solar ponds and heap leaching
Heap Leaching Option routines
Merge for merging flowsheets routines
Calc Model calculation and calculation checks options
Display for model stream displays and spreadsheets
Cost routines for operating cost options
Graphics for graphic routines
Equip List for generating equipment lists and specifications
Output to output model stream data to screen and printer
Tools routines for model analysis
New highlights latest METSIM developments
Help to access METSIM online help programme

2.2 Task Buttons

In addition, immediately below the menus, there are a series of task buttons for the most
common tasks used in drawing and manipulating the model flowsheet to facilitate rapid model
development.

The task bar and table provide direct access to the data programs, unit operation, streams, and
controllers used to construct a METSIM process model.

There are five groups of Task Bar buttons used for:

Loading and saving models from file, setting up models and printing model flowsheets
Manipulating and editing model flowsheets
Calculating unit operations and flowsheets
Displaying model data
Tools for calculation model parameters and interfacing models to other windows
applications

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2.3 Palette Area

The palette area enables the user to draw and edit flowsheets directly on the screen in graphic
form.

2.4 Module Buttons

Module Buttons give access to groups of unit operations supplied with METSIM modules for
the following types of flowsheets:

GEN - General Mass Balance

MIN - Mining
MTL - Materials Handling
COM - Comminution
BEN - Beneficiation and Gravity Separation
HYD - Hydrometallurgical
HBS - Pyrometallurgical
GAS - Gas Handling
MIS - Miscellaneous
CTL - Process Controls

Unit Operation Icons provide easy access to each of the unit operation, stream and controller
construction blocks, which are used to build the process model. Any of these items may be
dragged by the mouse onto the process flowsheet and connected to the existing model.

MODEL BUILDING AND EDITING

The following abbreviations are used to simplify the mouse movements and actions used in
building and editing model flowsheets

Mouse Button Actions and Abbreviations are:

MOUSE BUTTON ACTION ABBREVIATION TYPICAL USE

Press left button and release Open drop down menu,
PL activate interface button,
edit palette object
Press right button and release To drop output streams
PR
finishing points on palette
Press left button and hold down Drag object to new location
LD and release to drop on
palette
Press right button and hold down Drag object to new location
RD and release to drop on
palette

3.1 Initial Build

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On initiation METSIM using the New Model task bar button, the programme automatically sets
the first section of a flowsheet. The user can add further sections via the SECTION ICON in
the GEN unit operation module list.

Selection and Placement of Unit Operation Icons

To place unit operation icons on the palette, first select and activate a unit operation Module
button PL, select the required unit operation module icon and activate PL, then position the
icon on the palette and drop icon PL. Repeat selection and placement of all unit operations on
palette.

Note: unit operation icons are displayed with circles or nodes showing inlet and outlet
stream connecting points. White circles are for input streams and yellow circles are for
output streams. Also unit operations are calculated in the order of placement on the
palette.

Connection and Editing Unit Operation Input, Interconnecting and Output Flow Streams

To enter a flow streams, activate PL the GEN unit operation module butt, and activate PL the
STR icon. To place an input stream move the icon to a location on the palette where stream
starts PL. The message, Enter New Stream Number appears, and METSIM displays the next
available number. This can be accepted or another number entered. On exiting (OK), a white
start circle appears showing the stream start point. By moving the mouse cursor either placing
the mouse cursor vertically above or below the start point or horizontally to the right PL the first
section of the stream route will appear on the screen. This point is also the first change in
direction point for the stream route as placement of the cursor above or below or horizontally to
the right and PL will draw in the second section of the route. The procedure is repeated for
further changes in direction. The stream route will be displayed as a white line. To connect to a
unit operation locate the cursor over a suitable input node to the unit operation icon and PL will
connect the stream to the unit operation. The stream color will change to dark red indicating an
empty stream i.e. no material flow

Note: The stream icon does not have to be reactivated after entry of each stream. Stream
entry and placement mode remains active until another activity is activated such as
selection of a unit operation as described above,

Further input streams can be entered by repeating the procedure. To enter connecting or output
streams, place the mouse cursor over an exit node from the selected unit operation icon PL.
The message, Enter New Stream Number appears and on exiting OK route the stream as
described above and connect the stream to an input node on the selected unit operation icon. For
output streams the finish point is determined when the mouse right button is activated PR.

3.2 Flowsheet Editing

Unit operation icons are edited and moved on the palette by the Task bar buttons:

Reverse Unit Op – reverses an icon around the vertical axis,

Change Object Size - is used to resize icons.
Move Object allows unit operations to be relocated on the palette.

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On activation of any of the buttons a unit operation is selected by locating mouse cursor at the
lower left corner of the icon PL. In the case of Move the unit operation icon color changes to
Violet, to indicate it is being moved. Move the icon LD and drag and drop it at its new position
on the palette. Connecting streams will be re-routed by the program. To modify the routing of
a stream, activate the required stream by locating the mouse over the steam number. The
stream route will appear in Violet. The first active section will appear as flashing color. The user
can drag the stream to the first change in direction PL and so forth to the last change in
direction, and RD will either terminate an output stream or attach an interconnecting steam to
complete the activity. The stream color will return to normal.

Note: Change in direction points are added by PL and changes in direction and stream
disengagements by RD.

Sometimes a combination of relocating the unit operation, centring the screen and adjusting the
stream changes in direction is needed to achieve the final desired route.

Deletion of unit operations and streams is achieved by activating the Delete Object button X
PL followed by selecting the unit operation or stream number PL and confirming the selection
message Delete Unit Operation Number or Delete Stream Number.

Input of additional streams is achieved as described for new streams above

3.3 Editing Screen Objects Data

Activate the Edit Object Data button on the task bar. Select the unit operation icon by locating
the cursor at bottom left corner PL, unit operation changes to violet and input data screen
appears. Make changes and exit via OK or Cancel to palette. To edit stream locate the mouse
cursor at stream number PL, edit and exit via OK or cancel. Repeat as required for other unit
operations and streams.

4 DIRECTORIES, SUB-DIRECTORIES AND FILES

When METSIM has been installed on the hard disk of the computer, a METSIM directory is
created and the program and all data files are stored either in this directory or in a series of sub-
directories.

4.1 METSIM Directory

The METSIM directory contains the following files:

File Type Description
Install LOG File Log of selections on installation
Metsim adf APL Definition File
Metsim Application APL + Win runtime System. The
METSIM program
Metsim Help File All METSIM online HELP
Metsim Icon METSIM Screen Icon
Metsim W3 File METSIM APL Program files
Uninst Application Uninstall program for METSIM
Unwise Application Uninstall program for WISE

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4.1.1 METSIM Directory Sub-Directories

DBF contains about 100 thermodynamic database files as METDBxx.SF, where xx

is the element symbol. Components are stored in file with the highest element
Number first.

ICONS contains all METSIM screen objects Icons

MET contains the following METSIM operating files:

METCOST.sf METCOST Data File

METEQL.sf Equipment List File
METMAC.SF File containing Licensee configuration for DOS
METMACW.SF File containing Licensee configuration for Windows
METTAB.sf File contain METSIM tabulated data
METWINI.sf Metsim windows initiation file

XXX additional sub-directories can be created to store model files in. The pointer to the
model sub-directory may be changed to any directory on any drive. It should be noted
that these sub-directories should not have further sub-directories, or the file handling will
indicate an error.

MEX contains the current list of examples of flow sheet models supplied with the program e.g.

MWXAP Sulphuric Acid Plant

MWXCC SAG Mill/Ball Mill Comminution Model with Costing
MWXUCIP CIP/CIL Unit Operation
MWXCuHL Copper Heap Leach
MWXDPS Dynamic Pierce Smith Converter
MWXDTNK Dynamic Tank with XCEL DDE Exchange
MWXFC Lead/Zinc Flotation
MWXFF Flash Furnace Smelting
MWXHYL Direct Iron Ore Reduction using HYL Process
MWXNG Nickel Hydrometallurgy
MWXpHCTL pH Control
MWXSMLT Smelter with Sections
MWXSXEW Solvent Extraction and Eletrowinning
MWXAUT Autoclave

4.2 Model Files

A METSIM model is saved in a single file containing all data, graphics, etc.
All models are saved as internal format windows APL component files, (filename.SFW).
After a model is loaded, all of the stored data becomes immediately available.

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In addition to the flowsheet data the METSIM version number that created the file and the date
and time are recorded. When the model is reloaded from file the model data is updated to the
current version of METSIM. The program displays both version numbers.

A note of caution when a new version of the program is released it is prudent to store existing
models with that version on a disk or in a separate directory for security purposes. Then load in
new version of the program and test input /outputs and if there is a problem then one can revert
back to the old version

All data, the flowsheet, all unit operation data, graphics etc. are stored in that single file. When
creating the component database for a model this is also retained in the file so that the program
does not have to go back to the database for information. The component database
automatically updates data in a flowsheet file and hence the program has complete control of all
of its data as it was saved.

5.0 MODEL ARRAYS AND VARIABLES

METSIM stores model in arrays, vectors or scalars see examples in On-line Help.

All data related to unit operations is stored with the unit operation i.e. its operating parameters,
chemical reactions, heat loss/gains, specific controls and operating costs.

The model flowsheet streams mass data is stored in a stream array STR. STR array is two
dimensional, the first dimension being the flowstreams and the second the components. The
data is saved as the mass flowrates of each component in the units of mass/time selected.

STR dimensions are NOS by NOC

NOS is the number of streams NOC is the number of components
NOS and NOC are accessible variables in METSIM

In flowsheets where size analysis data is used the array SSA is used to stores size analysis data.
This is also two-dimensional being number of streams by the number of sizes (NSA) chosen by
the user for his flowsheet

Components are defined by the phases in which they are present, of which there are eight: -

SI - Solids Inorganic
SO - Solids Organic
LI - Liquids Inorganic
LO - Liquids Organic
M1 - usually the metal phase
M2 - usually the matte phase
M3 - usually the slag phase
GC - Gaseous phase

6.0 KEY METSIM DEFINITIONS

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The are several key definitions which are used in METSIM

COMPONENTS mass balance entities such as molecular compounds, pure
elements, pseudo compounds, ions, etc.

PHASES groups of components, which do not physically mix.

STREAMS material flows of components between unit operations.

UNIT OPERATIONS process units where streams merge interact and separate.

MODULES unit operation programs or groups of programs.

MODELS process flowsheets composed of unit operations and streams.

CONTROLLERS programs which adjust variables to meet process criteria.

MASS BALANCE calculated or simulated flows into and out of a process.

MATERIAL BALANCE measured plant data adjusted to give a perfect mass balance

7.0 STEPS TO CREATE A MODEL

The recommended procedure to follow in developing a new flowsheet model is: -

1) Sketch a process flowsheet with all unit operations and streams present.
2) Make a list of all phases present and list all components in each phase.
3) Load METSIM, use New Model button in Task Bar to initialize the model and zero data.
4) Use Model Parameters button in the Task Bar to set the major switches and select the
units of mass and time.
5) Select the component from the database using the DBAS Component Database routine in
the Components Drop Down Menu
6) Edit component data with ICOM Edit Components in Components Drop Down Menu.
7) Build the flowsheet as described in Section 3.
8) Add unit operation data, equipment sizes and separation parameters to the unit operation
modules selected.
9) Add chemistry and heat balance data via the unit operation data input screens.
10) Enter stream names and input stream flowrates composition as described in section 3.3
Editing Screen Objects Data
10) Calculate flowsheet and check results to verify input and mechanisms.
11) Add process controls to adjust parameters to meet design criteria.
12) Add detailed algorithms, minor streams, and trace elements to completion.

8.0 COMPONENTS AND COMPONENT DATABASE

The user can input components into a model and edit model component data, as follows:

ROUTINE Used to Input Components Used to Edit Component Data

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DBAS Component Database Select and Input Only No

ICOM Edit Components Create new Components Edit all Components Data
IUSR Edit User Database No Create and Edit User Database

8.1 Component data Flowsheet

The chart below illustrates the source and movement of component data. Data may be retrieved
from the METSIM database or entered by the user. Model component data may be edited to suit
the application. The model data is always stored with the model to guarantee consistency with
time.
METSIM
Process
Database OCOM Screen
DBAS Flowsheet
METSIM METDBxx.
Add Model
SF Display
FILES
User Data
IUSR In DBF ICOM Componen OIDT Printer
Database t
Edit Print
METDBUS.
Create/Edit IUS2
SF
Database IUS2 Process
File
in DBF Save Save Model
Model Storage
Model File
Load filename.sf
When the component list is assembled components can be deleted w
from the list, re-arranged,
duplicated etc.

Some points on the data stored on components.

Specific gravity data is stored as follows: -

Solids and Gases are single values. It is assumed the gas is an ideal gas. For aqueous and
organic liquids the specific gravity can be entered as a single value. If the user has specific
gravity data the SGF values are left at zero and the program will then allow the user to input
specific gravity data on various strengths of solutions via the routine ISGF Aqueous Specific
Gravity Data in the Components Drop Down Menu. This routine will be automatically called
by the program upon completion of input of components data. The program fits a curve to the
data points entered by the user, and displays the coefficients in the relevant component data.

The program operates as follows: -

First component phase is the solvent e.g. aqueous 1 0 0. Next component is the solute 0 0 0.

If the program detects a zero in the second position of the solute phase it will initiate ISGF at
the appropriate time. The default shape of the Specific gravity concentration curve is a straight
45-degree line.

It is advisable to choose concentrations which cover the expect range in all flowstreams. After
the program has analysed the data and determined the equation the coefficients are displayed on
the screen as follows: -
SGF ( ) SGF ( ) SGF ( )
which are the Constant term, linear term and square term of the quadratic equation relating
specific gravity to percent by weight solute in solvent.

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Heat of formation data is stored in kilocalories per kilogram.

For enthalpy data the coefficients of the curves are given.

Gibbs Free Energy data is stored as the pure Gibbs free energy of the component.

Solubility coefficients are future developments.

8.2 Components and Phases

Components are assigned to the phase in which they are present: -

METSIM METSIM
Component Phase
Variable Number Example components

Solid Components SC Includes SI & SO

Solid Inorganic SI 1 Minerals, Salts
Solid Organic SO 2 Coal, Resin, Carbon
Fluid Components FC Includes LC & GC
Liquid Components LC Includes LI, LO, M1, M2 & M3
Liquid Inorganic LI 3 Water, Acids, Dissolved Salts
Liquid Organic LO 4 Fuel, Kerosene, Organics
Molten 1 M1 5 Molten Metals, Speiss
Molten 2 M2 6 Molten Sulphides, Halides
Molten 3 M3 7 Molten Oxides, Slags
Gaseous components GC 8 Air, Gaseous, Metal Vapours

The following variables give the total components for phases and total streams

Solid components SC which equals SI + SO

Liquid components LC which equals LI + LO
Fluid components FC which equals LI + LO +M1+M2+M3+GC
i.e. liquids +melt + Gaseous components
Total components is variable TC

9.0 UNIT OPERATION MODULES

METSIM was originally developed to calculate mass and energy balances around any type of
flowsheet. To facilitate this task generic unit operations were used. These modules are
available if no suitable model can be found in the Unit operation listed under the Unit Operation
Buttons. They are located in the GEN group. Chemistry and heat balance data could be added to
any of these units as required. The generic modules are:

MIX mixes all of the input stream and tanks, sumps, bins, mills,
has a single output stream. reactors, pumps, conveyors
SPC allows components to be split flotation cells, gravity

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differently in output streams concentrators, recovery plants

SPP allows phases to be split solvent extraction, CIP/CIL
differently in output streams furnaces
SLS simulates solids/liquid separations classifiers, thickeners, filters, ponds
SPS allow stream to be split streams split by fraction
SUB distributor allows streams to be closes water balance, reagent
controlled at different flow rates totals

9.1 Calculation Philosophy and methodology

The calculation philosophy used in METSIM is to take the feed streams to a unit operation
module and have a mechanism to handle the inputs and to output according to the module: -

FEED MECHANISM PRODUCTS

The calculation methodology for a typical unit operation is illustrated in the schematic below.

Feedback Controller

IS1 > XDAT Retrieve unit op data OS6

IS2 > Ctb – get control variables OS5
IS3 > XADD Add input streams OS4
IS4 > XCHE Calc chemistry OS3
IS5 > XUOP Calc unit op OS2
IS6 > XOUT separate output streams OS1
Cta reset control variables
XDAS Save unit op data

All unit operations follow the calculation sequence:

Input data retrieval and sorting

XDAT - retrieves unit operation input parameters and assigns them to the two letter
variables used in the unit operation input data screens.

CtB - data stored in the controls input data screen – these controls are executed before
the unit operations calculation routine. Ctb enables the user to adjust unit operation
variable by assigning controllers such as feedback controls.

Unit operation calculations are performed in the following order

XADD Input stream flows are summed and put into stream OS1

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XCHE - chemical calculations are carried out on the combined feed stream according
to the sequence defined in the Reactions input data screen.

Equil - equilibrium calculations are carried out on the products of the chemical
reactions.

XUOP - Unit operation calculation routines are performed.

XQHT - Heat balance calculations are performed, and heat losses calculated according
to the data entered via the Heat Bal input data screen

Unit operation output data

XOUT - redistributes the output stream OS1 data according to the requirements of the
unit operation.

CtA - is used to extract data from the unit operation two letter variables in the unit
operation input data screens and assign it to user object scalars, vectors or arrays.

XDAS - stores the new unit operation parameters settings.

9.2 Controls

There are two types of controls

9.2.1 Feed Forward Controls

Feed forward controls are calculated before the unit operation calculations. They are
calculated in the following:

XLOG - Logic,
XSCH - Schedule for batch dynamic flowsheets, this is located in the section
XFRC - Flowrate control
XFFC - Feed forward ratio control
XPSC - Percent control

The logic for the sequence is that if for example, a reactor is being calculated, the ore
flowrate is setup first, then ratio any acid addition and finally control water addition to
achieve a certain percent solids.

9.2.2 Feedback Controls

If an output stream parameter is controlled by a feedback controller, the parameter value

is compared to the controller set point, and if it is not within the controller convergence
tolerance, the main calculation routine returns to the unit operation where the adjusted
variable is located. The variable is adjusted according to its variance and the unit
operations between the point where the adjusted variable is located and where the
controller set point is measured are re-calculated until the measured variable and
controller set point are re-compared. If it is within the tolerance of the controller the next
unit operation in sequence is calculated, and if not the controller sets a new value for the
controlled variable, and calculations are repeated until convergence is achieved.

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9.3 Heat Balance Calculations

Heat balance data is stored in array Heat of Operations HOP, dimensioned the number
of unit operations (NOO) by seven columns, accessed by OHOP Unit Op Heat
Balance located in the Output Drop Down Menu. Streams heat contents data is stored in
vector SHC.

Heat input (4) Heat loss (5)

Heat required (6)

IS1 Heat of reaction (2) OS1

IS6 Heat of solution (3) OS6
Heat In (1) Heat Out (7)

HOP Column 1 is the total heat content of all input streams.

HOP Column 2 is the heat of chemical reactions or phase changes.
HOP Column 3 is the heat of solution or other chemical heat generation.
HOP Column 4 is the total of all direct energy input.
HOP Column 5 is the total of all heat losses or heat removal.
HOP Column 6 is the energy required to achieve specified temperatures.
HOP Column 7 is the total heat content of all output streams.

OHBS Heat Balance Summary routine located in the Output Drop Down Menu is used to
outputs a total heat balance summary.

Most unit operation modules mix the feed streams then the mechanism is applied. That
mechanism can be followed by a chemical reactions or a phase change and if the result
required is not achieved then the mechanism or chemical reaction can be changed or a
control applied as a feed forward or feedback loop.

In addition it is possible to add chemistry to any unit operation and then add controls to simulate
any type of reactor without having specific reactor model.

The program calculates each unit operation using the mass units chosen. It always calculates
splits on output streams from a unit operation by difference to eliminate errors caused by
multiplication and division. Therefore always achieve a perfect balance of input and output.

9.4 Data Entry

The object editor is used to enter and edit unit operation modules. The unit operation
data required depends upon the type of unit operation and calculation options chosen.
Extra screens are accessed via the page tabs for reactions, equilibrium reactions, heat
balance data, controls and costing data as relevant.

Generally the essential input data is highlighted on the data input screens with an *
Asterisk, and calculation options by the option numbers.

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9.4.1 Chemical Reactions Input

Chemical reactions are entered via a separate input screen. It is important to note that
the reactions are calculated sequentially from top to bottom in the reaction listing.

Several calculation options are available to control chemical reaction. Reactions are
entered stochiometrically and reaction completion is determined by either a single value
or a mathematical expression for:

- reaction extent
- residual weight fraction
- mass conversion
- equilibrium where KE is entered
- equilibrium where TM is entered
- equilibrium, where no value or expression is entered.

In addition some unit operations such as the autoclave kiln and packed column can use
factors to control progressive reactions through the unit.

Reaction equation components are entered as either reactants or the products of the
reaction. The program will calculate the stochiometric balance, by calculating the
number of elements and components and then uses simultaneous equations to arrive at a
solution. If there is more than one solution to the chemical reaction then the user can
enter the stochiometry directly, in which case the program will not balanced the reaction.

9.4.2 Input Heat Balance Data Input

The unit operation heat balances is calculated from the heats of reaction and component
heat contents. The heat content of the output components plus the heat of reaction are
calculated and assigned to the output stream based on them all being at the same
temperature.

Heat loss or heat input are input heat as defined as a fraction e.g. - .05 (5% lost) or an
absolute amount. electrical energy or as an APL expression: -

Q = U x A x T entered as follows 256 x 2000 x (TEM [23] - 30)

where U = 256, A = 2000, TEM [23] is a stream temperature.

An additional constraint to heat balances, i.e. to specify output stream temperatures can be
entered via the ISTQ – Other Stream Data/Controls routine located in the Input Drop
Down Menu or direct through the relevant stream object data screen ( TC Control).
Hence the user can specify the temperature of one stream and then the remaining heat is
apportioned between the other output streams at new temperature. If the user chooses two
temperatures the program will balance the remaining and similarly with three etc. If all
streams are specified METSIM will calculate the in-balance in heat and add or remove heat
to achieve a balance. The discrepancy will be displayed as heat input/output from/to another
source in the Heat required column of HOP.

9.4.3 Unit Operation Controls

Two types of control are used specifically by unit operations and are stored with the unit

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operation data

LOG - Logic Control

Unit Operation Controls – Controls

LOG - Logic Control – allows the user to input a decision prior to execution of the unit
operation calculation routine.
It is based upon:
IF a rule or result is satisfied
THEN some action is taken
ELSE some other action is taken
.
Unit Operation Controls there are two types CtA and CtB. CtA is used before the unit
operation is calculated, to assign values to parameters within the unit operation which are
used for control. CtB is used after the unit operation is calculated and is used to extract
parameter values.

9.4.4 Cost Data Input

Operating costs are generated as a spreadsheet, with the cost items listed in rows and the costs in
columns. The spreadsheet is set up by defining the cost areas, then the items in each area with
their costs and then their types.

The types are:

Labor - where the labor type is defined, they’re working hours and payment method.

Material - which can be independent of the process

Reagents - which are related to the process i.e. flotation reagents

On completion of the simulation the cost data can be calculated immediately and output as
standard reports or to spreadsheets.

10.0 PROCESS CONTROLS

The following controls are used in steady state simulation:-

- Feed forward
- Flowrate
- Percent solids
- Feed back control

10.1 - Feed forward

This control is used to control the ratio of streams entering a unit operation. The stream to be
adjusted is always in the numerator. A function FZDV (function for zero division), can be used
for the situation when the number below the line is zero which eliminates the zero divide error.

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10.2 – Flowrate Control

This control fixes the flowrate of a stream entering a unit operation.

10.3 - Percent Control

This control is used to control streams entering a unit operation to maintain an outlet
composition e.g. solids percent in a sump or tank or oxygen enrichment for a furnace.

10.4 - Feed Back Control

Feedback control is used to control inlet streams and unit operation variables to achieve an
outlet composition or flow from a unit operation or group of unit operations. The measured
variable is after the unit operation(s) and the variable to be adjusted is either before or within
the unit operation(s). The sequence of calculation is:

- controller uses first flow or variable condition,

- the program calculates the unit operation(s)
- the controller compares the value of the measured variable to the desired value
(controller set point).
- if the value is outside the controller tolerance 1E-10, the controller make a change to
the controlled variable
- the program repeats the calculation of the unit operation(s), using the new values
- the controller compares the new measured value and if outside the tolerance repeats
the calculation or if within the program proceeds with calculation of the next unit
operation.

Note: when applying a number of controls to a group of unit operations the unit operations
where the measured variables are located (field OP in the controller) should be in ascending
order and the unit operations where the adjusted variables are located (field NO in the
controller) should be in descending order. This method of listing will ensure nested loops are
converged.

There are several relationships, which the controller has to compensate for:

Caustic use to Neutralize Acid

Negative Slope – Curve which flattens at the neutralization point when the acid value at the
outlet is used for the measured variable. The value will reduce until neutralisation is achieved
and will remain at zero with further caustic addition.

Positive sloped curve - Curve which starts at zero and then goes positive e.g. when caustic in
the outlet is the measured variable, it will remain at zero until all acid is neutralised and will
then increase with further caustic additions.

A composite curve consisting of caustic minus acid in the outlet provides the best solution. In
this case the curve starts at the caustic value and reduces until the caustic value is zero (i.e. the
neutralization point), then continues to decrease below zero as more acid is added. This curve
has no flat section and enables precise control to be achieved.

pH Control

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This is particularly difficult control as the curve changes rapidly for a small part of the range
and then no further change. e.g. pH when neutralising acid with limestone and there is no OH
radical present in solution i.e. pH cannot exceed 7.

Control of Chemistry

Control of Chemical reactions should be evaluated using a truth table:

For example: the following reactions are to be controlled to achieve the following control
objective

gHCl  a HCl
MgSO4 + HCl  MgCl2 + aH2O
aH2O  gH2O

Control Effect of Control on Reaction

gpl HCl MgCl2 Temperature Order

Add Acid to get gpl HCl Major 1 Minor0 Some1 2

React MgS04 to MgCl2 Minor Major1 Minor 3

Evaporate to get temperature Some1 Some1 Major1 1

Put the order of reactions with the first being the reactions which has the most affect on the
others and the reaction which has the least effect last.

11.0 IMPORTANT POINTS ON MODELLING

An efficient flowsheet model will have the minimum disturbances built into it. To ensure an
accurate balance is achieved steady state flowsheet models must converge to 1E- 6 on repeated
calculations with minimal or no changes to recycle stream convergences. If disturbances
continue to occur on repeated re-calculations after the flowsheet has been converged to 1E -6
then there are instabilities which should be minimized. METSIM will converge all flowsheets to
the above tolerance. Decreasing the level of tolerance to say 1E-4 does not solve the problem it
hides it. To test the balance use Check Elemental Balance routine button on the Task Bar. All
elements inputs and outputs must balance.

An analogy to flowsheet modelling is measuring the level of a large pond using a number of
level measuring probes spaced out across the surface. They have to give the same reading to
give the true level of the pond. There is only one solution when this is possible when the surface
is totally smooth and there are no disturbances.

If a rock is thrown into the pond the level will change and ripples will be formed on the pond
surface. Depending on the size of the rock, the surface ripples may be large or small; however
the overall average level recorded by the measuring devices will appear the same even with a
large state of turbulence. This is convergence. If it is set large it allows bigger ripples and hence
it must be set low to give an accurate level as close to a perfectly still pond.

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In METSIM disturbances are caused by not choosing the most efficient combination of unit
operation for the purpose, miss-use of controls and when there are excessive recycle streams.

Unit operations, which can contribute to flowsheet instability, are:

SPS - Stream splitter. This unit operation splits output by fractions. Hence each time it is
calculated and if there has been a slight change to input flow then there will be a change in flow
in the output streams, no matter how small. A superior unit operation to use is the SUB which
can give precise flow distribution to the major flowsheet streams.

SPC - Component splitter. This uses proportional splits as well as fixed flow splits and gives
similar problems to SPS. The FLT unit operation is superior, as it will give an exact value
output.

These unit operations are like throwing a rock in the pond.

Similarly flowsheets have instability imposed by not choosing the correct type of controls. For
example feedback control should be avoided because it does not give an exact result. It is better
to use:

Feed forward
Flowrate
Logic

controllers which give precise values.

Using the pond analogy, the feedback control is like throwing an extra rock into the pond.
Where feedback control is used try to apply it such that it creates minimal disturbance. An
example is controlling a cooling water heat exchanger is used for cooling a process stream.

A common control strategy users used in the past was to fix the exit cooling water outlet
temperature from the heat exchanger, using ISTQ Other Stream Data/Controls and control
the flow of cooling water to maintain the process stream at a specific temperature using a
feedback controller (FBC). The FBC will not give an exact process stream temperature,
which will create flowsheet disturbances further downstream.

The better strategy is to fix the main process stream temperature leaving the heat exchanger
using ISTQ Other Stream Data/Controls and control the process water flow to ensure that
the cooling water exits at a controlled temperature using a FBC. The disturbance in this
case will be restricted to the minor stream and the main process stream leaving the heat
exchanger at an exact temperature.

Another situation is recycle streams. These should be carefully evaluated to minimise their
number. Each time a recycle stream has to be calculated it causes a disturbance because it
converges to a pre-determined tolerance.

An example of reducing recycle streams is in a flowsheet where dust is being recycled from a
furnace off gas system. Initially each dust recovered from the waste heat boiler, cyclones, bag
filter, electrostatic precipitator and exhaust stack is recycled separately. There are five recycle
streams. These can be reduced to one by taking all the dusts after calculating the exhaust stack,
mixing them in a MIX unit operation and returning the single outlet stream.

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12.0 APL FUNCTIONS

Users may develop functions for their own use.

This is done via User Objects in TOOLS.

These functions are saved with the flowsheet model.

Functions can be saved to a separate directory Fns outside the model, where they can be
accessed for use in any model.

13.0 STEADY STATE AND NON STEADY STATE (DYNAMIC) MODELLING

The major differences between steady state and dynamic flowsheet modelling are listed below:

STEADY STATE DYNAMIC

1.0 UNIT OPERATIONS
INPUT = OUTPUT INPUT= OUTPUT + ACCUMULATION
There is no control on output streams User has to control output streams
2.0 CONTROLS
FBC PID
Controller must know slope Need to input tuning parameters
of the curve of adjusted Suggested parameters given using
and controlled variable Instrument Society of America
1 = positive, 0 = negative algorithm
3.0 CONVERGENCE
CONVERGENCE ON CONVERGENCE OFF
Will iterate until largest change Once through per unit of time
is less than tolerance
RECYCLE ON RECYCLE OFF
4.0 CHEMISTRY
Chemistry uses conversion Chemistry uses rate per unit of time
5.0 OUTPUTS FROM MODEL
No control applied Some outputs need controls
6.0 OUTPUT REPORTING
One output balance Plots stored in PLTD

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